The Boiler Integrity Engineer (Mid Level) is responsible for monitoring, assessing, and ensuring the structural integrity, safety, and performance of boiler systems and pressure equipment. This role supports inspection planning, fitness-for-service assessments, and reliability improvement initiatives in line with regulatory and industry standards.
Inspection Planning & Coordination:
Develop and implement inspection plans for boilers and associated pressure parts.
Coordinate with third-party NDT vendors and internal inspection teams.
Schedule internal, external, and operational condition assessments during shutdowns and online periods.
Integrity Evaluation:
Analyze inspection findings to evaluate component degradation (e.g., corrosion, fatigue, creep).
Perform or support Fitness-for-Service (FFS) assessments (as per API 579).
Recommend repairs, de-rating, or replacement based on findings.
Regulatory Compliance & Documentation:
Ensure boilers and pressure parts comply with IBR, ASME Section I & VIII, API 510, and NBIC requirements.
Maintain inspection records, condition monitoring logs, and certification documents.
Prepare for audits and inspections by statutory authorities and certification bodies.
Risk-Based Inspection (RBI):
Support implementation of Risk-Based Inspection programs for boiler systems.
Identify high-risk areas and adjust inspection frequencies based on risk profiles.
Root Cause Analysis (RCA):
Participate in investigations of boiler failures or deviations.
Support root cause analysis and contribute to preventive recommendations.
Technical Advisory:
Provide guidance to operations and maintenance teams on safe boiler operation and limitations.
Support engineering teams in equipment design changes, material selection, and failure prevention.
Shutdown & Turnaround Support:
Participate in planning and execution of boiler inspections and repairs during major plant shutdowns or turnarounds.
Ensure readiness of all documentation, procedures, and safety protocols.
Structural Integrity: Ensuring boiler components maintain mechanical integrity throughout their lifecycle.
Code Compliance: Adhering to ASME, IBR, API, and NBIC standards.
Condition Monitoring: Tracking degradation mechanisms and maintaining real-time asset health records.
Failure Prevention: Detecting early warning signs and addressing root causes to prevent unplanned shutdowns.
Asset Lifecycle Management: Supporting long-term reliability, safety, and performance improvement initiatives.
Strong knowledge of boiler and pressure vessel construction, operation, and failure mechanisms.
Familiarity with NDT techniques (UT, RT, PT, MT, VT) and interpretation of results.
Understanding of codes and standards: ASME Section I & VIII, API 510, API 579, IBR.
Proficiency in reading engineering drawings, isometrics, and P&IDs.
Experience with Fitness-for-Service (FFS) evaluations.
Ability to perform degradation analysis and recommend mitigation.
Familiar with inspection data management systems (IDMS) or asset integrity software.
Well-versed in boiler certification requirements and documentation standards.
Skilled in preparing technical reports and audit-ready documentation.
Strong teamwork and communication skills for interfacing with maintenance, inspection, and operations teams.
Ability to convey technical issues and recommendations clearly to both technical and non-technical stakeholders.
Education: B.E./B.Tech in Mechanical Engineering, Metallurgical Engineering, or equivalent.
Certifications (preferred):
API 510 – Pressure Vessel Inspector
API 579 – Fitness-for-Service (or equivalent experience)
IBR Certified (if applicable)
Experience: 5–8 years in boiler inspection, maintenance, integrity, or reliability roles in oil & gas, refining, petrochemicals, or power sectors.