BOILER ENGINEER JOB DESCRIPTION

A Boiler Engineer keeps a plant running within safe pressure limits. In power generation and utilities, boiler availability directly determines generation capacity - and the engineer responsible for maintaining it must interpret ASME and NBIC compliance codes, manage R-stamp programs, and develop repair plans drawn from metallurgical analysis and failure data. This is a field-intensive, technically demanding role that sits at the center of plant reliability operations. It requires physical presence inside boiler internals and sustained coordination with Operations, Maintenance, and external contractors.

As the Boiler Engineer, you own the inspection, repair planning, and performance engineering of high-pressure boiler systems across utility-scale facilities, directly sustaining generation availability and regulatory compliance. You work within a cross-functional plant team that includes Operations, Asset Management, and Maintenance, with the technical authority to recommend system improvements and lead compliance programs under ASME and NBIC standards.

Career Impact: Deep experience with ASME boiler and pressure vessel codes and the R-stamp program establishes measurable technical authority that utility employers recognize as a senior qualification benchmark.

Business Impact: When forced outages are reduced through proactive tube failure analysis and targeted inspection programs, the financial and operational cost to the plant drops in direct proportion to this engineer's judgment.

Growth Opportunity: Leading capital improvement planning and managing outage engineering cycles builds the project ownership track record that supports progression toward Principal Engineer or Plant Engineering Manager roles.

• Inspect boiler internals during planned and forced outages to assess material condition and remaining component life.
• Develop repair plans based on applicable ASME and NBIC codes, failure mechanisms, metallurgy, and welding process requirements.
• Lead the R-stamp compliance program, including valve and piping inspections and documentation of all repair procedures.
• Create Critical Piping System packages and coordinate safety relief valve inspection programs across assigned facilities.
• Partner with Operations, Maintenance, and Contractors to implement system improvements and execute approved repair plans.
• Monitor boiler performance trends and develop health indicators that flag component degradation before forced outage events occur.
• Manage project engineering deliverables including budgets, schedules, specifications, and capital improvement justifications for future planning cycles.
• Coordinate combustion tuning and recommend operating or maintenance practice changes to improve boiler reliability and efficiency.

• Bachelor's degree in Mechanical Engineering, Metallurgical Engineering, or a closely related field, or equivalent work experience.
• 5 or more years of utility-scale boiler engineering experience, with demonstrated exposure to coal-fired, gas-fired, or HRSG systems.
• Working knowledge of ASME Boiler and Pressure Vessel Code and NBIC repair and inspection requirements.
• Proficiency in interpreting failure mechanisms, metal grades, and welding processes as applied to high-pressure boiler tube systems.
• Fourth Class Power Engineer certification (NIULPE), Facility Operating Engineer certification (ASOPE), or equivalent power engineering license.
• Physical capability to work at elevated heights, in confined spaces, and to traverse boiler internals through access doors.
• Availability for extended shifts, on-call emergency response, and travel up to 50% of the time as outage schedules require.
• Strong communication and coordination skills with demonstrated ability to resolve technical issues under time-constrained plant conditions.

• Advanced knowledge of high-energy piping systems and power piping codes beyond standard BPV scope.
• Experience managing fuel changes at operating power plants, including associated combustion and materials implications.
• Familiarity with QA/QC documentation processes and construction feasibility review for capital replacement projects.
• Prior exposure to cycling unit failure modes, including fatigue cracking, thermal stress damage, and creep mechanisms.

• Forced outage rate attributed to boiler tube failures, measuring effectiveness of proactive inspection programs.
• R-stamp compliance audit score, reflecting accuracy and completeness of program documentation across all covered components.
• Capital project schedule adherence, measured against approved timelines for boiler improvement and replacement work.
• Component remaining-life assessment accuracy, tracked against actual failure intervals over rolling inspection cycles.
• Repair plan approval cycle time, reflecting the speed and quality of post-inspection engineering documentation.
• Typical tools: Boiler inspection reporting systems (commonly AWARE or equivalent); ASME code reference platforms and plant CMMS systems.

• Base Salary Range: $90,000 to $125,000 annually, depending on experience and plant size.
• Bonus: Annual performance bonus of 5% to 12% of base salary, tied to plant reliability targets.
• Equity: Not typically offered in utility sector roles at this level.
• Health Benefits: Medical, dental, and vision coverage with employer contribution standard for utility employers.
• PTO: 15 to 20 days annually, plus paid holidays and outage-schedule flexibility provisions.
• Common Perks: Tool and safety equipment allowances, travel reimbursement, and professional certification support.

Figures are estimates based on general US market benchmarks and may be outdated. Adjust based on location, company size, and seniority level.

Employment decisions for this position are made without regard to race, color, religion, sex, national origin, age, disability, veteran status, genetic information, or any other characteristic protected under applicable federal, state, and local law. Background checks, including verification of work history and relevant credentials, are required as a condition of employment. Candidates must be authorized to work in the United States. Reasonable accommodations for qualified individuals with disabilities are available throughout the application and employment process upon request.

The Boiler Engineer owns the full engineering lifecycle for mechanical equipment including boilers, piping systems, ash systems, and pulverizers, developing repair plans, managing capital improvement budgets, and leading the R-stamp compliance program. Working closely with Operations, Maintenance, and Contractors, this role shapes plant reliability outcomes by reducing forced outages and advancing long-term boiler performance across utility-scale facilities.

Key Responsibilities

• Inspect boilers during outages and develop repair plans based on applicable codes, failure mechanisms, material conditions, metallurgy, welding processes, and knowledge of water, steam, and flue gas systems.
• Determine proactive measures to stop or reduce forced outages due to tube failures, including managing inspections and testing to assess remaining component life.
• Perform project engineering duties including developing budgets, schedules, specifications, and documents.
• Create Critical Piping System packages and lead safety relief valve inspections.
• Participate in planning and budgeting for boiler performance management and justify future capital improvement projects.
• Collaborate with Operations, Maintenance, and Contractors on system improvements, repair plans, and project implementation.
• Recommend equipment or system improvements based on code, manufacturer guidance, and plant operational experience.
• Lead the R-stamp program, utilizing ASME and NBIC codes to ensure compliance, and provide repair recommendations as requested.

Required Qualifications

• Bachelor's degree in Engineering, preferably in Mechanical or Metallurgical Engineering, from an ABET-accredited university.
• Fourth Class Power Engineer certification (NIULPE), Facility Operating Engineer certification (ASOPE), or equivalent power engineering license required.
• Minimum 8 years of relevant experience, with utility industry experience preferred.
• Advanced knowledge of boiler pressure vessels, high energy piping, and power piping codes and standards.
• Proficiency in understanding failure mechanisms, metal grades, welding processes, and steam flow through boiler tube systems.
• Ability to create and enter boiler inspection reports into AWARE.
• Strong communication, teamwork, and people skills with the ability to work in cold, hot, dirty, and noisy environments.
• Ability to work at heights, in confined spaces, and to crawl or climb inside boilers.

Embedded within Asset Management and plant operations teams, the Boiler Engineer serves as the primary technical support resource for boiler and piping design, repair, and replacement, with the primary objective of improving boiler availability. Working closely with plant teams and contractors, this role develops health indicators, root cause analyses, and remediation plans that sustain reliable generation across utility-scale facilities.

Core Functions

• Assist in developing specifications and standards for boiler and pressure vessel replacement components.
• Provide support during planned and forced outages, including inspection of boiler internals and developing repair procedures.
• Collaborate with Asset Management and plant teams to troubleshoot boiler component issues and develop repair, remediation, and replacement plans.
• Develop and maintain health indicators for boiler components and determine root cause of failures with recommendations to address.
• Review and recommend component testing, maintenance, and replacement plans for boiler components.
• Coordinate combustion tuning on boilers.

Qualifications and Experience

• Bachelor's degree in Engineering required.
• Minimum 5 years of utility-scale boiler experience, including coal and gas fired boiler inspections and HRSG inspections.
• Advanced knowledge of boiler pressure vessels, high energy piping, and power piping codes and standards.
• Advanced knowledge of maintenance of power boilers and heat-recovery steam generators, including experience with fuel changes and failure modes associated with cycling units.
• Advanced knowledge of company QA/QC processes and working knowledge of construction feasibility.
• Strong communication and coordination skills with aggressive issue resolution approach.
• Ability to work extended shifts including weekends, holidays, and nights, and to be on-call for emergency shutdowns.
• Physical ability to traverse facilities involving climbing, crawling, lifting, and bending in hot or cold conditions, at heights up to 180 feet, and in confined spaces with limited light.

Reporting to facilities leadership, the Boiler Engineer operates, monitors, and maintains high-pressure boilers, boiler auxiliaries, and related life safety equipment while ensuring compliance with local, state, and federal regulatory requirements. Partnering with maintenance and facilities teams, this role sustains safe and reliable building mechanical systems by performing preventive maintenance, repairs, and equipment control functions across assigned facilities.

Primary Duties

• Operate, monitor, and perform preventive maintenance on high-pressure boilers, boiler auxiliaries, and related mechanical and life safety equipment.
• Inspect equipment for malfunctions and make adjustments or repairs to restore operating condition.
• Maintain specified pressures, temperatures, and prescribed chemical concentrations in boilers and auxiliary equipment.
• Observe meters and gauges to regulate flow of water, fuel, steam pressure, and oxygen in accordance with safety standards.
• Perform installation and repair of minor piping, structural, and electrical systems.
• Operate and maintain automated building and equipment control systems.
• Compute job costs and order parts, equipment, supplies, and materials.
• Maintain daily logs, preventive maintenance records, and equipment repair files to comply with local, state, and federal regulatory requirements.
• Assist in construction, remodeling, and maintenance projects as needed.

Skills and Qualifications

• Fourth Class Power Engineer certification (NIULPE), Facility Operating Engineer - First or Second Class (ASOPE), Power Plant Operating Engineer Third Class (ASOPE), MECH certification (WHEA), or Universal CFC certification (EPA) required.
• Valid driver's license and current driving record meeting fleet safety standards required.
• Stationary Engineer's permit for the City of Milwaukee must be obtained within one year of hire.
• Knowledge of applicable codes and regulations of assigned equipment and operations.
• Basic computer skills with strong communication and interpersonal skills.
• Demonstrated ability to work independently and to problem solve.