Job Posting: Power Plant Manager (Captive Cogeneration & Utilities)

Location : Apply who are willing to relocate only - Survey No: 36,38,41 & 43, Jakkepally Village, Yalal Mandal, Vikarabad District, Telangana state, India 501144

Supervises: Shift In-charges

Position Overview

We are seeking a seasoned, hands-on Power Plant Manager to oversee the end-to-end operation, maintenance, and compliance of our Captive Cogeneration Power Plant and Utility Section supporting continuous ethanol distillation operations.

The successful candidate will lead daily operations and maintenance across a 37 TPH AFBC boiler, a 4.5 MW backpressure steam turbine generator (STG), the Water Treatment Plant (WTP/RO/DM), the Effluent Treatment Plant (ETP/CPU), and induced/forced draft cooling towers. The role demands an operational leader focused on achieving high steam and power availability, optimal specific fuel consumption, stringent statutory compliance (IBR/Pollution Control Board), and zero unplanned downtime.

Key Responsibilities

1. Boiler & Fuel Management (37 TPH AFBC)

* Direct safe, continuous operation of the 37 TPH Atmospheric Fluidized Bed Combustion (AFBC) boiler to meet fluctuating process steam demands from the distillation and evaporation sections.
- Optimize combustion parameters (bed temperature, primary/secondary airflow, bed height, fluidization, excess air, and flue gas O_2 levels) to maximize boiler thermal efficiency and minimize specific coal/biomass consumption.
- Oversee fuel handling, sizing, blending (coal, rice husk, bagasse, or briquettes), and bed material management; implement strict ash handling and disposal protocols (fly ash/bed ash).
- Manage boiler water chemistry in coordination with water lab standards to prevent scaling, silica carryover, tube fouling, attemperator cracking, and caustic gouging.
- Drive annual boiler overhaul schedules, non-destructive testing (NDT), hydraulic tests, and coordinate boiler inspections for statutory renewal under Indian Boiler Regulations (IBR).

1. Turbine & Electrical Generation (4.5 MW Backpressure STG)

* Oversee operations of the 4.5 MW backpressure turbine generator set, ensuring steady exhaust steam flow, correct backpressure, and reliable temperature supplied to the process plant.
- Monitor vibration spectra, bearing temperatures, axial displacement, gland steam sealing, lube oil systems, governor valve response, and Woodward/electronic governing controls.
- Coordinate plant synchronization, load shedding, and electrical export/import logic with the electrical team to prevent tripping during islanding or grid disturbances.
- Lead planned capital overhauls,



lube oil centrifuging/filtration, blade and nozzle ring inspections, and steam trap audits.

1. Water Treatment Plant (WTP / RO / DM Plant)

* Oversee high-purity feed water generation systems (Pre-treatment, Clarifiers, Sand/Dual Media Filters, Reverse Osmosis, Degasser, Mixed Bed / Demineralization Plant, and Electro-deionization).
- Ensure strict adherence to feedwater quality standards: electrical conductivity, pH, silica (SiO_2), total dissolved solids (TDS), and dissolved oxygen at the deaerator outlet.
- Manage chemical consumption, resin regeneration schedules, RO membrane cleaning (CIP) cycles, and antiscalant/biocide dosing programs.

1. Effluent Treatment Plant (ETP) & Condensate Polishing (CPU)

* Manage the operation of the Condensate Polishing Unit (CPU) to ensure maximum recycle of process condensates back to the boiler feed system.
- Supervise biological and chemical wastewater treatment operations (UASB/anaerobic digesters, aerobic aeration basins, clarifiers, and filtration systems) handling distillery wash, blowdowns, and plant domestic waste.
- Maintain Zero Liquid Discharge (ZLD) systems where applicable, managing multi-effect evaporators (MEE) or concentrate treatment to ensure 100% environmental compliance with Central/State Pollution Control Board (CPCB/SPCB) norms.
- Monitor continuous online emission monitoring systems (CAAQMS/CEMS) and online effluent monitoring analyzers.

1. Cooling Towers & Plant Auxiliaries

* Manage induced draft / forced draft counterflow cooling towers servicing the distillation condensers, turbine condenser, and auxiliary equipment.
- Regulate cooling water treatment programs (biocides, scale/corrosion inhibitors, dispersants) to control cycles of concentration (COC), prevent biological fouling, and mitigate Legionella risks.
- Monitor cooling tower basin cleaning, fan gearboxes, drift eliminators, distribution nozzles, and fill pack integrity to maintain approach and range targets.
- Manage high-pressure boiler feed pumps (BFPs), ID/FD/PA fans, air compressors, and instrument air driers.

1. Maintenance, Reliability & Planning

* Implement proactive, preventive, and predictive maintenance programs (vibration monitoring, thermography, oil analysis)



across all rotary and stationary utility equipment.
- Enforce Root Cause Failure Analysis (RCFA) for every trip, leak, or breakdown, instituting corrective actions to target continuous, uninterrupted runs (>180-day stretch targets).
- Formulate annual operation and maintenance (O&M;) operational expenditure (OPEX) budgets and control store inventories of critical spares, mechanical seals, tubes, valves, and refractory materials.

1. Safety, Statutory Compliance & Team Leadership

* Ensure strict adherence to statutory norms: Indian Boiler Act & Regulations (IBR), Factory Act, Environmental Clearance conditions, Electricity Acts, and hazardous waste handling.
- Maintain plant safety standards: implement Permit-to-Work (PTW), Lockout-Tagout (LOTO), confined space entry procedures, and conduct regular emergency mock drills.
- Lead, train, and mentor a multidisciplinary team of engineers, certified boiler operation engineers, chemists, and field operators.

Candidate Qualifications & Requirements

Educational Background

- B.E. / B.Tech in Mechanical or Electrical Engineering from a recognized university/institution.
- First Class Boiler Operation Engineer (BOE) Certificate of Competency under Indian Boiler Regulations (IBR) is highly preferred / mandatory.

Experience

- 9 to 15 years of hands-on experience in captive power plant operations and maintenance, with at least 3 to 5 years in a managerial or lead capacity.
- Direct operational expertise with AFBC boilers (minimum 3050 TPH) and backpressure steam turbines (310 MW range).
- Solid background working in continuous process industries such as Grain/Molasses Distilleries, Ethanol Plants, Sugar Cogeneration, or Chemical Processing.

Technical Competencies

- Deep understanding of fluidized bed dynamics, fuel-air stoichiometry, bed temperature stability, and refractory maintenance.
- Strong grasp of water treatment chemistry, reverse osmosis flux rates, ion-exchange resin kinetics, and biological wastewater systems.
- Proficiency in interpreting P&IDs;, electrical single-line diagrams (SLDs), DCS logic, and turbine trip schematics.
- Familiarity with computerized maintenance management systems (CMMS/ERP) and inventory management workflows.

Key Performance Indicators (KPIs)

- Power plant and utility uptime / availability (>98%).
- Auxiliary power consumption percentage and specific fuel consumption (kg steam / kg fuel).
- Boiler thermal efficiency (>82%).
- Water recycle ratio and compliance with ZLD/PCB water quality parameters.
- Zero lost-time injuries (LTIs) and zero statutory non-conformances.

📌 Power Plant Manager (Captive Cogeneration & Utilities) (Tandur)
🏢 Radical Bio Organics
📍 Tandur