Purpose - Why does this role exist?:

The Project Manager - Blast Furnace (BF) exists to lead the complete engineering, procurement, construction, and commissioning (EPCC) of the Blast Furnace facility within the Rajayyapeta Green Field Integrated Steel Plant (ISP) project. This critical leadership role ensures that the BF facility - spanning Blast Furnace proper, Cast House, Stock House, Top Recovery Turbine (TRT), Gas Cleaning Plant (GCP), cooling water recirculation and treatment system, and Gas Holder is built from the ground up. The primary objective is to deliver a state-of-the-art, high-capacity mill on schedule, within budget, and in strict compliance with global safety and quality standards, transforming Pellets, Sinter, lump ore and coke into high-grade hot metal.

One Safety Culture:

- Champion Safety First by embedding safety considerations into all engineering designs, layouts, specifications and technical deliverables.

- Ensure application of safety-in-design principles covering process safety, operational safety, maintainability, access safety, fire protection, emergency response and equipment safety.

- Drive HAZOP, HAZID, risk assessments, design safety reviews and constructability reviews in coordination with Safety, Operations, Construction and Project teams.

- Ensure engineering deliverables comply with applicable statutory, environmental, process safety and industrial safety standards.

- Minimize design-related hazards, unsafe layouts, access constraints, maintenance risks and site execution risks through proactive engineering reviews.

- Ensure that engineering solutions support safe construction, safe commissioning and safe long-term plant operations.

- Promote zero-harm culture through technically robust designs, standardization, disciplined review mechanisms and timely closure of safety-critical design issues.

Key Result Areas (Key Performance Indicators):

- Project Timeline Adherence: Baseline schedule variance maintained as per budget, ensuring timely milestones for structural erection and blow-in.

- Budget Management: Cost variance kept within approved limits, minimizing project cost overruns.

- Safety Performance: Achieving zero Loss Time Injuries (LTI) and maintaining Injury Rate below industry benchmarks on-site.

- Quality Compliance: Ensuring 100% adherence to engineering specifications, non-destructive testing (NDT) passes, and refractory lining standards.

- Contractor and Vendor Performance: Timely evaluation, onboarding, and delivery management of main technology suppliers and civil contractors.

- Regulatory Compliance: Securing all necessary statutory clearances and environmental approvals related to the Blast Furnace complex prior to commissioning.

- Risk Mitigation: Identifying project risks early and maintaining an active, updated risk register with effective mitigation strategies.

- Resource Optimisation: Efficient management of project manpower, equipment, and material resources to maximize output and reduce waste.

- Commissioning Readiness: Seamless handover of the operational Blast Furnace and its auxiliaries to the Operations and Maintenance (O&M) team.

- Stakeholder Satisfaction: Clear communication, reporting accuracy, and alignment across internal steering committees, consultants, and external partners.

Critical Tasks (Key Activities):

- Master Planning: Formulate the detailed project execution plan, master schedule, and logic networks for the entire Blast Furnace facility.

- Engineering Coordination: Review and approve basic and detailed engineering drawings (including civil, structural, mechanical, electrical, instrumentation and automation systems) alongside the consultant.

- Procurement Support: Collaborate with the commercial team to draft technical specifications, evaluate tender bids, and select vendors for critical long-lead equipment.

- Deep handling experience with global technology suppliers and equipment OEMs for Blast Furnace.

- Site Infrastructure Supervision: Oversee the piling, heavy equipment foundations, and structural fabrications specific to the Blast Furnace complex.

- Technology Alignment: Ensure integration of the core furnace with auxiliary units like the Stock house, Cast House, Hot Blast Stoves, Top Recovery Turbine (TRT), Gas Cleaning Plant (GCP), and Pulverized Coal Injection (PCI) system, Gas Holder, cooling water system, power distribution system within BF area.

- Contract Management: Monitor EPC contractor deliverables, manage variations, verify billing milestones, and resolve contractual disputes.

- Rigging and constructability studies, erection sequencing, Modularization: Carry out rigging studies, constructability studies and erection sequencing, modularize supplies from contractors, OEMs to minimize overall construction timelines.

- HSEQ Implementation: Enforce stringent health, safety, environmental, and quality assurance protocols across all execution teams and sub-contractors on-site.

- HAZOP, HAZID, risk assessments: Ensure HAZOP, HAZID, risk assessments outcomes/recommendations are incorporated in project design and engineering, construction.

- Progress Monitoring: Conduct daily and weekly site progress reviews, identify bottlenecks, and deploy recovery plans to counter project delays.

- Testing and Inspection: Supervise shop inspection of critical items at vendor workshops and manage on-site material receiving inspections.

- Trial Runs and Commissioning: Lead the dry runs, cold trials, hot trials, and final hot-metal commissioning activities up to the stable blow-in/hot metal production stage.

Education Qualification and Certifications:

- Primary Degree: Bachelor's Degree in Mechanical Engineering, Metallurgical Engineering, or Electrical Engineering from a recognized institution. A Master's degree in Project Management or an MBA is an advantage.

- Primary Certification: Project Management Professional (PMP) is highly preferred.

- Technical Safety: Certifications in industrial safety (e.g., NEBOSH, IOSH) are a strong asset.

Relevant Experience:

- Minimum 18 years of total experience of which, with at least 8 years dedicated to greenfield or major brownfield Blast Furnace (BF) installations.

- Proven track record of successfully commissioning at least one integrated BF project involving large scale structural erection and heavy equipment alignment.

- Extensive experience in managing large-scale civil foundations specific to steel plants, including heavy Blast Furnace and related foundations.

- Deep handling experience with global technology suppliers and equipment OEMs (e.g., SMS Group, Primetals, Danieli).

Skills and Competencies:

- Technical Mastery: Deep understanding of Blast Furnace layout, hot metal logistics, gas cleaning plants (GCP), BF slag handling systems, water treatment systems, power distribution system for Blast Furnace.

- Project Software Competency: High proficiency in project management tools like Primavera P6 or Microsoft Project (MSP).

- Contract Management: Expert ability to interpret commercial contracts, manage claim disputes, and evaluate variation orders.

- Leadership and Stakeholder Management: Strong capability to influence cross-functional teams, external consultants, and local government bodies.