Job Title: Boiler Engineer

Job Summary:

The Mid-Level Boiler Engineer is responsible for the efficient operation, maintenance, troubleshooting, and optimization of boiler systems in industrial, commercial, or power plant settings. This role involves leading operational support for boiler systems, performing preventive and corrective maintenance, managing boiler performance, and ensuring compliance with safety standards and regulations. The Boiler Engineer will also assist in the integration of new technologies, oversee junior engineers and technicians, and contribute to process improvements to ensure boiler systems are operating at peak efficiency.

Key Responsibilities:

1. Boiler Operation and Performance Monitoring:

   • Oversee day-to-day operations of boiler systems, ensuring they are functioning within the specified parameters (pressure, temperature, fuel efficiency).
   • Monitor and control boiler performance, identifying opportunities to optimize efficiency, reduce energy consumption, and ensure the reliable generation of steam.
   • Analyze operational data and provide feedback on boiler performance, suggesting areas for improvement or optimization.

2. Maintenance and Troubleshooting:

   • Perform and supervise routine maintenance activities, including cleaning, calibration, and replacing worn parts such as valves, gaskets, and pressure relief valves.
   • Lead troubleshooting efforts to identify and resolve complex boiler system issues, such as combustion problems, pressure inconsistencies, or steam distribution issues.
   • Manage emergency repairs, ensuring that issues are resolved quickly to minimize downtime and impact on operations.

3. Preventive and Predictive Maintenance:

   • Develop, implement, and manage preventive maintenance schedules to ensure boiler systems are regularly inspected and maintained in optimal working condition.
   • Use predictive maintenance techniques and tools to assess the condition of components and predict potential failures before they occur.
   • Ensure all maintenance activities are documented and that all regulatory inspections are passed.

4. Boiler System Testing and Calibration:

   • Perform comprehensive testing and calibration of boiler components, including pressure testing, leak testing, and burner optimization.
   • Assist in the development of testing procedures to improve the reliability and performance of the boiler systems.
   • Ensure that all systems are operating within safety limits and in compliance with local, state, and national regulations.

5. Safety and Regulatory Compliance:

   • Ensure that all boiler operations and maintenance activities are performed in compliance with safety standards and regulatory requirements (e.g., ASME, API, OSHA).
   • Lead safety audits and ensure that the boiler systems adhere to safety protocols, including proper pressure relief, safe operating limits, and emergency shutdown procedures.
   • Participate in risk assessments, safety drills, and process reviews to ensure safe operation and mitigate risks associated with boiler operation.

6. Energy Efficiency and System Optimization:

   • Monitor and analyze the energy consumption of the boiler system, identifying opportunities to optimize fuel use, reduce emissions, and increase overall efficiency.
   • Collaborate with other teams to implement energy-saving initiatives, including tuning combustion systems, optimizing heat recovery, and using advanced control systems.
   • Assist in the integration of energy-efficient technologies and practices into boiler operations to minimize operational costs and environmental impact.

7. Mentoring and Training:

   • Provide guidance and training to junior engineers and technicians, helping them develop technical skills and knowledge of boiler systems.
   • Ensure that junior staff members are trained on safety procedures, equipment maintenance, and troubleshooting techniques.
   • Assist in the development of training materials and manuals for boiler operations, ensuring team members have access to the latest operational best practices.

8. Documentation and Reporting:

   • Maintain detailed records of boiler operations, inspections, maintenance activities, and repairs to ensure compliance with regulatory standards.
   • Provide regular operational reports to senior management, including key performance indicators (KPIs), energy consumption, and maintenance status.
   • Ensure that all maintenance activities and system changes are properly documented for future reference and audits.

9. Collaboration with Cross-Functional Teams:

   • Work closely with the engineering, maintenance, and operations teams to ensure that boiler systems are integrated seamlessly with other plant systems.
   • Collaborate with procurement teams to ensure timely delivery of spare parts and materials required for maintenance activities.
   • Participate in project planning and execution for major upgrades or replacement of boiler systems.

Skills and Knowledge Required:

• Strong technical knowledge of boiler systems, including various types of boilers (fire tube, water tube, etc.), burners, pumps, valves, and pressure relief devices.
• Experience with boiler performance monitoring tools, combustion analysis, and energy optimization techniques.
• Expertise in troubleshooting and diagnosing complex mechanical and electrical issues in boiler systems.
• Knowledge of safety regulations and industry standards (e.g., ASME, API, OSHA) related to boiler operation and maintenance.
• Experience with SCADA and control systems for monitoring and optimizing boiler performance.
• Ability to manage preventive maintenance schedules, including identifying critical tasks and prioritizing repairs.
• Strong problem-solving and analytical skills to improve boiler system efficiency and reliability.
• Excellent communication skills for providing reports, collaborating with teams, and mentoring junior engineers.

Educational Qualifications:

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, or a related technical field.
• Certifications in Boiler Operations, Pressure Vessel Systems, or Energy Efficiency are preferred.
• Professional certifications (e.g., ASME, API, OSHA) related to boiler systems and maintenance are beneficial.

Experience:

• 3-5 years of experience in boiler operations, maintenance, or engineering, preferably in power plants, industrial facilities, or manufacturing environments.
• Hands-on experience in troubleshooting and optimizing boiler systems, including combustion management and energy efficiency practices.
• Experience with boiler system control systems (e.g., SCADA) for monitoring performance and ensuring safe operation.
• Proven track record of implementing preventive and predictive maintenance strategies.

Tools and Technologies:

• Proficiency in using diagnostic and testing tools, including pressure gauges, thermometers, flow meters, combustion analyzers, and vibration sensors.
• Familiarity with boiler system control and monitoring software (e.g., SCADA) for performance optimization.
• Experience with computerized maintenance management systems (CMMS) is a plus.

Other Requirements:

• Ability to work in industrial environments, including high-pressure systems and confined spaces.
• Willingness to work in shifts, on-call, or during emergencies to address boiler system breakdowns or operational issues.
• Strong organizational skills with the ability to manage multiple tasks, prioritize effectively, and meet deadlines.
• Commitment to maintaining a high standard of safety and operational excellence.