The Senior Boiler Design Engineer is responsible for leading and managing the design, analysis, and code compliance of complex boiler systems in accordance with ASME Boiler and Pressure Vessel Code (BPVC) Section I (Power Boilers) and Section IV (Heating Boilers). This role involves technical leadership, design optimization, mentoring of junior engineers, and cross-functional coordination with fabrication, quality, and project management teams. The engineer ensures all designs meet code, performance, reliability, and safety standards.
Lead the mechanical design and engineering of complete boiler systems including drums, headers, water walls, superheaters, economizers, piping, and casing structures.
Perform advanced calculations involving pressure containment, stress analysis, thermal expansion, fatigue, supports, and nozzle loading in compliance with ASME Section I/IV and other applicable codes (e.g., NBIC, IBR, PED).
Review and approve detailed design documents, CAD drawings, data sheets, fabrication drawings, and code compliance reports.
Interface with thermal engineers to align heat transfer performance with mechanical design.
Provide technical leadership during design reviews, customer meetings, audits, and code inspections.
Prepare or oversee preparation of ASME Code documentation, including U-1 forms, design calculation reports, and manufacturer’s data reports.
Resolve high-level technical issues during fabrication, quality inspections, or site erection phases.
Ensure alignment of design with project timelines, budgets, and client specifications.
Guide the selection of materials, welding procedures, and NDE specifications.
Mentor junior engineers and contribute to internal design standards, tools, and knowledge base.
Lead root cause analysis for design-related failures and initiate design improvements.
Code Compliance & Advanced Engineering
Expert-level application of ASME Section I/IV with strong command of related pressure vessel design rules.
Design Optimization
Deliver safe, cost-effective, and manufacturable boiler designs while improving lifecycle performance.
Technical Leadership
Serve as a subject matter expert and mentor for mechanical design and pressure part engineering.
Cross-Functional Collaboration
Interface with fabrication, QA/QC, thermal, and project teams to ensure seamless project execution.
Client & Regulator Engagement
Act as a technical point of contact for client reviews, third-party inspectors, and code auditors.
Bachelor's degree in Mechanical Engineering (Master’s preferred).
8–15+ years of experience in boiler or pressure vessel design with direct application of ASME BPVC Section I and IV.
In-depth expertise in mechanical design principles, allowable stresses, material behavior, and thermal-mechanical interactions.
Strong proficiency in design tools such as PV Elite, Compress, AutoCAD, Inventor, and SolidWorks.
Proven ability to manage multiple projects and guide design teams through technical and execution phases.
Hands-on familiarity with welding standards, fabrication techniques, and shop practices.
Solid understanding of code stamping, regulatory documentation, and inspection procedures.