The Senior Boiler Technician is the technical lead responsible for the safe operation, maintenance, optimization, and troubleshooting of industrial steam systems, including high-pressure boilers, feedwater equipment, burner management systems, and steam distribution networks. This role ensures regulatory compliance, supports energy optimization initiatives, mentors junior staff, and collaborates across departments to ensure reliable plant utility performance.
Lead daily operation of high- and low-pressure boilers, ensuring optimal steam generation and distribution.
Monitor and adjust boiler controls, fuel-air ratios, and water treatment systems to maintain system stability and efficiency.
Oversee alarm responses, safety shutdowns, and rapid diagnostics using SCADA/HMI systems.
Perform and lead in-depth maintenance on burners, combustion controls, flame sensors, modulating actuators, valves, and pumps.
Conduct root cause analysis of recurring boiler issues, implement long-term fixes, and document maintenance strategies.
Calibrate instrumentation and maintain historical maintenance and compliance records.
Ensure systems meet OSHA, ASME (BPVC), NFPA, and EPA regulations.
Coordinate or lead inspections, hydrostatic tests, emissions reports, and documentation for internal and third-party audits.
Manage testing of safety relief valves, flame safeguard systems, and interlocks in accordance with plant and regulatory schedules.
Mentor and train junior and mid-level technicians on boiler operations, troubleshooting, and documentation.
Support capital projects involving boiler system upgrades, fuel conversions, or utility expansions.
Collaborate with engineering, maintenance, and quality teams to integrate boiler systems with plant needs.
Analyze system performance data to recommend improvements in fuel efficiency, condensate recovery, and water usage.
Contribute to sustainability goals by identifying boiler-related energy-saving opportunities.
Recommend automation or control enhancements to improve system uptime and efficiency.
Advanced operation and optimization of steam generation systems
Regulatory compliance, inspection readiness, and documentation
Technical leadership and troubleshooting of BMS and boiler instrumentation
Training and development of operations/maintenance staff
Energy efficiency and steam system reliability
Cross-functional collaboration on utilities projects and upgrades
High school diploma required; technical school or associate degree preferred
Valid Boiler Operator License (State/City) required
Advanced certifications (e.g., ASME, NIULPE, or EPA) preferred
7–10+ years of experience operating and maintaining industrial boiler systems
Experience in a regulated industry (Food & Beverage, Pharma, or Chemical) required
Background working with advanced BMS, PLC/HMI, and SCADA systems
Deep understanding of steam generation, fuel-air combustion systems, and safety interlocks
Proficiency in reading and interpreting P&IDs, control logic diagrams, and OEM documentation
Skilled in water treatment principles, chemical feed systems, and condensate recovery
Leadership and mentorship capabilities
High attention to safety, detail, and documentation
Excellent problem-solving and communication skills
Ability to lead during emergencies, shutdowns, and audits