Senior Executive

To manage and ensure the safe, reliable, and efficient operation and maintenance of plant utilities in an API manufacturing facility. The role is responsible for utility operations, preventive and breakdown maintenance, energy management, equipment reliability, statutory compliance, GMP documentation, and coordination with Production, Quality Assurance, EHS, and other engineering departments.

The Senior Executive will ensure uninterrupted availability of critical utilities, including HVAC, chillers, refrigeration systems, boilers, cooling towers, compressed air, vacuum systems, water systems, and other installed utility equipment.

3. Key Responsibilities
A. Utility Operations Management
Supervise day-to-day operation of plant utility systems and ensure uninterrupted supply to production and other plant areas.
Monitor utility equipment performance, operating parameters, consumption, and availability.
Prepare daily operating schedules and coordinate utility requirements with Production and other departments.
Ensure availability of utilities during manufacturing, cleaning, shutdown, and maintenance activities.
Monitor operating conditions, alarms, abnormal readings, and equipment breakdowns.
Coordinate shift handovers and maintain operating logbooks.
Ensure proper allocation of manpower and work assignments for utility operators and technicians.
Escalate major failures, abnormal utility consumption, and safety-related issues to the Utility Manager.
Develop operating procedures and checklists in accordance with approved site procedures.
B. HVAC and Air Conditioning Systems
Manage operation and maintenance of HVAC systems serving production, laboratories, warehouses, and controlled areas.
Supervise AHUs, fresh air units, exhaust systems, ventilation equipment, and associated controls.
Monitor temperature, relative humidity, room differential pressure, and airflow as specified.
Ensure timely cleaning and replacement of pre-filters, fine filters, and terminal filters where applicable.
Monitor fan motors, belts, bearings, dampers, control valves, and temperature sensors.
Coordinate troubleshooting of HVAC alarms, inadequate cooling, high humidity, abnormal pressure differentials, and reduced airflow.
Ensure HVAC maintenance is carried out without compromising product quality or controlled-area conditions.
Support HVAC qualification, requalification, filter integrity testing, and other verification activities as applicable.
Maintain HVAC operating records and maintenance documentation.
C. Chiller and Cooling Tower Operations
Operate and maintain air-cooled and water-cooled chillers as installed.
Monitor chilled water supply and return temperatures, refrigerant operating parameters, compressor current, and alarms.
Ensure reliable operation of chilled water pumps and condenser water pumps.
Supervise cooling tower fan operation, water levels, water distribution, and general equipment condition.
Coordinate condenser and evaporator cleaning, descaling, and water treatment.
Investigate high-pressure trips, low-pressure trips, abnormal vibration, and poor cooling performance.
Monitor chiller efficiency and specific energy consumption where practical.
Maintain equipment operating logs, maintenance schedules, and breakdown records.
D. Boiler and Steam System Operations
Supervise boiler operations and associated steam distribution systems where installed.
Monitor steam pressure, temperature, water level, feedwater supply, and operating alarms.
Ensure proper operation of feedwater pumps, fuel systems, burners, and associated controls.
Coordinate boiler blowdown, water treatment, and routine inspection activities.
Inspect steam traps, condensate recovery systems, valves, and distribution lines.
Monitor steam leakage and implement corrective actions.
Ensure boiler operation, inspection, and maintenance comply with applicable statutory requirements.
Coordinate with authorized boiler personnel and service providers for inspections, repairs, and certification.
E. Compressed Air and Instrument Air Systems
Operate and maintain air compressors, air dryers, receivers, filters, and associated piping.
Monitor discharge pressure, compressor temperature, operating hours, and alarms.
Ensure compressed air quality meets the specified requirements for its intended use.
Inspect air leaks, condensate drains, filters, and dryer performance.
Maintain pressure dew point and oil carryover monitoring where required.
Coordinate periodic maintenance of compressors, dryers, and filtration systems.
Ensure instrument air availability for process instruments and automated valves.
Track compressed air consumption and implement leakage reduction initiatives.
F. Refrigeration and Process Cooling Systems
Maintain refrigeration plants, cold rooms, deep freezers, and process cooling systems where installed.
Monitor refrigeration compressors, suction and discharge pressures, temperatures, and refrigerant leaks.
Coordinate refrigerant recovery, repair, and charging using approved procedures.
Ensure required temperature conditions are maintained in designated storage and process areas.
Investigate equipment trips, insufficient cooling, compressor overheating, and abnormal frosting.
Maintain temperature records, equipment logs, and service reports.
Coordinate with specialist vendors for major refrigeration repairs.
G. Water Systems and Water Treatment
Supervise operation and maintenance of raw water, soft water, treated water, and other utility water systems.
Maintain pumps, storage tanks, filtration units, softeners, dosing systems, and distribution piping.
Monitor water quality parameters according to the intended application and approved procedures.
Coordinate water treatment activities and maintain chemical consumption records.
Inspect leaks, pressure fluctuations, pump performance, and abnormal water consumption.
Coordinate with Quality Control and Quality Assurance for applicable sampling and monitoring requirements.
Maintain water-system maintenance records and ensure the correct procedures are followed for shutdowns and maintenance.
Support purified water or other pharmaceutical-grade water systems only where these systems fall within the assigned scope.
H. Vacuum and Other Utility Systems
Operate and maintain vacuum pumps, vacuum receivers, and associated piping.
Monitor vacuum levels, pump temperatures, seals, and equipment performance.
Maintain nitrogen, process gas, and other utility systems where installed and assigned.
Coordinate leak checks and inspection of associated valves, regulators, and piping.
Ensure safe handling and storage of gases according to applicable requirements.
Maintain utility availability for reactors, dryers, condensers, and other process equipment.
Coordinate with Production and Process Engineering for utility demand and abnormal operating conditions.
I. Preventive Maintenance and Breakdown Management
Prepare and execute annual preventive maintenance plans for all assigned utility equipment.
Ensure timely completion of daily, weekly, monthly, quarterly, and annual maintenance activities.
Review maintenance checklists and equipment history.
Supervise breakdown troubleshooting and coordinate timely restoration of equipment.
Perform root-cause analysis for repeated failures and implement corrective and preventive actions.
Coordinate OEM service visits, annual maintenance contracts, and major equipment overhauls.