The Senior Supervisor – Boiler Safety and Controls is responsible for leading the safety integrity, regulatory compliance, and control system functionality of high-pressure boiler systems and associated steam infrastructure. This leadership role ensures that all boiler safety mechanisms, burner management systems (BMS), control logic, and emergency interlocks function correctly, reliably, and in alignment with ASME, NFPA, OSHA, and state/local codes. The position involves supervision of technical teams, direct engagement in audits and inspections, troubleshooting complex control failures, and driving safety-focused reliability programs.
Lead the supervision, testing, and validation of all boiler safety devices including:
Flame safeguard systems
Low-water cutoffs
High-pressure and temperature trip devices
Safety relief valves
Emergency shutdown systems
Ensure all safety interlocks and shutdown sequences are tested routinely and comply with NFPA 85 and ASME CSD-1 standards.
Manage the operation, configuration, and reliability of boiler control systems (PLC, SCADA, BMS).
Coordinate logic validation, control loop tuning, and integration with plant-wide monitoring platforms.
Supervise alarm handling protocols, real-time data trends, and diagnostic responses to system anomalies.
Ensure all boiler safety and control activities are documented, logged, and audit-ready.
Prepare and present documentation for internal audits, insurance inspections, and compliance reviews with regulatory agencies.
Maintain CMMS records related to safety valve certifications, interlock test results, and compliance schedules.
Supervise and mentor a team of boiler operators, control technicians, and junior supervisors.
Conduct technical training on safety standards, control system operations, and emergency procedures.
Lead daily toolbox talks and weekly safety reviews.
Work closely with maintenance and instrumentation teams to ensure proactive servicing of safety-critical components.
Oversee predictive diagnostics (e.g., flame scanner fouling, actuator drift, pressure sensor lag).
Lead root cause analysis (RCA) of any boiler safety or control-related incident or deviation.
Analyze steam usage, boiler cycling, and operational KPIs to ensure safety is maintained alongside energy efficiency.
Recommend control modifications or burner tuning improvements to enhance safety margins and reduce risk of failures.
Boiler Burner Management Systems (BMS)
Flame safeguard programming and logic testing
PLC/DCS/SCADA systems for high-pressure boilers
NFPA 85, ASME CSD-1, OSHA compliance
Safety valve testing and interlock verification
Risk-based inspections (RBI) and safety performance reviews
Bachelor’s degree in Mechanical Engineering, Instrumentation, Process Controls, or a related technical field (or equivalent hands-on experience)
7–10 years of experience in boiler safety systems and controls, with at least 3–5 years in a supervisory capacity
Expertise in ASME Boiler and Pressure Vessel Code, NFPA 85, and OSHA 1910
Demonstrated experience with steam system safety design, auditing, and instrumentation troubleshooting
Valid Stationary Engineer License or Boiler Operator License (as required by jurisdiction)
OSHA 30-Hour Certification
Certified Control Systems Technician (CCST) or equivalent
NFPA 85 and ASME CSD-1 safety system training
First Aid/CPR, Lockout/Tagout, and Confined Space Entry certified
Advanced technical knowledge of steam safety and control systems
Strong leadership and crisis management capabilities
Excellent documentation, audit readiness, and communication skills
Proficient with control platforms (Rockwell, Siemens, Honeywell, etc.)
Data-driven, detail-oriented, and safety-first mindset