Boiler Performance Engineer

The Mid-Level Boiler Performance Engineer is responsible for evaluating and improving the thermal and operational efficiency of boiler systems in industrial or utility-scale operations. This role involves leading data-driven performance analyses, conducting combustion and heat rate evaluations, and developing strategies to optimize steam generation and fuel utilization.

The engineer collaborates closely with operations, maintenance, controls, and environmental teams to ensure reliable, compliant, and cost-effective boiler performance. This position bridges theoretical knowledge and field application, requiring both technical acumen and practical problem-solving.

Key Responsibilities:

1. Performance Monitoring and Optimization

• Analyze operational trends and equipment performance metrics to evaluate boiler efficiency, heat rate, and steam quality.

• Identify performance degradation or abnormal operating behavior and develop corrective action plans.

2. Combustion and Heat Transfer Analysis

• Conduct combustion diagnostics, fuel-to-steam ratio assessments, and excess air tuning.

• Assess heat exchanger performance, flue gas temperature profiles, and combustion gas analysis for improvement opportunities.

3. Testing and Field Evaluations

• Lead or support performance testing, including ASME PTC test procedures, emissions testing, and flue gas analysis.

• Coordinate field testing with vendors and third-party auditors during major efficiency evaluations.

4. Efficiency Improvement Projects

• Develop and implement projects to improve fuel efficiency, reduce emissions, and optimize auxiliary power usage.

• Support upgrades of burner systems, economizers, and control systems to improve thermal performance.

5. Maintenance and Outage Support

• Provide technical input during outages to inspect boiler tubes, burners, and pressure parts for performance-related issues (e.g., fouling, slagging, erosion).

• Collaborate with maintenance and reliability teams to assess the impact of component degradation on system efficiency.

6. Technical Reporting and Documentation

• Prepare detailed performance reports, root cause analyses, and energy balance models.

• Maintain accurate documentation of test results, tuning records, and baseline performance metrics.

7. Cross-Functional Coordination

• Work with control engineers to calibrate instruments and optimize boiler control strategies.

• Interface with environmental teams to ensure compliance with NOx, CO, and particulate emissions limits during tuning.

Key Focus Areas:

1. Boiler Efficiency and Heat Rate Optimization
   Focus on reducing heat losses, improving combustion performance, and enhancing steam generation efficiency.

2. Thermal Performance Evaluation
   Apply thermodynamic models and field data to assess boiler and auxiliary equipment effectiveness.

3. Combustion Analysis and Burner Tuning
   Fine-tune air/fuel ratios and burner performance to improve flame stability and fuel economy.

4. Operational Troubleshooting
   Identify root causes of performance issues such as high flue gas temperatures, pressure fluctuations, or excessive blowdown.

5. Data-Driven Decision Support
   Use plant data, control system trends, and manual readings to recommend operational improvements and maintenance actions.

Qualifications:

• Bachelor’s degree in Mechanical Engineering, Energy Engineering, or related discipline (Master’s preferred).

• 4–7 years of experience in boiler performance engineering, energy systems, or power plant operations.

• Strong knowledge of combustion theory, thermodynamics, and ASME PTC test codes.

• Proficiency in data analysis tools (e.g., Excel, PI System, MATLAB, or similar).

• Hands-on experience with tuning, flue gas analysis, and system diagnostics.

• Strong technical writing and communication skills for reporting and cross-department collaboration.