Kiln - Electrical-Incharge

Purpose/Objective

Ensure safe, reliable, and optimized electrical performance for Kiln & Cooler circuits—including HT/LT power systems, MCCs, VFDs, motors, PLC/DCS interlocks—supporting stable clinker production, energy efficiency, and audit-readiness.

Key Responsibilities of Role

Kiln Electrical Availability & Reliability - Own uptime of kiln main drive and critical auxiliaries (ID/FD/PA fans, cooler fans, blowers). - Maintain MCCs, VFDs, soft starters, switchgear, transformers, and cable systems. - Implement preventive/predictive maintenance (thermography, IR, vibration coordination). Protection & Power Quality - Review and set protection relays (OC/EF/Differential/Under-Voltage/Under-Frequency). - Monitor PF, THD/harmonics, flicker; optimize APFC, filter banks, and drive parameters. Control Systems & Interlocks - Own kiln start/stop permissives, ESD trip chains, and safety interlocks. - Manage PLC/DCS logic changes, IO mapping, alarm rationalization, and SOE analysis. - Coordinate loop checks before commissioning/after shutdowns. Breakdown Management & RCA - Lead diagnostics during trips; perform structured RCA (5-Why/FMEA). - Implement CAPA and update SOPs, interlocks, and maintenance standards. Statutory & Safety Compliance - Enforce PTW/LOTO, arc-flash mitigation, earthing practices. - Ensure compliance with applicable IE Rules, CEIG audits, and internal EHS standards. - Conduct mock drills aligned with kiln electrical trip scenarios. Stakeholder & Vendor Coordination - Collaborate with Process, Mechanical, Utilities, QC during shutdowns and startups. - Manage OEM/vendor SLAs, spares strategy for critical equipment, and upgrades. Energy Optimization - Track and reduce specific power consumption (kWh/t clinker) across kiln/cooler circuits. - Tune VFD ramps/PIDs and load management strategies for peak shaving. Documentation & Governance - Maintain SLDs, protection settings, cable schedules, red-line drawings. - Deliver daily shift reports, weekly reliability reviews, monthly KPI dashboards.

Technical Competencies

Kiln Electrical Availability & Reliability,Protection & Power Quality,Breakdown Management & RCA,Statutory & Safety Compliance

Qualifications and Experience

- Education: B.E./B.Tech/Diploma in Electrical/Electrical & Electronics Engineering. - Experience: 7–12 years in cement/continuous process industry; 3+ years in kiln/cooler section preferred. - Tools/Systems: Hands-on with VFDs (ABB/Siemens/etc.), PLC/DCS (Siemens PCS7/DeltaV/etc.), protective relays, CM tools (thermal imaging, MCSA), and EHS systems. - Certifications (Preferred): Electrical Safety/Arc-Flash, Relay Coordination, VFD/PLC OEM trainings.