The Senior Boiler Mechanic is responsible for leading, executing, and optimizing the mechanical maintenance, repair, and reliability of boiler feed pumps, boiler tubes, and burner systems within industrial, utility, or water treatment boiler plants. The role demands in-depth technical knowledge, troubleshooting expertise, and the ability to lead maintenance teams in high-pressure steam environments while ensuring regulatory and safety compliance.
Lead major overhauls and repairs of feedwater pumps, including bearing replacement, shaft alignment, mechanical seal upgrades, and impeller balancing.
Supervise the inspection, repair, and replacement of boiler tubes, including coordination of tube rolling, welding, and non-destructive testing (NDT) services.
Manage full-cycle burner maintenance, including the tuning of combustion systems, servicing of atomizers, igniters, and air/fuel delivery mechanisms.
Diagnose complex mechanical failures and implement permanent corrective actions across the boiler system, piping, and support structures.
Review equipment performance and advise on design or operational changes to reduce downtime and improve thermal efficiency.
Coordinate with controls/instrumentation teams to align mechanical repair with control loop and burner management system (BMS) functionality.
Prepare and review detailed maintenance procedures, SOPs, risk assessments, and reports for inspections and incident root cause analyses.
Train and mentor junior and mid-level boiler mechanics and ensure safe work execution in compliance with ASME Section I, NBIC, and OSHA standards.
Participate in shutdown planning, resource allocation, and contractor oversight during scheduled outages or emergency repairs.
Ensure inventory of critical spares and work closely with procurement and reliability engineers to manage long-lead maintenance items.
Advanced Boiler Feed Pump Overhaul
Oversight of high-pressure feed pump servicing and performance optimization for sustained boiler water supply.
Boiler Tube Life Extension & Failure Prevention
Lead predictive and preventive maintenance strategies for tube bundles to mitigate thermal fatigue, scaling, and rupture risks.
Combustion System Reliability
Supervise mechanical aspects of burner performance, including burner tuning support and air-fuel ratio stabilization.
High-Level Troubleshooting & RCA
Conduct root cause analysis on boiler mechanical failures and recommend strategic mechanical solutions.
Safety, Compliance & Team Leadership
Enforce rigorous safety practices aligned with national boiler codes and lead teams to execute complex tasks safely and efficiently.
Diploma or Bachelor's in Mechanical Engineering, or Certified Boiler Technician with extensive field experience.
7–10+ years of direct experience in boiler mechanical maintenance, including feed pumps, tubes, and burners in industrial or utility settings.
Proficient in alignment tools, tube replacement techniques, mechanical seal technologies, and combustion system components.
Familiarity with ASME Boiler & Pressure Vessel Code, NBIC, and industry best practices for high-pressure steam systems.
Strong leadership and mentoring ability with experience managing shift mechanics or contractors.
Proficiency in reading mechanical drawings, isometrics, and equipment specifications.