Engineer

Job Description – Engineer (CPP) Department: Captive Power Plant (CPP) Position Title: Engineer Reports to: Senior Engineer Location: Meghalaya - Plant. Job Objectives The Electrical Engineer for the Captive Power Plant is responsible Planning, erection, commissioning, maintenance and troubleshooting of 6.6 KV HT breakers, LT switchgear, Synchronizing panel, Power Transformers, Transformer Rectifier Sets up to 120 KV DC , Relay protection systems, In house development of Relay testing bench and centralized testing of all HT & LT electrical equipment, AVR, GRP,,APFC, MCC, PCC, ESP, VFD Drives , RTD ‘s, Capacitors bank, HT Key Responsibilities 1. Operation & Maintenance (O&M) Monitor, operate, and maintain electrical equipment in the CPP, including HT/LT switchgear, transformers, generators, excitation systems, motors, MCCs , and auxiliary electrical systems. Conduct routine inspections, predictive and preventive maintenance to ensure equipment reliability. Troubleshoot electrical faults, analyze root causes, and implement corrective actions. Maintain safe isolation procedures, LOTO practices, and ensure adherence to operating parameters. 2. Power Plant Equipment Handling Support operation and maintenance of Waste Heat Recovery (WHR) boilers, AFBC, steam turbines, DG sets , and associated auxiliaries. Coordinate with mechanical and instrumentation teams for integrated system performance. Ensure reliable synchronization and load sharing between CPP and grid (if applicable). 3. Projects & Improvements Participate in installation, commissioning, and upgrades of electrical systems, energy-efficient drives (VFDs), and automation systems. Lead or support reliability improvement initiatives, including predictive maintenance tools (thermography, motor signature analysis, vibration analysis). Prepare technical specifications for procurement of electrical equipment and spares. 4. Safety & Compliance Ensure compliance with electrical safety standards , statutory norms, and regulatory requirements (CEA, IE Rules, Factory Act). Maintain documentation for audits, statutory inspections, and internal safety systems. Conduct toolbox talks, risk assessments, and safety training for O&M personnel. 5. Documentation & Reporting Maintain daily logs, maintenance records, breakdown reports, and energy consumption reports. Develop maintenance schedules, SOPs, and MIS reports for management review. Track KPIs such as plant availability, power generation efficiency, electrical breakdown frequency , etc. 6. Coordination Work closely with cement plant operations, utilities, procurement, and external vendors/contractors. Manage manpower for electrical maintenance activities and supervise contract labour when required. 3. Key Performance Indicators (KPIs) ≥ 99.5% CPP Electrical Availability ↓ 20% YoY Mean Time to Repair (MTTR) ↑ 20% YoY Mean Time Between Failures (MTBF) Zero tolerance: ≤ 1 per quarter Unplanned Electrical Breakdowns 100% Preventive Maintenance (PM) Compliance ≥ 99% WHRS Electrical Availability ≥ 99% Turbine Electrical Reliability KPI Category Performance Indicator Target / Benchmark Operational Efficiency Electrical System Availability (%) ≥ 98% Auxiliary Power Consumption ↓ 3–5% YoY Mean Time to Repair (MTTR) ↓ 10% YoY Mean Time Between Failures (MTBF) ↑ 10% YoY Reliability & Maintenance Breakdown Frequency (per month) Critical Equipment Failure Rate Zero Critical Failures Energy Performance Power Factor ≥ 0.98 Cost Control Spare Utilization Efficiency Within Budget People Team Productivity ≥ 95% Digitalization Predictive Maintenance Analytics Usage ≥ 90% Digital Work Order Closure (within 24 hrs) ≥ 95% 4. Competency Framework Functional Competencies Waste heat recovery (AFBC) TG (Turbine Generator) operations Boiler & auxiliary system power distribution Synchronization with grid & captive loads Leadership Competencies Manpower allocation Shutdown planning Spare parts & inventory management 5. Qualification & Experience BE/Diploma in Electrical. 5–7 years of experience in maintenance and troubleshooting of 6.6 KV HT breakers, Power Transformers, Transformer Rectifier Sets up to 120 KV DC. 6. Roadmap of Success Year Focus Area Key Deliverables Expected Outcome Year 1 (Stabilize) System Reliability & Compliance - Assess current electrical infrastructure - Standardize preventive maintenance (PM) checklists - Implement strict PTW & LOTO discipline - Complete statutory audit compliance (CEA / Safety) - Initiate SCADA data accuracy improvement Improved equipment stability, 98% electrical system availability Year 2 (Optimize) Efficiency Improvement & Digitalization - Implement predictive maintenance tools (thermography, PD tests, PQ analysis) - Reduce auxiliary power consumption via optimization projects - Digitize work order and maintenance workflows - Energy management program roll-out - Skill enhancement for operators & shift engineers. 8–10% maintenance cost savings, Year 3 (Transform) Advanced Reliability & Strategic Excellence - Deploy AI/analytics for failure prediction & energy optimization - Modernize aging assets (motor rewinding strategy, switchgear upgrades) - Achieve zero critical electrical failures - Implement best-in-class reliability practices (TPM/Lean/Kaizen) - Benchmark performance against top CPPs in cement industry. Near-zero downtime, industry-leading energy efficiency, fully optimized and digitally transformed CPP 7. Annual Success Plan (FY2025–26) Quarter Key Priorities Target Outcome Q1 Comprehensive electrical system audit (HT/LT panels, transformers, motors) 100% system & compliance accuracy Q2 Implement preventive & predictive maintenance schedule (thermography, PD, PQ analysis) Achieve 98–99% system availability Q3 Energy efficiency improvement initiatives (motor efficiency, PF improvement, load balancing) 6–8% energy or maintenance cost reduction Q4 Annual cost review & reliability benchmarking 12–15% improvement over baseline KPIs