The Boiler Manager / Steam Cycle Manager is responsible for overseeing all aspects of boiler operation, maintenance, and steam cycle performance in a power plant or industrial facility. This role ensures safe, reliable, and efficient steam generation and distribution, compliance with environmental and safety regulations, and continual improvement of cycle efficiency.
Operational Leadership
Manage day-to-day operation of industrial boilers and steam turbines/expansion equipment.
Coordinate with control room, operations, and maintenance teams to optimize load changes, startups, and shutdowns.
Maintenance & Reliability
Develop and implement preventive, predictive, and corrective maintenance plans for boiler pressure parts, auxiliaries, and steam cycle components.
Oversee major inspections, tube replacements, refractory repairs, and pressure vessel integrity tests.
Performance Monitoring & Optimization
Track key steam cycle KPIs (boiler efficiency, stack losses, blowdown rates, steam purity, heat rate).
Lead root-cause analysis for performance deviations and implement improvement projects (e.g., economizer upgrades, superheater tuning).
Safety & Compliance
Ensure all boiler and steam cycle operations comply with ASME, API, NFPA, and local boiler codes.
Enforce lockout/tagout (LOTO), confined-space entry, high-pressure safety valves, and combustion safety protocols.
Oversee water chemistry control, feedwater treatment, and blowdown procedures to prevent corrosion and scaling.
Team Management & Development
Supervise boiler operators, technicians, and chemical treatment staff; conduct training and competency assessments.
Establish shift rotations, staffing plans, and on-call coverage for 24/7 steam generation reliability.
Budgeting & Resource Planning
Prepare O&M budgets for boiler fuel, water treatment chemicals, spare parts, and contractor services.
Optimize fuel blending (coal, oil, gas) and auxiliary steam/blowdown recovery to minimize operating costs.
Project & Upgrade Oversight
Lead boiler and steam cycle upgrade projects (e.g., turbine bypass systems, heat-recovery modifications).
Coordinate with engineering, procurement, and contractors during brownfield modifications or capacity uprates.
Optimize combustion air/fuel ratios, burner management systems, and flue-gas recirculation to maximize thermal efficiency and minimize NOₓ/SOₓ emissions.
Maintain tight control of feedwater pH, conductivity, and dissolved oxygen; supervise chemical dosing and blowdown schedules to protect pressure parts.
Ensure turbine throttle, desuperheaters, steam traps, and condensate recovery systems operate with high reliability to preserve cycle efficiency.
Implement condition-monitoring (vibration, thermography) on boiler drums, superheaters, headers, and piping to preempt failures.
Foster a zero-incident mindset; streamline standard operating procedures (SOPs), incident investigations, and safe-work practices.
Education: Bachelor’s Degree in Mechanical/Power Engineering or equivalent
Experience: 10+ years in boiler operations and steam cycle management; 5+ years in a lead or management position
Certifications: Boiler Operator License (as required by jurisdiction), ASME Boiler & Pressure Vessel Code training, NEBOSH/OSHA (preferred)
Deep technical knowledge of drum‐type and once‐through boilers, BMS/DCS control systems, and steam turbine auxiliaries
Strong analytical skills for performance trending, heat‐balance calculations, and thermodynamic assessments
Leadership and team development capabilities in a 24/7 operational environment
Budget management, cost‐control, and project planning proficiency
Excellent communication, stakeholder management, and emergency response coordination
On‐site role in high-temperature, high-pressure boiler areas; PPE and safety training required
Shift work and on-call availability to support continuous steam supply and emergency situations
Exposure to noise, steam, and chemical treatment areas; strict compliance with safety procedures mandatory