Power Plant Manager (Captive Cogeneration & Utilities)

Radical Bio Organics Limited; Tandur; On-site; INR 1,800,000 - 2,400,000; Full time

Job summary

Radical Bio Organics Limited is seeking an experienced Power Plant Manager to oversee the operation, maintenance, and compliance of a captive cogeneration power plant supporting ethanol distillation. The role covers a 37 TPH AFBC boiler, a 4.5 MW backpressure STG, WTP/RO/DM, ETP/CPU and cooling towers, with a focus on high uptime, optimal fuel use, and strict IBR and PCB compliance.

You will lead a multidisciplinary team, drive preventive maintenance, and implement RCFA-driven improvements to

Qualifications

• BE/BTech in Mechanical or Electrical engineering with good academic record.
• First Class Boiler Operation Engineer (BOE) certificate is highly preferred or mandatory.
• 9 to 15 years of hands-on captive power plant experience, with 3–5 years in a lead role.
• Direct exposure to AFBC boilers (≥ 30–50 TPH) and backpressure turbines is essential.
• Experience in process industries like ethanol/distillery or sugar cogeneration is preferred.

Responsibilities

• Direct safe operation of the 37 TPH AFBC boiler to meet steam demand.
• Oversee 4.5 MW backpressure STG operation, steam flow, and electrical export readiness.
• Manage WTP/RO/DM and ETP/CPU systems, water chemistry, and chemical dosing.
• Ensure ZLD, CPCB/PCB compliance, and regulatory reporting.
• Lead maintenance planning, RCFA, and annual O&M budgeting.
• Develop and mentor a multidisciplinary operations team.
• Uphold safety standards: PTW/LOTO, training, and incident prevention.

Skills

Boiler operation

Turbine operation

Water treatment

Maintenance planning

Safety compliance

Team leadership

Education

B.E./B.Tech Mechanical or Electrical

BOE certification

Tools

CMMS/ERP systems

Job description

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).

2. 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 stable 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.

3. 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.

4. 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.

5. 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.

6. 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.

7. 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&ID, 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.