Assistant Manager - Mechanical (Boiler Operations & Maintenance)

Key Responsibilities 1) Boiler Operations & Optimization

• Own day‑to‑day operation of utility boilers (e.g., subcritical/supercritical PC, AFBC/CFBC), coal & secondary fuel systems, soot‑blowing, and combustion tuning to meet load demands and maintain SH/RH steam temperature within limits.
• Monitor and optimize boiler efficiency, auxiliary power consumption, vacuum/pressure profiles, excess air/O₂, flue gas temperatures, and stack emissions.
• Drive heat rate and SPC (specific coal consumption) improvements via data‑driven actions.

2) Mechanical Maintenance & Reliability

• Plan and execute preventive, predictive, and condition‑based maintenance of boiler pressure parts, fans (FD/ID/PA), APH, ESP, coal mills/feeders, fuel handling, ash handling (pneumatic/hydraulic), and soot blowers.
• Lead fault diagnostics and root cause analysis (RCA) for tube leaks, erosion/corrosion, clinker/choking, vibration, imbalance, and bearing/gear failures.
• Implement RCM/FMEA, spares strategy, inventory min–max, and CMMS/SAP PM discipline (notifications, work orders, history).
• Oversee cold/warm/hot start‑ups and shutdowns, boiler light‑up, purging, and lay‑up procedures.

3) Outage/Shutdown Management

• Prepare AOH/COH scope, method statements, resources, and schedules (PERT/Gantt) for boiler and auxiliaries.
• Manage contractors, permit‑to‑work (PTW), LOTO compliance, quality checkpoints, and post‑outage performance testing.
• Ensure NDT (UT, MT, PT, RT) and metallurgical inspections, thickness mapping, and weld repairs per codes.

4) Safety, Environment & Compliance

• Enforce PTW, LOTO, confined space, hot work, working at height, and scaffolding standards.
• Comply with IBR (Indian Boiler Regulations)/Indian Boilers Act (or local equivalent), Factory Act, and internal SOPs.
• Maintain Boiler Operation Engineer (BOE) license compliance where required.
• Ensure adherence to ISO 45001 (safety), ISO 14001 (environment), ISO 50001 (energy) and statutory emission/water norms; coordinate with CEMS/stack monitoring.
• Lead incident reporting, near‑miss capture, and corrective/preventive actions.

5) Performance, Documentation & Stakeholder Management

• Track and publish KPI dashboards: availability, PLF‑impacting downtime, MTBF/MTTR, tube leak rates, heat rate, auxiliary consumption.
• Ensure accurate logbooks, shift reports, condition monitoring (vibration, thermography, oil), and updated P&IDs/As‑built.
• Coordinate with Operations, Electrical, I&C, CHP, AHP, Water Chemistry, EHS, and Procurement for seamless plant performance.
• Support audits (internal/external/regulatory) and customer or management reviews.

6) Continuous Improvement & People Development

• Lead Kaizen/Lean projects (e.g., APH sealing improvement, soot‑blow optimization, mill availability).
• Introduce predictive analytics (trend alarms, soft sensors) with DCS/PI historian data.
• Mentor shift engineers and technicians; deliver toolbox talks and skill matrix‑based training.

Qualifications & Experience

• B.E./B.Tech in Mechanical Engineering (or equivalent).
• 7–10 years of relevant experience in thermal power plant boiler operations & mechanical maintenance (utility scale).
• Boiler Operation Engineer (BOE) Certificate preferred/mandatory as per state regulations.
• NDT Level II exposure desirable; Green Belt/Lean/TPM is a plus.