Head – Captive Power Plant (CPP)

Department: Captive Power Plant

Location: Bhandara Plant, Maharashtra

Reports To: CEO & DIRECTOR

Experience: 18–25 years

Qualification: B.E. / B.Tech – Electrical Engineering; First-Class Power Engineer's Certificate of Competency preferred

Role Purpose The Head – CPP holds unified accountability for the plant's entire power ecosystem: captive generation through the Captive Power Plant and grid interface management through the Main Receiving Sub-Station. The role ensures that every tonne of steel produced at Bhandara is backed by reliable, safe, and cost-optimised electrical power — whether sourced from captive generation, the state grid, or a seamless combination of both.

Key ResponsibilitiesIntegrated Power Operations

- Direct the integrated operation of the Captive Power Plant (AFBC / WHRB / DG sets as applicable) and the Main Receiving Sub-Station (MRSS) as a single, unified power function — ensuring coordinated load management, switchover protocols, and zero-gap supply to all plant consumers.
- Maintain and optimise all CPP plant equipment — boilers, turbines (condensing/backpressure), generators, heat recovery systems, BOP auxiliaries — targeting maximum availability, minimum heat rate, and lowest auxiliary consumption.
- Own the full MRSS infrastructure: EHV/HV incoming feeders, power transformers, bus-bar and feeder protection, SF6/VCB switchgear, numerical protection relays, CT/PT metering, earthing systems, and outdoor switchyard — ensuring equipment health and protection coordination at all times.

Grid Interface & Compliance
- Manage grid synchronisation and interface with MSEDCL/MSLDC — handle demand scheduling, reactive power obligations, energy import/export metering, and grid disturbance response; maintain all HV/EHV connection licenses and utility compliance records.
- Ensure full statutory compliance — CEA Safety Regulations, Factories Act (electrical provisions), MSEDCL connection conditions, MEDA/energy audit requirements, and OHSAS 18001 / ISO 45001; represent the company during regulatory inspections and energy audits.

Power Distribution & Energy Management
- Drive plant-wide power distribution planning — coordinate with Steel Making, Rolling Mills, and other departments on load scheduling, peak demand management, power factor correction, and emergency load-shedding priority lists.
- Monitor and improve energy performance indices — unit heat rate, specific power consumption, auxiliary power %,



and grid import cost — and lead structured energy-saving initiatives across CPP and distribution network.

Safety, Quality & Compliance
- Enforce a zero-LTI electrical safety culture across CPP and MRSS — implement and audit Permit-to-Work (PTW) systems, conduct periodic HV safety audits, manage emergency drills (grid outage, generation trip, transformer fault), and lead toolbox talks for all shift and maintenance staff.
- Ensure all CPP and MRSS operations meet ISO 9001 and IATF 16949 quality system requirements as they interface with plant energy supply, maintaining documentation standards and participating in internal and external audits.
- Drive compliance with ISO 14001 environmental obligations — monitor stack emissions, effluent from cooling systems, and ash/waste management from CPP operations; implement corrective actions arising from environmental audits.
- Maintain OHSAS 18001 / ISO 45001 compliance across the power function — conduct risk assessments for all electrical and mechanical hazards in CPP and substation areas, update safe operating procedures, and ensure all staff are trained and certified as per CEA and statutory requirements.
- Liaise with statutory authorities including CEA, Electrical Inspector, MSEDCL, MPCB, and Factories Inspectorate for inspections, approvals, license renewals, and compliance reporting; maintain a current and complete statutory register for the power function.
- Track and close non-conformances identified through internal audits, energy audits (BEE), and regulatory inspections within committed timelines; report compliance status to Plant Head and senior management.

People & Budget Management
- Lead the CPP & MRSS team: shift engineers, HV operators, substation attendants, boiler operators, and technicians; define KPIs, conduct performance reviews, and build succession at every critical position.
- Own CAPEX and OPEX budgets for both CPP and MRSS; evaluate and present business cases for capacity augmentation, technology upgrades, and efficiency improvement projects.
- Plan and maintain critical spares inventory for both functions — transformers, relay modules, SF6 gas, turbine/boiler spares,



cable terminations — in coordination with Procurement to eliminate production-impacting stoppages.

Qualifications & Experience
- Education: B.E. / B.Tech in Electrical Engineering from a recognised university. First-Class Power Engineer's Certificate of Competency (under Indian Electricity Act) strongly preferred.
- Experience: 18–25 years in captive industrial power generation and HV/EHV substation operations, with a minimum of 5 years heading a combined or separate CPP and MRSS function in a steel plant, cement plant, or comparable energy-intensive heavy-manufacturing facility.
- Plant Coverage: Hands-on experience operating and maintaining an MRSS at 33 kV / 66 kV / 132 kV level — including grid synchronisation, protection relay coordination, and utility liaison — is essential.
- Certifications (preferred): First-Class Power Engineer's Certificate of Competency; Electrical Supervisor Competency Certificate (CEA); BEE Certified Energy Auditor; familiarity with numerical protection relay platforms (ABB REF/REL, Siemens SIPROTEC, SEL, or equivalent) and SCADA/DCS systems.

Skills & CompetenciesTechnical
- Thermal power plant cycles: AFBC/CFBC boilers, condensing/backpressure steam turbines, WHRB.
- EHV/HV substation systems: protection relays, SF6/VCB switchgear, power transformers, bus-bar protection, earthing, metering.
- Power quality and power factor management; load dispatch and grid interface; energy accounting and audit.
- SCADA/DCS and PLC-based control systems for CPP and substation operations.
- ISO 9001, IATF 16949, ISO 14001, OHSAS 18001 / ISO 45001 requirements as applied to power generation and distribution functions.

Behavioural
- Decisive leadership under high-stakes conditions — generation trips, grid faults, MRSS outages.
- Data-driven performance management; robust coordination with production and maintenance teams.
- Effective engagement with regulatory authorities (MSEDCL, CEA, MPCB, Factories Inspectorate).
- Uncompromising commitment to electrical safety, statutory compliance, and continuous improvement.

Why Join Sunflag
- Sunflag's integrated, iron-ore-based steelmaking route — spanning Mini Blast Furnace to Super Alloy production via VIM, VAR, and ESR — is among the most technically demanding in central India. The Head – CPP & MRSS role offers genuine end-to-end ownership of the plant's power system in a growing, export-oriented steel major with a Daido Steel Japan technical collaboration and a clear commitment to energy efficiency and operational excellence.

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