The Senior Boiler Control Systems Technician is a subject matter expert in the maintenance, configuration, troubleshooting, and optimization of Boiler Management Systems (BMS), Programmable Logic Controllers (PLCs), and SCADA systems used in the operation of industrial and utility boilers. The technician ensures high reliability, safety, and performance of automated steam generation systems by leading diagnostic efforts, reviewing control logic, and maintaining regulatory compliance with industry standards.
Lead the maintenance and troubleshooting of BMS, PLC, and SCADA/HMI systems used in boiler control operations.
Conduct advanced diagnostics of control loop failures, communication faults, and logic anomalies affecting boiler performance.
Program or modify PLC logic and HMI sequences to improve system stability, safety interlocks, or efficiency.
Oversee calibration and lifecycle management of instrumentation including flow, pressure, temperature, level sensors, transmitters, flame detectors, actuators, and valves.
Ensure compliance with relevant safety codes such as NFPA 85, ASME CSD-1, ISA, and OSHA requirements related to boiler controls.
Review and update P&IDs, electrical/control schematics, interlock diagrams, and I/O documentation.
Act as the technical lead during planned outages, plant commissioning, upgrades, and controls retrofits.
Mentor junior technicians, develop SOPs, and lead training sessions related to automation system maintenance and safety.
Work with engineers and plant managers to implement control system improvements that reduce emissions, enhance boiler efficiency, and maintain regulatory compliance.
Interface with third-party vendors and system integrators during audits, upgrades, and FAT/SAT testing.
System Optimization & Reliability
Ensure boiler automation systems run reliably with minimal downtime and optimal response to demand changes.
Advanced Diagnostics & Programming
Use expert-level PLC/HMI programming and analysis to solve complex automation issues.
Safety Compliance & Code Adherence
Maintain compliance with NFPA 85, ASME Section I & CSD-1, and site-specific safety regulations for boiler combustion control and interlocks.
Instrumentation Management
Oversee the accurate configuration and calibration of all sensors and final control elements related to boiler automation.
Project & Team Leadership
Lead small automation improvement projects and mentor mid-level and junior technicians to uphold plant reliability.
Associate or Bachelor’s Degree in Instrumentation & Control Engineering, Electrical Engineering, Automation, or related field.
7+ years of experience in industrial control systems, with a strong focus on boiler automation and utility plant operations.
Advanced knowledge of BMS, PLC platforms (Allen-Bradley, Siemens, Schneider, etc.), and SCADA systems (Wonderware, Ignition, GE iFIX, etc.).
Proficiency with control loop tuning, safety logic, PID control, and industrial communication protocols (Modbus, Profibus, OPC, Ethernet/IP).
Familiarity with emissions controls, NOx/CO trim, and energy efficiency strategies in boiler operations.
Skilled in reading and interpreting technical drawings, loop diagrams, and interlock matrices.
Excellent leadership, communication, and documentation skills.
Ability to lead during plant outages, respond to emergency failures, and work off-hours when necessary.