The Boiler Maintenance Manager is responsible for the planning, execution, and oversight of all maintenance activities related to boilers and auxiliary systems in a power generation or industrial facility. The role ensures high availability, reliability, safety, and compliance of boiler systems through preventive, predictive, and corrective maintenance strategies. This manager leads a team of technicians and contractors, coordinates with engineering and operations, and manages maintenance budgets, schedules, and compliance with statutory requirements.
Plan and execute scheduled and unscheduled maintenance of high-pressure boilers, economizers, superheaters, air preheaters, and associated auxiliary systems (fans, soot blowers, fuel feeding, etc.).
Develop and oversee preventive and predictive maintenance programs to minimize downtime and maximize boiler efficiency.
Lead all boiler-related outage activities including scope development, resource planning, inspection, execution, and post-outage review.
Manage and respond to boiler breakdowns and operational issues with root cause analysis and immediate action plans.
Ensure compliance with statutory and regulatory boiler codes (IBR, ASME, NBIC, etc.) and manage interface with inspectors and certifying bodies.
Monitor equipment performance, track KPIs (e.g., forced outages, MTBF, availability), and implement continuous improvement initiatives.
Maintain detailed documentation of maintenance records, inspections, certifications, and work orders.
Manage spare parts inventory, procurement planning, and vendor coordination for boiler components and services.
Ensure strict adherence to safety procedures, lock-out/tag-out (LOTO), confined space entry, and other EHS protocols.
Train and mentor boiler technicians and junior staff, fostering a high-performance and safety-first culture.
Boiler Reliability & Uptime
Maximize boiler availability by minimizing forced outages and improving maintenance effectiveness.
Outage & Turnaround Management
Lead the planning and execution of boiler outages, ensuring timely and high-quality completion.
Regulatory Compliance & Safety
Maintain compliance with national boiler regulations and safety standards.
Cost & Resource Optimization
Control maintenance budgets and ensure efficient use of materials, manpower, and vendors.
Performance Monitoring & Reporting
Track operational data, analyze trends, and report KPIs to management for decision support.
Bachelor's degree or diploma in Mechanical Engineering, Power Plant Engineering, or a related field.
10–15+ years of experience in boiler maintenance, preferably in thermal power plants, utilities, or large industrial setups.
Strong knowledge of boiler systems, pressure part components, combustion systems, and auxiliary equipment.
Hands-on experience with maintenance planning systems (e.g., SAP PM, Maximo) and CMMS.
Familiarity with welding, NDT, pressure testing, and inspection techniques.
Proven ability to manage teams, coordinate contractors, and lead high-stakes maintenance events.
Good understanding of safety regulations (e.g., OSHA, ISO 45001) and boiler operation certifications.
Boiler Operation Engineer (BOE) or IBR Competency Certificate
API 510 (Pressure Vessel Inspector)
PMP (Project Management Professional) – desirable
NEBOSH / IOSH Safety Certification
Based at plant or facility, with regular field inspections and active supervision during outages and major maintenance events.
May involve working during non-standard hours during emergencies or planned shutdowns.