Blast Furnace - Shift Incharge Electrical

Blast Furnace - Shift Incharge Electrical :
JOB DESCRIPTION Blast Furnace Electrical Shift In-Charge (Electrical Maintenance) 1. Position Details 2. Job Purpose

To ensure the safe, reliable, and continuous operation of Electrical, Instrumentation, and Automation (E & I) systems during the assigned shift. The role is responsible for effective breakdown maintenance, preventive maintenance, troubleshooting, and operational maintenance support to maximize equipment availability and minimize downtime.

The position ensures compliance with corporate safety standards, statutory requirements, and established maintenance procedures while coordinating closely with Operations, Mechanical Maintenance, and Control Room teams to support uninterrupted plant operations.

3. Role Summary

The Electrical Shift In-Charge is responsible for planning, coordinating, supervising, and executing electrical maintenance activities during the assigned shift to ensure reliable and uninterrupted plant operations.

The role focuses on maximizing equipment availability, minimizing downtime, promptly restoring failed equipment, executing preventive maintenance schedules, identifying equipment abnormalities, maintaining accurate SAP shift logbook entries, and ensuring strict compliance with Electrical LockoutTagout (LOTO) and Permit-to-Work (PTW) procedures.

The position requires strong technical troubleshooting capabilities, effective shift team supervision, sound emergency decision-making, and close coordination with cross-functional teams to achieve operational reliability, equipment availability, and zero-harm objectives.

4. Key Responsibilities 4.1 Equipment Availability and Downtime Management

• Ensure maximum availability and reliability of electrical equipment within the assigned plant area.
• Minimize equipment downtime through prompt fault diagnosis, effective troubleshooting, and timely restoration.
• Monitor equipment performance and identify recurring failures and opportunities for reliability improvement.
• Coordinate with relevant departments to minimize production losses arising from electrical equipment failures.

4.2 Breakdown Maintenance and Troubleshooting

• Identify, diagnose, and rectify electrical breakdowns in a safe and timely manner.
• Troubleshoot faults in HT/LT systems, electrical drives, VFDs, MCCs, control panels, and associated electrical equipment.
• Coordinate with Control Room Operators and Operations personnel for safe equipment isolation, handover, testing, and restoration.
• Ensure appropriate corrective actions are implemented to prevent recurrence of equipment failures.

4.3 Shift Maintenance Execution

• Plan, coordinate, and execute electrical maintenance activities during the assigned shift.
• Supervise maintenance personnel and ensure timely completion of assigned work.
• Carry out routine equipment inspections in accordance with approved checklists and maintenance plans.
• Ensure proper equipment handover and communicate pending maintenance activities to the incoming shift.

4.4 Preventive Maintenance and Equipment Health Monitoring

• Ensure full compliance with scheduled preventive maintenance activities and shift inspection checklists.
• Inspect HT/LT electrical systems, motors, drives, instruments, control panels, and gas analyzers for abnormal conditions.
• Identify early warning signs of equipment deterioration and initiate corrective action.
• Maintain equipment health records and report abnormal operating conditions to the concerned authority.

4.5 Cross-Functional Coordination and Communication

• Coordinate with Operations, Mechanical Maintenance, Instrumentation, and Control Room teams to ensure smooth plant operations.
• Communicate equipment status, breakdown details, maintenance progress, and restoration requirements clearly.
• Facilitate safe equipment handover, trial runs, testing, and commissioning activities.
• Ensure effective shift-to-shift communication regarding equipment health, pending jobs, and operational risks.

4.6 SAP and Maintenance Documentation

• Ensure accurate and timely recording of shift activities, breakdown details, maintenance actions, and equipment status in the SAP shift logbook.
• Maintain electrical maintenance records, inspection checklists, equipment history, and relevant technical documentation.
• Ensure electrical drawings, schematics, and single-line diagrams are updated whenever changes are made and approved.
• Maintain proper documentation of breakdown analysis, corrective actions, and pending maintenance work.

4.7 Safety, Permit Compliance, and Statutory Requirements

• Ensure strict compliance with electrical safety standards, LOTO requirements, PTW procedures, and applicable statutory regulations.
• Verify safe isolation, de-energization, testing for absence of voltage, and appropriate earthing wherever required before maintenance work.
• Ensure personnel use prescribed Personal Protective Equipment (PPE) and follow approved safe work practices.
• Conduct safety briefings and reinforce hazard identification, risk assessment, and safe maintenance practices.
• Strive for zero electrical safety incidents and ensure immediate reporting of unsafe conditions and near misses.

4.8 Emergency Response and Decision-Making

• Make timely, technically sound decisions during electrical breakdowns and emergency situations.
• Prioritize safety, equipment protection, and operational continuity while responding to critical failures.
• Coordinate with Operations and other stakeholders to restore equipment safely and minimize production losses.
• Escalate critical equipment failures, recurring issues, and major safety risks to the appropriate authority.

4.9 Shutdown, Testing, and Commissioning Support

• Support planned shutdowns, major maintenance activities, equipment inspections, and statutory testing as required.
• Assist in the installation, testing, commissioning, and trial operation of electrical equipment.
• Coordinate with relevant departments and contractors to ensure safe and timely execution of shutdown activities.
• Verify equipment readiness and compliance with approved procedures before returning equipment to service.

5. Technical Skills and Competencies

• Hands-on experience in electrical drive maintenance and troubleshooting, including Variable Frequency Drives (VFDs).
• Strong knowledge of HT/LT electrical systems, power distribution, switchgear, and electrical protection schemes.
• Working knowledge of Motor Control Centres (MCCs), electrical control panels, motors, and associated protection systems.
• Familiarity with electrical instrumentation, field instruments, and gas analyzers used in process plants.
• Basic knowledge of control valves and process field instruments relevant to plant operations.
• Strong fault diagnosis, breakdown handling, and equipment restoration capabilities.
• Practical experience in preventive and breakdown maintenance practices.
• Ability to monitor electrical power consumption, identify abnormal trends, and support energy-efficiency initiatives.
• Thorough understanding of electrical safety, LOTO, PTW, equipment isolation, and safe maintenance practices.
• Ability to read and interpret electrical drawings, wiring diagrams, schematics, and single-line diagrams.
• Working knowledge of SAP maintenance documentation and shift logbook entries.

6. Behavioral Competencies

• Safety Leadership:

  Demonstrates a strong safety mindset and ensures adherence to safety procedures and permit systems.

• Decision-Making:

  Remains calm, confident, and decisive during breakdowns and emergency situations.

• Team Leadership:

  Effectively supervises, guides, and motivates shift maintenance personnel.

• Communication and Coordination:

  Communicates clearly and coordinates effectively with Operations, Mechanical Maintenance, and Control Room teams.

• Ownership and Accountability:

  Takes responsibility for assigned equipment, maintenance quality, and shift performance.

• Problem-Solving:

  Applies a systematic approach to fault diagnosis, root-cause identification, and corrective action.

• Execution Discipline:

  Ensures timely completion of maintenance activities, checklists, and documentation.

• Adaptability:

  Works effectively in a shift-based, high-pressure industrial environment without compromising safety or reliability.

7. Key Performance Indicators (KPIs)

Performance will be evaluated against applicable departmental targets and approved performance standards, including:

• Electrical equipment availability and reliability.
• Breakdown response time and equipment restoration time.
• Electrical downtime and repeat breakdown frequency.
• Compliance with preventive maintenance schedules and shift inspection checklists.
• Electrical safety performance and compliance with LOTO/PTW requirements.
• Accuracy and timeliness of SAP shift logbook entries and maintenance documentation.
• Timely completion of assigned maintenance activities and effective shift handover.
• Identification and closure of equipment abnormalities and corrective actions.
• Support for production continuity, shutdown execution, and commissioning activities.

8. Qualification and Experience

Educational Qualification

• Diploma in Electrical Engineering.
• B.E. in Electrical Engineering.
• B.Tech in Electrical Engineering.

Professional Experience

• Minimum 37 years of relevant experience in electrical maintenance in a steel plant, heavy industry, or process industry.
• Practical exposure to HT/LT systems, electrical drives, MCCs, breakdown maintenance, and preventive maintenance is desirable.
• Experience in shift-based maintenance operations and industrial electrical safety practices is preferred.

9. Working Conditions

• Shift-based working in an integrated steel plant environment.
• Exposure to high-temperature industrial areas, heavy equipment, and operationally critical electrical systems.
• Availability to support emergency breakdowns, planned shutdowns, testing, and commissioning activities as required.
• Strict adherence to plant safety procedures, PPE requirements, and applicable statutory standards.