The Senior Boiler Integrity Engineer is responsible for leading the integrity management, inspection planning, and reliability strategy for all boiler and pressure-retaining systems within oil and gas or process facilities. This position ensures compliance with industry codes, regulatory standards, and corporate asset integrity programs. The role demands technical leadership, risk-based decision-making, and effective collaboration across engineering, inspection, and maintenance functions.
Boiler Integrity Program Leadership:
Lead the development and execution of boiler integrity strategies in line with corporate and regulatory requirements.
Ensure all boiler systems (e.g., steam drums, economizers, superheaters) are operated and maintained within safe operating limits.
Advanced Inspection Planning & Execution:
Develop and manage detailed inspection plans for boilers and associated pressure equipment using RBI (Risk-Based Inspection) methodology.
Review and interpret inspection reports and NDT results, including UT, RT, MT, PT, and advanced techniques like TOFD and phased array.
Fitness-for-Service (FFS) & Engineering Assessments:
Perform or lead FFS evaluations per API 579/ASME FFS-1.
Recommend repair, re-rating, or replacement strategies based on component condition and remaining life assessments.
Compliance & Certification:
Ensure compliance with ASME Section I & VIII, IBR regulations, API 510, NBIC, and other applicable codes.
Coordinate with third-party inspectors and statutory bodies for certifications and audits.
Root Cause Analysis & Failure Investigations:
Lead or participate in the root cause analysis of boiler failures or abnormal conditions.
Develop long-term corrective and preventive measures based on findings.
Turnaround & Shutdown Support:
Plan, execute, and supervise boiler inspection and repair scopes during major turnarounds.
Review contractor performance, documentation, and post-shutdown assessments.
Team Leadership & Technical Support:
Mentor and guide junior engineers and inspection staff.
Provide subject matter expertise to other departments including operations, process, and projects.
Data Management & Reporting:
Maintain integrity databases, inspection history, and life cycle records.
Generate technical reports, performance dashboards, and compliance summaries for leadership review.
Asset Integrity Management: Leading boiler system integrity across its lifecycle.
Regulatory Compliance: Enforcing code and legal adherence with IBR, ASME, API, NBIC.
Risk-Based Inspection (RBI): Applying RBI principles to optimize inspection resources.
Lifecycle Extension: Driving FFS assessments and corrosion control strategies for long-term reliability.
Reliability Leadership: Influencing site-wide reliability programs through subject matter expertise.
In-depth knowledge of high-pressure boiler systems, degradation mechanisms, metallurgy, and water chemistry.
Strong command of inspection methods, RBI methodology, and FFS tools.
Hands-on experience with codes and standards: API 510, API 579, ASME Sec I & VIII, IBR, NBIC.
Ability to analyze complex degradation scenarios and operational data.
Skilled in using integrity management software and inspection databases (e.g., PCMS, SAP, Meridium).
Proven leadership in cross-functional environments.
Strong communication and presentation skills for technical and management audiences.
Experience in planning and executing inspection activities during shutdowns and turnarounds.
Ability to manage vendors, budgets, and schedules.
Education: B.E./B.Tech in Mechanical or Metallurgical Engineering (Master’s Degree preferred).
Certifications:
API 510 – Pressure Vessel Inspector (Required)
API 579 – Fitness-for-Service
IBR certification (as per local statutory requirements)
Experience: 10+ years in boiler and pressure equipment integrity roles, with at least 3–5 years in a senior or lead capacity within oil & gas, refining, petrochemicals, or power sectors.