Reliability Engineer – Boiler Systems

The Mid-Level Reliability Engineer – Boiler Systems plays a critical role in improving the performance, safety, and operational uptime of boiler plants, steam systems, and pressure vessels. This role focuses on failure prevention, data-driven maintenance strategies, reliability-centered design improvements, and adherence to NFPA, OSHA, and ASME standards. The engineer works collaboratively with maintenance, operations, and compliance teams to drive long-term equipment reliability and cost-effectiveness.

Key Responsibilities:

1. Boiler Reliability Analysis & Optimization

• Monitor boiler system health using reliability metrics: MTBF, MTTR, OEE, availability.

• Analyze failure modes and performance data to identify reliability improvement opportunities.

• Drive boiler system optimization (e.g., combustion tuning, feedwater quality improvements, burner system reliability).

2. Predictive & Preventive Maintenance Strategy

• Develop and refine preventive maintenance (PM) plans for:

  • Fire-tube and water-tube boilers

  • Feedwater systems, economizers, deaerators

  • Condensate recovery and blowdown systems

• Lead predictive maintenance (PdM) programs, including:

  • Vibration analysis, thermography, ultrasound

  • Condition monitoring for pumps, motors, fans, and refractory wear

3. Root Cause Analysis (RCA) & Reliability Engineering Tools

• Lead structured root cause analysis for boiler-related failures and operational incidents.

• Apply FMEA, RCM, and Pareto analysis to develop corrective actions and system redesigns.

• Use data from SCADA, PLC, CMMS, and historian systems for reliability insights.

4. Code Compliance & Safety Assurance

• Ensure adherence to applicable codes and standards including:

  • NFPA 85 (Boiler and Combustion Systems Hazards Code)

  • OSHA 1910 (General Industry & Process Safety)

  • ASME Boiler and Pressure Vessel Code (Sections I, IV, VIII)

• Participate in safety inspections, third-party boiler audits, and insurance reviews.

5. Asset Management & Documentation

• Maintain detailed documentation of reliability programs, work orders, inspection results, and improvement plans.

• Support reliability KPIs, trend reports, and boiler system performance dashboards.

• Collaborate on capital projects to ensure maintainability and reliability are integrated into new installations.

6. Cross-Functional Support & Leadership

• Provide technical support to operations, maintenance, and utilities teams on boiler system troubleshooting and enhancements.

• Train junior engineers, technicians, and operators in reliability practices and boiler fundamentals.

• Interface with OEMs, service contractors, and third-party inspectors.

Focus Areas:

• Reliability engineering for steam and boiler systems

• Predictive maintenance & condition monitoring

• Root cause failure analysis and continuous improvement

• ASME/NFPA/OSHA compliance

• Downtime reduction and performance tracking

Qualifications:

• Bachelor’s degree in Mechanical Engineering, Reliability Engineering, or a related field

• 3–6 years of experience in reliability engineering, boiler maintenance, or plant utilities

• Working knowledge of high- and low-pressure boiler systems

• Familiarity with CMMS systems (SAP, Maximo, eMaint) and predictive maintenance tools

Certifications (Preferred):

• Certified Maintenance & Reliability Professional (CMRP)

• OSHA 30-Hour General Industry Certification

• NFPA 85 Combustion Safety or ASME Boiler Code Training

• Engineer-in-Training (EIT) or PE license (a plus)

Key Skills:

• Strong knowledge of steam systems and pressure equipment

• Root cause analysis and problem-solving

• Experience with CMMS, PM scheduling, and PdM tools

• Technical documentation and report writing

• Cross-functional collaboration and project management