Engineer

Job Description – Engineer (CPP)Department: Captive Power Plant (CPP)Position Title: Engineer Reports to: Senior EngineerLocation: 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 Responsibilities1. 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 HandlingSupport 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 & ImprovementsParticipate 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 & ComplianceEnsure 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 & ReportingMaintain 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. CoordinationWork 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% YoYMean Time to Repair (MTTR)↑ 20% YoYMean Time Between Failures (MTBF)Zero tolerance: ≤ 1 per quarterUnplanned Electrical Breakdowns100%Preventive Maintenance (PM) Compliance≥ 99%WHRS Electrical Availability≥ 99%Turbine Electrical ReliabilityKPI CategoryPerformance IndicatorTarget / BenchmarkOperational EfficiencyElectrical System Availability (%)≥ 98%Auxiliary Power Consumption↓ 3–5% YoYMean Time to Repair (MTTR)↓ 10% YoYMean Time Between Failures (MTBF)↑ 10% YoYReliability & MaintenanceBreakdown Frequency (per month)< 2Critical Equipment Failure RateZero Critical FailuresEnergy PerformancePower Factor ≥ 0.98Cost ControlSpare Utilization EfficiencyWithin BudgetPeopleTeam Productivity≥ 95%DigitalizationPredictive Maintenance Analytics Usage≥ 90%Digital Work Order Closure (within 24 hrs)≥ 95%4. Competency FrameworkFunctional CompetenciesWaste heat recovery (AFBC) TG (Turbine Generator) operations Boiler & auxiliary system power distribution Synchronization with grid & captive loads Leadership CompetenciesManpower allocation Shutdown planning Spare parts & inventory management 5. Qualification & ExperienceBE/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 SuccessYearFocus AreaKey DeliverablesExpected OutcomeYear 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 improvementImproved equipment stability, 98% electrical system availabilityYear 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 reportingYear 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 CPP7. Annual Success Plan (FY2025–26)QuarterKey PrioritiesTarget OutcomeQ1Comprehensive electrical system audit (HT/LT panels, transformers, motors)100% system & compliance accuracyQ2Implement preventive & predictive maintenance schedule (thermography, PD, PQ analysis)Achieve 98–99% system availabilityQ3Energy efficiency improvement initiatives (motor efficiency, PF improvement, load balancing)6–8% energy or maintenance cost reductionQ4Annual cost review & reliability benchmarking12–15% improvement over baseline KPIs