Boiler Operator

The Senior Boiler Operator leads the operation, troubleshooting, and performance optimization of industrial steam boilers and auxiliary systems. This role ensures uninterrupted steam supply by overseeing start-up/shutdown activities, monitoring boiler efficiency, ensuring safety compliance, and mentoring junior staff. The senior operator is also involved in emergency response, audits, and liaising with maintenance teams during shutdowns or breakdowns.

📌 Key Responsibilities:

🔧 Boiler Plant Operation & Optimization

• Operate high-capacity boilers (e.g., 20+ TPH or >40 bar pressure), ensuring stable pressure, temperature, and flow rate.

• Optimize fuel-to-air ratio and combustion controls to reduce fuel consumption and emissions.

• Coordinate boiler load balancing across multiple units or standby operations.

🛠️ Preventive & Predictive Maintenance

• Lead or assist in the inspection, overhaul, and servicing of burners, pressure parts, safety valves, economizers, and feed pumps.

• Identify symptoms of wear, corrosion, or mechanical failure in boiler systems and propose maintenance actions.

• Oversee scheduled blowdowns, soot blowing, and periodic descaling operations.

📊 Reporting & Recordkeeping

• Maintain detailed logs for shift operations, abnormalities, and maintenance interventions.

• Analyze operational trends to improve performance and minimize unplanned downtime.

• Prepare reports for energy consumption, water usage, and boiler efficiency.

🧪 Boiler Water Quality Management

• Supervise water sampling, testing (pH, hardness, TDS, phosphate), and chemical dosing procedures.

• Ensure boiler feedwater and condensate return systems meet treatment specifications to prevent scaling and corrosion.

🛡️ Safety & Regulatory Compliance

• Ensure compliance with boiler codes (ASME Section I/IV, IBR, or local statutory norms) and environmental regulations.

• Lead implementation of safety systems including emergency shutdowns, fire suppression readiness, and HAZOP.

• Coordinate with regulatory inspectors for boiler certifications and pressure tests.

👥 Leadership & Training

• Supervise junior and mid-level boiler operators, assigning tasks and reviewing shift handovers.

• Conduct training on standard operating procedures (SOPs), boiler emergency response, and control systems.

• Serve as point-of-contact during plant audits, shutdowns, and critical maintenance windows.

🔍 Key Focus Areas:

• Safe, efficient, and uninterrupted steam generation

• High-pressure boiler operation and monitoring

• Boiler water chemistry management

• Code compliance (ASME/IBR/API)

• Supervisory leadership and operational troubleshooting

🎓 Qualifications:

• Education:

  • Diploma or ITI in Mechanical / Boiler Operations / Power Plant Engineering

  • B.Tech / B.E. (optional, but preferred in large industrial plants)

• Experience:

  • 7–10+ years operating and maintaining industrial steam boiler systems

  • Exposure to multiple fuel types (gas, oil, coal, biomass) and auxiliary equipment

• Skills & Competencies:

  • Expert in reading P&IDs, DCS/SCADA systems, and boiler schematics

  • Strong mechanical understanding of valves, pumps, burners, and instrumentation

  • Excellent knowledge of permit-to-work systems, confined space, and hot work protocols

  • Capable of mentoring and developing less experienced operators

• Certifications (Mandatory):

  • 1st Class Boiler Attendant Certificate or Boiler Engineer License (as per local regulation)

  • Safety certifications: confined space entry, firefighting, LOTO, emergency response