AGM - DRI Electrical (Maintenance)

Position: Assistant General Manager - DRI Electrical Maintenance

Industry: Steel Industry (Direct Reduced Iron - DRI Plant)

Experience: 12-18 years in Electrical Maintenance of DRI (350 TPD or higher)

Location: Jharsuguda

Reporting To: Head-Operations

Roles & Responsibilities:

1. Electrical Maintenance & Plant Reliability

• Oversee the electrical maintenance of the DRI Plant, WHRB (Waste Heat Recovery Boiler), Induction Furnace, SMS, and Rolling Mill.
• Ensure the smooth operation of HT/LT panels, transformers, circuit breakers, VFDs, MCCs, PCCs, and motor control centers.
• Implement preventive, predictive, and breakdown maintenance strategies to reduce plant downtime.
• Troubleshoot and resolve electrical faults in motors, switchgear, and control panels.

2. Power Distribution & Energy Management

• Manage the power distribution network for uninterrupted plant operations.
• Monitor power factor, load distribution, and voltage regulation across the plant.
• Optimize power usage and implement energy-saving initiatives to reduce costs.
• Coordinate with the captive power plant team (WHRB, FBC Boilers) for efficient power utilization.

3. Automation & Control Systems

• Ensure proper maintenance and troubleshooting of PLC (Siemens, ABB, Allen Bradley), SCADA, and DCS systems.
• Monitor and maintain automation systems in the DRI plant, Induction Furnace, and Rolling Mill.
• Ensure proper calibration and maintenance of temperature sensors, pressure transmitters, and flow meters.

4. Equipment Maintenance & Troubleshooting

• Maintain transformers, circuit breakers, busbars, relays, and electrical switchgear.
• Ensure the smooth operation of AC/DC motors, gearboxes, and variable frequency drives (VFDs).
• Troubleshoot issues related to harmonics, voltage fluctuations, earthing, and electrical protection systems.

5. Safety & Compliance

• Ensure adherence to electrical safety standards and statutory compliance as per industry regulations.
• Conduct electrical safety audits, risk assessments, and preventive inspections.
• Implement LOTO (Lockout-Tagout) procedures for equipment maintenance safety.
• Ensure compliance with CEA, IEC, and factory act regulations for electrical installations.

6. Manpower Management

• Lead and mentor a team of electrical engineers, supervisors, and technicians.
• Conduct training sessions on electrical safety, maintenance best practices, and troubleshooting.
• Ensure proper shift planning and availability of manpower for round-the-clock maintenance support.

7. Spare Parts & Inventory Management

• Maintain an inventory of critical electrical spares like circuit breakers, relays, fuses, sensors, and VFD modules.
• Coordinate with the purchase and stores department to ensure timely procurement of electrical materials.
• Evaluate and manage vendors and contractors for electrical maintenance services.

8. Coordination with Other Departments

• Work closely with production, mechanical, instrumentation, and utilities teams for smooth plant operations.
• Support the project team in capacity expansions, electrical upgradations, and new installations.
• Collaborate with the power plant team for efficient electricity generation and distribution.

9. Root Cause Analysis & Continuous Improvement

• Conduct Root Cause Analysis (RCA) for major electrical failures and implement corrective actions.
• Drive continuous improvement initiatives to enhance plant efficiency and reduce power losses.
• Keep updated with latest technologies in industrial electrical systems, automation, and energy management.

10. Reporting & Documentation

• Prepare and submit daily, weekly, and monthly reports on electrical performance, maintenance activities, and downtime analysis.
• Maintain records of equipment history, maintenance schedules, and power consumption trends.
• Present electrical system efficiency reports and improvement plans to senior management.

Key Skills & Competencies:

✅ Strong technical knowledge of HT/LT electrical systems, transformers, and power distribution networks.
✅ Expertise in PLC, SCADA, and DCS-based automation systems.
✅ Hands-on experience in electrical maintenance of Kilns, Furnaces, Rolling Mills, and SMS.
✅ Knowledge of electrical safety standards, statutory compliance, and power regulations.
✅ Strong leadership and team management abilities.
✅ Proficiency in SAP, CMMS, and other maintenance management tools.

Educational Qualifications:

• B.E./B.Tech in Electrical Engineering (Preferred)
• Diploma in Electrical Engineering with extensive experience can also be considered