The Senior Boiler Performance Engineer is the technical authority responsible for driving performance optimization, energy efficiency, and operational reliability of high-capacity boiler systems across one or more industrial or utility-scale plants. This role combines advanced thermodynamic analysis with field-based diagnostics, working to improve boiler combustion, heat transfer, and system integration. The engineer leads performance audits, outage evaluations, and energy improvement initiatives, serving as the primary advisor for senior leadership on boiler energy KPIs.
This position also mentors junior engineers, ensures alignment with environmental and safety requirements, and interfaces with controls, operations, and regulatory teams to achieve peak performance and compliance.
Develop and lead implementation of comprehensive boiler performance monitoring programs, focused on efficiency, heat rate, and emissions optimization.
Lead boiler tuning activities, including burner management and air/fuel ratio calibration, ensuring low excess air and stable combustion.
Perform detailed thermodynamic modeling of steam generation systems, combustion processes, and heat recovery.
Use ASME PTC standards to conduct high-precision testing and performance benchmarking.
Identify and lead performance improvement initiatives, including economizer upgrades, sootblower optimization, and combustion air preheating projects.
Support capital projects involving boiler modifications, burner replacements, and control system enhancements.
Investigate issues such as excessive fuel consumption, slagging/fouling, steam pressure variability, or feedwater imbalance.
Conduct root cause analyses (RCA) for degraded heat transfer, unplanned shutdowns, or emissions exceedance.
Ensure alignment with environmental limits for NOx, CO, SOx, and particulate matter.
Integrate performance engineering with air permit requirements and emissions reporting systems.
Define performance criteria for inspections of boiler tubes, burners, heat exchangers, and headers.
Participate in major shutdowns to assess component condition, recommend corrective actions, and validate performance restoration.
Develop performance dashboards using plant data systems (e.g., PI, SCADA, DCS).
Generate monthly and quarterly reports for leadership, including performance trends, energy KPIs, and actionable recommendations.
Provide technical guidance to junior engineers and technicians.
Lead training sessions for plant operators on performance impacts of operational parameters.
Boiler Thermal Efficiency & Combustion Optimization
Drive performance improvements by fine-tuning combustion systems and minimizing heat losses.
Data-Driven Performance Engineering
Use real-time data analytics to support proactive decision-making and predictive performance management.
Advanced Troubleshooting & Root Cause Analysis
Lead the technical investigation and resolution of complex operational inefficiencies and failures.
Strategic Energy Optimization Projects
Champion plant-wide initiatives to reduce energy consumption and improve heat recovery.
Cross-Functional Technical Leadership
Act as a bridge between operations, controls, maintenance, and environmental teams for performance-related decisions.
Bachelor’s degree in Mechanical or Energy Engineering (Master’s degree preferred).
8–12+ years of experience in boiler performance, energy systems engineering, or power plant optimization.
Deep understanding of combustion theory, heat transfer, and thermodynamic cycles.
Proficient in ASME PTC testing standards, flue gas analysis, and plant data systems (e.g., PI System, DCS).
Strong leadership, project management, and report-writing skills.
Experience with emissions compliance, combustion controls, and fuel switching is an asset.
Familiarity with tools such as Aspen Plus, EBSILON, MATLAB, or equivalent is desirable.