Engineer

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 < Motors, EOT Cranes, HT Cables end termination, Jointing jobs, control power circuit, Engineering drawings, ,LT DG Sets O & M . and Grid import/export knowledge. alternator working principle and O/M.

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)

< 2

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, <2 breakdowns/month, 100% digital reporting

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