The Outage/Shutdown Manager – Boiler Systems is responsible for planning, executing, and closing all activities related to major outages, shutdowns, and turnarounds of boiler systems in power generation or industrial facilities. This role ensures that outages are completed safely, within budget, on schedule, and to the highest quality standards.
The manager coordinates cross-functional teams including maintenance, operations, engineering, inspection, procurement, and contractors to deliver successful boiler maintenance events with minimal operational disruption.
Lead full-cycle planning and execution of scheduled and emergency outages of boilers and associated systems (e.g., economizers, superheaters, air preheaters, burners, drums, headers).
Develop detailed outage scopes, work packages, schedules, budgets, and manpower/resource plans.
Manage the mobilization and coordination of contractors, OEMs, inspection agencies, and internal teams.
Monitor work execution to ensure adherence to safety standards, technical specifications, and quality requirements.
Conduct risk assessments, establish contingency plans, and enforce strict safety protocols during high-risk shutdown activities.
Oversee inspection, testing, and quality control of boiler pressure parts and auxiliary systems (e.g., hydrotest, NDT, thickness checks).
Track progress with daily reports, resolve bottlenecks, and communicate updates to plant leadership.
Lead post-outage reviews, root cause analysis (RCA), and lessons-learned sessions to drive continuous improvement.
Ensure statutory compliance with boiler codes (IBR, ASME, NBIC) and interface with regulatory authorities for re-certification.
Manage documentation including work orders, inspection reports, contractor evaluations, and close-out packages.
Shutdown Planning & Scheduling
Develop detailed outage plans and ensure all logistics and technical requirements are addressed pre-shutdown.
Execution Oversight
Supervise on-site execution, manage interfaces between trades, and resolve field-level issues quickly.
Safety & Compliance
Enforce rigorous EHS procedures, including permit-to-work, lockout-tagout, and confined space protocols.
Quality Assurance & Control
Ensure repairs and replacements meet OEM and code specifications through rigorous QA/QC checks.
Stakeholder Coordination
Act as the focal point for communication between departments, contractors, and external regulators.
Bachelor’s degree in Mechanical Engineering, Power Plant Engineering, or a related discipline.
10–15+ years of experience in boiler maintenance and outage/shutdown management in power plants, refineries, or heavy industries.
Deep knowledge of boiler systems, pressure parts, welding, refractory, NDT, and hydrotesting.
Experience in managing multi-disciplinary shutdown teams, contractors, and technical vendors.
Strong understanding of project management tools (Primavera, MS Project) and maintenance management systems (SAP PM, Maximo).
Proven ability to manage large-scale turnarounds under high-pressure environments with safety and precision.
PMP (Project Management Professional)
Boiler Operation Engineer (BOE) or equivalent license
API 510 / ASME / IBR inspection certifications
NEBOSH / ISO 45001 Safety Certification
Six Sigma or Lean certification for process improvement
Field-intensive role during outages with exposure to high-temperature, confined spaces, and high-pressure systems.
May require extended hours, night shifts, and weekend work during peak shutdown windows.
Frequent coordination with third-party vendors, inspectors, and cross-functional internal teams.