The Senior Mechanical Engineer – Boiler Systems plays a critical technical leadership role in the design, assessment, optimization, and reliability of high-pressure boiler systems and associated thermal equipment. This role demands in-depth knowledge of ASME codes, pressure part engineering, failure analysis, and lifecycle evaluation. The senior engineer will be responsible for leading projects, mentoring junior engineers, and ensuring compliance with safety and regulatory standards.
Lead the design, analysis, and modification of boiler systems and associated mechanical components (e.g., steam drums, headers, superheaters, economizers).
Conduct advanced mechanical calculations including stress, creep, fatigue, and life assessment per ASME Section I, Section VIII, B31.1, and API 579.
Drive the execution of boiler-related capital projects, including upgrades, retrofits, and major overhauls.
Collaborate with inspection, operations, and safety teams to address chronic issues, root causes, and system performance gaps.
Perform and lead failure analysis (RCFA), risk-based inspection (RBI), and fitness-for-service (FFS) evaluations for degraded or aged equipment.
Review and approve technical specifications, datasheets, vendor drawings, and QA/QC plans for boiler packages and associated equipment.
Act as the subject matter expert (SME) in interactions with regulatory bodies for code compliance, inspection approvals, and certification requirements.
Lead energy efficiency studies, thermal audits, and boiler-turbine integration assessments.
Mentor and supervise junior and mid-level engineers on code application, best practices, and technical report writing.
Code Compliance & Advanced Design
Deep application of ASME BPVC (Section I, VIII Div. 1 & 2), B31.1, and NBIC in complex boiler and pressure vessel systems.
Lifecycle Engineering & Risk Management
Focus on high-temperature creep, corrosion-fatigue, and weld integrity in aging or high-demand boiler systems.
Performance Optimization
Evaluate and implement strategies for fuel savings, boiler efficiency, heat recovery, and emissions control.
Project & Technical Leadership
Direct large-scale boiler engineering projects, including scope definition, budget planning, and vendor coordination.
Cross-Functional Integration
Collaborate across controls, civil/structural, and electrical teams to ensure integrated boiler plant designs and upgrades.
Bachelor’s degree in Mechanical Engineering (Master’s degree preferred).
10+ years of progressive experience in boiler and pressure systems engineering, including field exposure and project leadership.
Extensive knowledge of ASME Section I, VIII, B31.1, NBIC, and related standards.
Proficiency in tools such as ANSYS, PV Elite, AutoPIPE, or similar.
PE (Professional Engineer) license or Chartered Engineer certification preferred.
Strong analytical, report writing, and cross-disciplinary collaboration skills.