The Project Manager – Boiler Upgrades or Retrofits is responsible for leading the full lifecycle execution of boiler modernization, life extension, emission reduction, or performance enhancement projects in thermal power plants or industrial facilities. This includes planning, design coordination, procurement, installation, commissioning, and close-out activities.
The role involves working closely with internal stakeholders (engineering, maintenance, operations) and external parties (OEMs, EPCs, contractors, consultants) to ensure timely, cost-effective, and technically sound delivery of boiler upgrade or retrofit projects.
Manage end-to-end execution of boiler upgrade/retrofit projects, including feasibility analysis, design review, procurement, installation, and commissioning.
Develop detailed project scopes, budgets, timelines, and resource plans in line with organizational objectives and regulatory compliance.
Coordinate with OEMs and engineering teams for design customization, thermal calculations, and equipment selection.
Oversee procurement of boiler components (e.g., burners, economizers, superheaters, fans, control systems) and ensure material availability.
Supervise on-site activities including dismantling, fabrication, welding, NDT, pressure testing, and mechanical erection.
Ensure compliance with safety standards, environmental regulations, and codes such as ASME, IBR, and local emissions regulations.
Manage contractors, vendors, and field engineering teams, ensuring delivery against scope and quality expectations.
Track project performance using KPIs and reporting tools; escalate delays, risks, and cost deviations proactively.
Support performance testing, commissioning, and post-implementation reviews to verify retrofit effectiveness.
Maintain all project documentation including drawings, contracts, compliance certificates, and handover records.
Project Execution & Coordination
Deliver complex boiler upgrade or retrofit projects on time and within budget.
Engineering & Design Oversight
Ensure modifications comply with operational goals, technical standards, and code requirements.
Vendor & Contractor Management
Coordinate multiple stakeholders to ensure smooth and safe execution on site.
Cost, Quality & Risk Control
Monitor costs, enforce quality control, and mitigate technical and execution risks.
Commissioning & Performance Verification
Validate retrofit performance and ensure expected thermal efficiency and emissions outcomes are achieved.
Bachelor’s degree in Mechanical Engineering, Power Plant Engineering, or a related field; Master’s preferred.
10–15+ years of experience in boiler engineering and project management, with specific experience in retrofits, upgrades, or plant modernization.
Strong knowledge of various boiler types (subcritical, supercritical, HRSG, CFB), fuel types, and control systems.
Familiarity with emission control retrofits (e.g., low-NOx burners, OFA systems, SCR, FGD).
Hands-on experience with project management software (MS Project, Primavera) and ERP systems (SAP, Maximo).
Strong leadership, vendor negotiation, and cross-functional communication skills.
PMP (Project Management Professional)
Boiler Operation Engineer (BOE) License
API 510 or ASME Pressure Vessel Compliance (preferred)
Six Sigma or Lean Certification
NEBOSH / OSHA Safety Certification
Office and site-based role, with frequent field visits to active retrofit locations.
May involve extended hours during shutdowns, installation, and commissioning phases.