Company Overview
[$COMPANY_OVERVIEW]
Role Overview
[$COMPANY_NAME] is hiring a Senior Boiler Operator to lead safe, reliable, and efficient operation of high-capacity boiler and steam systems at our facility in [$COMPANY_LOCATION]. In this senior, hands-on engineering operations role you will be responsible for operational leadership of boiler plant systems, continuous improvement of thermal processes, and mentoring of operations staff. You will apply advanced knowledge of combustion, feedwater chemistry, pressure vessel controls, and industrial control systems (DCS/PLC) to maintain compliance with regulatory and company safety standards while optimizing fuel-to-steam efficiency and availability.
Responsibilities
- Lead daily and shift-level operation of multiple high-pressure boilers, economizers, deaerators, condensate return systems, feedwater pumps, and ancillary equipment to meet production and steam demand targets
- Develop, execute and continuously improve standard operating procedures (SOPs), start-up/shutdown checklists, and emergency response plans for boiler plant operations
- Perform advanced combustion tuning, burner management system (BMS) adjustments, and fuel/air ratio optimization to improve thermal efficiency and reduce emissions (NOx, CO)
- Configure, monitor, and troubleshoot Distributed Control Systems (DCS), PLC logic, and field instrumentation (pressure transmitters, temperature sensors, flow meters, level switches) to maintain stable boiler control loops
- Perform root cause analysis on equipment trips, alarms, and near-miss events using structured methods (5 Whys, fishbone) and produce Architecture/Design Decision Records (ADRs) for major changes
- Supervise and mentor junior operators and technicians; lead post-incident reviews, shift handovers, and operator training programs including simulator and hands-on training
- Coordinate predictive and preventive maintenance with reliability engineering: interpret vibration analysis, thermography, and oil analysis reports to schedule repairs and avoid unplanned downtime
- Manage water treatment protocols and feedwater chemistry (pH, conductivity, silica, hardness) to prevent scaling, corrosion, and optimize boiler longevity
- Ensure compliance with pressure vessel and boiler codes (ASME Section I/IV), environmental permits, and local regulatory requirements; participate in internal and external audits
- Own shift-level KPIs: boiler MCR availability, fuel consumption per steam ton, blowdown rates, emissions exceedances, and corrective maintenance turnaround time
Required Qualifications
- Minimum 7+ years of direct hands-on boiler operation experience in industrial or utility-scale plants; at least 3 years in a lead or senior operator capacity
- Demonstrated expertise operating high-pressure boilers, burner management systems, and steam distribution networks
- Deep familiarity with DCS/PLC platforms (e.g., Honeywell, Allen-Bradley/ControlLogix, Siemens), PID loop tuning, and industrial control logic
- Proven experience with boiler water chemistry management and working knowledge of water treatment programs
- Strong troubleshooting skills for mechanical, electrical, and control-system failures; experience using vibration analysis, infrared thermography, and diagnostic tools
- Current boiler operator certification/license where applicable (state or national), or ability to obtain within company-required timeframe
- Ability to read and interpret P&IDs, isometric drawings, and electrical single-line diagrams
- Valid OSHA 10/30 or equivalent safety training and first-aid/CPR certification preferred
Preferred Qualifications
- Bachelor's degree or technical diploma in Mechanical Engineering, Power Engineering, or Industrial Maintenance
- Experience with emission control systems (SCR, selective catalytic reduction), economizer design, and flue gas analysis
- Experience implementing continuous improvement projects (Lean, Kaizen, Six Sigma) that reduced fuel consumption or improved availability
- Experience with digital operations platforms, computerized maintenance management systems (CMMS) like Maximo or SAP EAM, and historian systems (OSIsoft PI)
- Certifications: ASME knowledge, Certified Boiler Operator, NCCER, or equivalent trade certifications
Technical Skills and Relevant Technologies
- Boiler plant systems: water-tube, fire-tube, deaerators, superheaters, economizers
- Control systems: DCS, PLC, BMS, PID control, SCADA, HMI
- Instrumentation: pressure, temperature, level, flow, and gas analyzers
- Maintenance and reliability tools: CMMS (Maximo/SAP), vibration analysis, thermography, ultrasonic testing
- Industrial safety and compliance: ASME codes, NFPA 85 (boiler and combustion systems), OSHA regulations
- Process optimization tools: heat balance analysis, FGR/oxygen trim, boiler thermal efficiency calculations
Soft Skills and Cultural Fit
- Operational leadership: track record of leading shifts, conducting effective handovers, and driving post-incident corrective action
- Communication: clear, concise technical writing for SOPs, incident reports, and maintenance requests; effective verbal communication with cross-functional teams
- Mentorship: demonstrated ability to train and upskill junior staff and to build resilient shift teams
- Decision-making under pressure: documented experience making timely, safety-first decisions during trips and emergency conditions
- Continuous improvement mindset with a pragmatic approach to balancing reliability, safety, and cost
Benefits and Perks
Salary: [$SALARY_RANGE]
- Comprehensive medical, dental, and vision coverage
- 401(k) with company match
- Paid time off and paid company holidays
- Shift differentials and overtime eligibility
- Certification and training reimbursement (boiler operator licenses, safety courses)
- Employee assistance programs and wellness resources
- Opportunities for advancement into lead reliability, plant operations management, or engineering roles
Equal Opportunity Statement
[$COMPANY_NAME] is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability status, protected veteran status, or any other characteristic protected by applicable law.
Location
This is an on-site position based in [$COMPANY_LOCATION]. Candidates must be able to work rotating shifts and be present at the facility for assigned shifts, emergency call-ins, and scheduled maintenance outages.
How to Apply
To apply, please submit your resume and a cover letter outlining your boiler operation experience, certifications, and relevant shift leadership examples through the [$COMPANY_NAME] careers portal.
