Supervisor – Boiler Safety and Controls

The Mid-Level Supervisor – Boiler Safety and Controls is responsible for supervising the safety, compliance, and performance of steam boiler systems, with a focus on automated safety controls, instrumentation, and regulatory adherence. This role involves managing safety device testing, overseeing boiler control systems (PLC/SCADA/BMS), coordinating routine inspections, and supporting operations teams to ensure safe, efficient steam generation and distribution. The position serves as a key link between maintenance, operations, and compliance functions.

Key Responsibilities:

1. Safety and Control System Oversight

• Supervise the day-to-day operation and maintenance of boiler safety systems including flame safeguards, low-water cutoffs, pressure relief valves, and interlock systems.

• Monitor and adjust boiler control systems (PLC, SCADA, or BMS), ensuring accurate setpoints and safe operation parameters.

• Coordinate scheduled testing of shutdown systems, alarm functionality, and fail-safes per regulatory standards.

2. Regulatory Compliance

• Ensure strict adherence to applicable codes and regulations: ASME BPVC, NFPA 85, OSHA 1910, and local boiler laws.

• Maintain inspection logs, calibration records, and compliance documentation required for internal and external audits.

• Serve as a liaison during inspections by regulatory agencies or insurance auditors.

3. Maintenance and Troubleshooting

• Support troubleshooting of safety-related boiler issues such as flame failures, control loop instability, or safety valve leaks.

• Collaborate with I&C technicians and boiler maintenance teams for system repairs and improvements.

• Oversee calibration and maintenance of key instrumentation (pressure gauges, transmitters, thermocouples, etc.).

4. Team Supervision and Training

• Lead and coach a team of boiler operators and safety technicians.

• Train personnel on emergency shutdown procedures, control system operation, and safety device testing.

• Conduct toolbox talks and shift briefings with a focus on operational safety and compliance.

5. Performance and Reliability Monitoring

• Track boiler performance indicators such as pressure trends, temperature variances, fuel-to-steam ratio, and control system alarms.

• Support process optimization and reliability improvement initiatives focused on reducing downtime and improving efficiency.

Focus Areas:

• Boiler safety mechanisms and fail-safe design

• Flame monitoring and combustion control

• PLC, SCADA, or DCS-based control systems

• Safety interlocks and trip logic

• Boiler code compliance (ASME, OSHA, NFPA)

• Preventive maintenance planning and documentation

Qualifications:

• Associate’s or Bachelor’s degree in Mechanical Engineering, Instrumentation, or related technical field

• 4–6 years of experience in boiler operations or controls, including at least 2 years in a supervisory or lead role

• Strong knowledge of boiler safety systems, burner management systems (BMS), and automation controls

• Working understanding of regulatory standards (e.g., ASME, NFPA 85, OSHA, state boiler codes)

Certifications (Preferred/Required):

• Valid Boiler Operator License or Stationary Engineer License (as per jurisdiction)

• OSHA 30-Hour General Industry Certification

• Instrumentation and Controls Technician Certification (optional)

• Lockout/Tagout, Confined Space Entry, and First Aid/CPR certified

Key Skills & Competencies:

• Deep understanding of control system architecture and safety programming logic

• Strong leadership and communication skills

• Capable of coordinating across operations, maintenance, and EHS teams

• Proficient in using CMMS, SCADA/BMS platforms, and digital reporting tools

• Attention to detail and a strong safety-first mindset