Project Manager - Thin Slab Casting & Rolling

Purpose:

The Project Manager - Thin Slab Casting and Rolling (TSCR) exists to lead the complete engineering, procurement, construction, and commissioning (EPCC) of the TSCR facility within the Rajayyapeta Green Field Integrated Steel Plant (ISP) project. This critical leadership role ensures that the TSCR facility - spanning Casting, Tunnel Furnace, rolling section, cooling water recirculation and treatment system 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 liquid steel capabilities into high-grade flat products.

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:

• 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 TSCR 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 TSCR 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:

• Master Planning: Formulate the detailed project execution plan, master schedule, and logic networks for the entire TSCR Block.

• Engineering Coordination: Review and approve basic and detailed engineering drawings 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 TSCR Block.

• Site Infrastructure Supervision: Oversee the piling, heavy equipment foundations, and structural fabrications specific to the TSCR complex.

• Technology Alignment: Ensure integration of the core TSCR block with auxiliary units such as cooling water recirculation/treatment system, power distribution system within TSCR block.

• 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 TSCR commissioning activities up to the stable rolling 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) or PRINCE2 Practitioner certification 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 Thin Slab Casting and Rolling (TSCR) installations.

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

• Extensive experience in managing large-scale civil foundations specific to steel plants, including heavy Rolling Mill and deep pits.

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

• Strong background in managing multi-disciplinary large contractor workforce under tight timelines.

Skills and Competencies:

• Technical Mastery: Deep understanding of TSCR technology, tunnel furnace dynamics, metallurgy of casting and flat products, and hydraulic gauge control (HGC) and water treatment systems, power distribution system for TSCR.

• 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.

• Problem Solving: High analytical capability to quickly resolve structural mismatches, engineering clashes, and logistical delays on the ground.