Senior HV Power Engineer - 161kV Systems & Safety Lead

Century Aluminum Company; Kentucky; Hybrid; USD 120,000 - 180,000; Full time

Job summary

Century Aluminum Company in Robards, Kentucky, seeks a lead HV Electrical Engineer to own and manage the HV switchyard and protection systems across production lines. You will develop and maintain HV protection settings, arc flash analysis, and work-zone procedures; lead multi-year maintenance plans and capital initiatives with cross-functional teams including the PMO.

A Bachelor’s in Electrical Engineering and 5+ years HV/MV experience in heavy industry are required; PE preferred and strong

Qualifications

• Bachelor’s degree in Electrical Engineering with emphasis on power systems, high voltage, or power distribution.
• Minimum 5 years of hands‑on HV and MV engineering experience in an industrial manufacturing or utility environment.
• Demonstrated ability to communicate effectively and provide technical direction across all levels of the organisation including maintenance crews, contractors, and plant management.
• Strong organisational skills and ability to manage multiple priorities including maintenance programs, capital projects, and day‑to‑day operational support simultaneously.

Responsibilities

• Own and manage the main HV switchyard including 161kV disconnects, transformers, and SF6 switchgear across production lines.
• Develop and maintain HV protection/relay settings and arc flash analysis; establish electrical safe work zones.
• Monitor transformer condition via DGA, oil sampling, and thermal assessments; lead maintenance decisions and lifecycle planning.
• Lead multi-year HV maintenance plans; drive capital budget initiatives for the HV system; coordinate with Project Management Office.
• Lead design, commissioning, and oversight of HV equipment installations (161kV, 34.5kV, 13.8kV, 480V).
• Provide 24/7 failure response for HV incidents; conduct root cause analysis and corrective actions.

Skills

HV engineering

Power systems

Electrical safety

Project leadership

Education

Bachelor’s degree in Electrical Engineering

Tools

SEL protection relays

SAP Plant Maintenance

DGA interpretation

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

Exempt Robards, KY, US

30+ days ago Requisition ID: 1891

The High Voltage and Power Systems Engineer is the technical authority for all HV and MV electrical infrastructure at Century Aluminum – Sebree Operations. This includes the main 161kV switchyard, rectifier and regulating transformers, MV and HV switchgear, protection and relay systems, and the power distribution network feeding the aluminum production lines. The engineer is accountable for the safe, reliable, and compliant operation of this infrastructure and provides technical engineering authority to maintenance crews, contractors, and plant management. This is a critical position – the facility’s production capacity depends directly on the reliability of the high voltage infrastructure this engineer owns.

Key Activities:

• Own and manage the main HV switchyard including all 161kV incoming disconnects, main power transformers, rectifier and regulating transformers, oil circuit breakers, and SF6 switchgear across all production lines.
• Develop and maintain HV protection and relay settings, functional injection testing schedules, and arc flash analysis for the full facility. Provide direction for establishing electrical safe work zones for all personnel working near HV hazards.
• Monitor transformer condition through dissolved gas analysis, oil sampling, and thermal assessment. Lead condition-based maintenance decisions and capital lifecycle planning for all major HV assets including active monitoring of rectifier transformers with known condition concerns.
• Develop and implement multi-year HV maintenance plans. Lead capital budget initiatives for the HV power system, prepare funding requests, and track execution in coordination with the Project Management Office.
• Lead the design, commissioning, and technical oversight of HV equipment installations and replacements, including rectifier transformers, main power transformers, and HV switchgear (system voltages: 161kV, 34.5kV, 13.8kV, and 480V).
• Provide 24/7 failure response capability for HV system incidents. Lead root cause analysis for all HV-related failures and implement corrective actions to prevent recurrence.
• Lead the HV competency development program for designated Electrical Engineers on site.
• Serve as the site’s HV electrical safety authority. Responsible for arc flash compliance, electrical safe work procedures, and HV safety protocol across the facility

Basic Qualifications:

• Bachelor’s degree in Electrical Engineering with emphasis on power systems, high voltage, or power distribution.
• Minimum 5 years of hands-on HV and MV engineering experience in an industrial manufacturing or utility environment.
• Demonstrated ability to communicate effectively and provide technical direction across all levels of the organisation including maintenance crews, contractors, and plant management.
• Strong organisational skills and ability to manage multiple priorities including maintenance programs, capital projects, and day-to-day operational support simultaneously.

Preferred Qualifications:

• In-depth knowledge of high current rectifier transformer systems including condition monitoring, OLTC maintenance, and dissolved gas analysis interpretation to IEEE C57.104 standards.
• Experience with SEL protection relay platforms including settings verification, relay coordination, and functional injection testing.
• Experience in a primary metals, smelting, or continuous process industrial environment.
• Understanding of short circuit, arc flash, load flow, and relay coordination studies. Familiarity with NFPA 70E electrical safety requirements.
• Demonstrated experience leading, managing, and commissioning electrical capital projects including design, contractor oversight, and installation.
• Can evaluate equipment condition, interpret electrical testing results, and perform reliability assessments. Familiarity with SAP Plant Maintenance for work order and asset management.
• Registered Professional Engineer (PE) or equivalent credential preferred.