JOB DESCRIPTION
Steam System Specialist / Senior Steam & Boiler Systems Engineer
Location: Vadodara, Gujarat | Experience: 18+ years
1. Role Overview
We are seeking a highly experienced Steam System Specialist / Senior Steam & Boiler Systems Engineer to act as a senior subject-matter expert (SME) and technical authority for industrial steam and boiler systems. The role provides end-to-end engineering support to industrial end-user customers, translating process and utility requirements into technically sound, safe, reliable and energy-efficient solutions. Responsibilities span design and engineering review, thermodynamic assessment, equipment selection, commissioning support, performance testing, troubleshooting, root-cause analysis and optimization.
The preferred candidate will have developed this expertise in a central engineering, OEM, EPC, engineering centre, technology-provider or industrial utility solutions environment, with technical engagement across multiple customer sites and projects. This is not intended to be a plant-side utility operations role alone.
2. Position Details
Position title: Steam System Specialist / Senior Steam & Boiler Systems Engineer
Location: Vadodara, Gujarat
Experience: Minimum 18 years relevant experience in steam generation, boiler systems, steam distribution/utilization and condensate recovery
Education: Bachelor’s degree in Mechanical, Thermal, Power or Chemical Engineering; a Master’s degree in Thermal/Power Engineering is an advantage
Work context: Central technical/engineering function supporting multiple customer projects and industrial end users.
3. Key Responsibilities
A. Steam-System Design and Engineering
· Lead, develop or technically review steam-generation, steam-distribution, steam-utilization, condensate-recovery and associated industrial utility-system solutions.
· Translate customer process requirements, utility demand, operating conditions and performance targets into system concepts, engineering deliverables and equipment requirements.
· Review process data, design basis documents, PFDs, P&IDs, process datasheets, equipment specifications, line lists, operating philosophies and engineering calculations.
· Assess steam demand, pressure levels, temperature requirements, turndown, load variation, operating flexibility, reliability and maintainability.
· Review steam-network configuration, pressure losses, piping sizing, pressure control, isolation, drainage, venting and condensate handling.
· Check interfaces among boilers, steam headers, PRDS/desuperheating stations, process users, heat exchangers, condensate return, feedwater and auxiliary systems.
B. Boiler Systems and Equipment Expertise
· Provide technical expertise across fire-tube boilers, water-tube boilers, HRSGs, once-through steam generators, package boilers and associated auxiliary systems.
· Review boiler sizing and selection, steam capacity, pressure/temperature conditions, efficiency, turndown, performance guarantees and operating constraints.
· Evaluate combustion systems, fuel-related operating considerations, feedwater requirements, blowdown arrangements and boiler auxiliary equipment.
· Review boiler performance-test results and identify causes of deviation from guaranteed or expected performance.
· Assess boiler and steam-system suitability for the customer’s process, operating profile, reliability needs and applicable technical requirements.
C. Steam Thermodynamics and Energy Analysis
· Perform or review steam and energy balance calculations across boiler houses, steam headers, process consumers and condensate-return systems.
· Analyze steam properties, enthalpy, mass flow, pressure/temperature conditions, heat duties and energy consumption to validate system performance.
· Assess steam-cycle and thermal performance, including opportunities to improve efficiency and reduce avoidable energy losses.
· Identify savings through condensate recovery, flash-steam utilization, heat recovery, feedwater improvement and optimization of steam usage.
· Support process simulation, thermal-performance assessments and engineering studies to quantify potential savings and technical benefits.
· Prepare or review technical calculations and recommendations with clear assumptions, findings, expected impact and implementation considerations.
D. Steam Distribution, PRDS and Condensate Recovery
· Review steam distribution networks, pressure-reducing and desuperheating (PRDS) stations, control arrangements and associated equipment.
· Assess pressure-reducing valves, temperature-control valves, desuperheating arrangements, steam traps, strainers, separators and other steam-system components.
· Evaluate condensate collection, pumping, return-line design, flash-steam recovery, condensate contamination risks and condensate-recovery potential.
· Review feedwater systems, deaeration interfaces and water-quality considerations affecting boiler reliability and performance.
· Identify steam leakage, poor trapping, water hammer, inadequate drainage, heat loss, excessive venting and other sources of inefficiency or reliability risk.
· Recommend practical engineering changes to improve steam quality, control stability, energy utilization, condensate return and availability.
E. Commissioning, Start-Up and Customer-Site Support
· Provide technical leadership or specialist support during installation checks, commissioning, start-up, shutdown and performance testing of steam and boiler systems.
· Review or contribute to commissioning plans, start-up/shutdown procedures, operating instructions and preservation requirements where applicable.
· Support site teams and customers in validating system readiness, operating parameters, control philosophy and performance against design expectations.
· Troubleshoot system problems and lead root-cause analysis using operating data, field observations, calculations and equipment history.
· Recommend corrective actions and longer-term design or operating improvements; support verification of implemented solutions.
· Travel to customer and project locations as required for technical reviews, performance assessments, commissioning and troubleshooting.
F. Technical Leadership, Reviews and Governance
· Act as a senior SME/technical authority across multiple projects and customer engagements, rather than being responsible for only one operating plant.
· Lead or contribute to multidisciplinary design reviews, technical bid/equipment reviews, HAZOPs, risk assessments, technical audits and engineering assurance.
· Coordinate technically with customers, consultants, EPC contractors, OEMs, suppliers and internal engineering, project, commissioning and service teams.
· Challenge assumptions, identify technical gaps and resolve interfaces while maintaining focus on safety, reliability, performance and lifecycle cost.
· Provide guidance to engineers and project teams; review deliverables and communicate complex technical matters clearly.
· Document technical decisions, design recommendations, risks, lessons learned and corrective actions.
4. Required Technical Competencies
· Strong command of steam thermodynamics and industrial steam-system engineering.
· Practical knowledge of boiler design principles, steam-generation technologies and boiler performance evaluation.
· Ability to perform and critically review steam, mass and energy balance calculations.
· Strong understanding of steam distribution networks, steam pressure management, PRDS and desuperheating stations.
· Detailed understanding of condensate recovery, steam traps, condensate pumping, flash steam and heat-recovery opportunities.
· Knowledge of feedwater systems, deaeration interfaces, blowdown requirements and relevant boiler auxiliaries.
· Experience interpreting and reviewing PFDs, P&IDs, datasheets, equipment specifications, calculations and operating philosophies.
· Proven capability in commissioning support, performance testing, troubleshooting and root-cause analysis.
· Ability to assess energy-efficiency opportunities and turn technical findings into practical improvement recommendations.
5. Preferred / Additional Knowledge
· Knowledge of ASME Boiler and Pressure Vessel Code, API requirements and other relevant international engineering standards.
· Exposure to steam-turbine auxiliary systems, heat exchangers, process heating applications and combined heat and power (CHP) systems.
· Familiarity with process simulation tools, steam/thermal performance software or engineering calculation tools.
· Experience across power generation, oil and gas, refinery, petrochemical, chemical/process industries or industrial utilities.
6. Essential Experience and Candidate Background
· At least 18 years of relevant, hands-on experience in steam generation, boiler systems, steam distribution/utilization and condensate recovery.
· Experience should include engineering, technical review, commissioning, troubleshooting and performance optimization; the profile should demonstrate more than routine operation or maintenance of one plant.
· Current or recent employment in a boiler/steam equipment manufacturer, power or energy equipment OEM, steam-system technology provider, industrial utility solutions company, EPC/engineering company or central engineering/technical centre is strongly preferred.
· Demonstrated technical engagement with external industrial customers, consultants, EPC contractors and/or multiple customer sites.
· Evidence of delivering or reviewing system-level solutions, including interaction among boilers, steam networks, PRDS, process consumers, feedwater and condensate recovery.
· A record of independently solving complex technical problems and providing recommendations with measurable improvements in reliability, efficiency, performance or energy use.
7. Preferred Industry Exposure
· Power generation and industrial power/utility systems.
· Oil and gas, refinery and petrochemical facilities.
· Chemical and process manufacturing industries.
· Industrial plants with complex steam-generation, distribution and process-heating requirements.
8. Communication and Leadership Attributes
· Strong analytical thinking, structured problem-solving and sound engineering judgment.
· Clear written and verbal communication, including the ability to explain complex technical issues to customers and senior stakeholders.
· Confidence in leading technical discussions, design reviews and problem-solving sessions with cross-functional teams.
· Customer-oriented approach, professional maturity and ability to manage multiple technical interfaces.
· Willingness to travel to customer/project sites when required.
9. Profiles That Are Less Suitable
· Candidates whose experience is limited primarily to plant utility operations, routine maintenance or shift supervision at a single end-user facility, without central engineering or multi-customer solution experience.
· Candidates focused mainly on instrumentation, DCS/PLC/automation, piping layout/detailing or general process engineering without strong steam-system engineering depth.
· Sales, marketing or account-management profiles without substantial hands-on engineering, calculations, design review and troubleshooting capability.
· Candidates with boiler exposure but limited understanding of steam distribution, PRDS, condensate recovery, thermodynamic analysis and system-level optimization.
· Candidates with fewer than 18 years of relevant experience, unless the hiring authority explicitly approves an exception.
10. Indicative Success Measures
· Quality and technical completeness of steam-system designs, reviews and engineering recommendations.
· Accuracy and usefulness of steam/energy balance assessments and thermal-performance evaluations.
· Successful resolution of customer steam/boiler problems through robust root-cause analysis.
· Demonstrable improvements in energy efficiency, condensate recovery, system reliability or operating performance.
· Effective technical coordination across customers, consultants, EPCs, OEMs and internal project teams.
· Consistent application of safe engineering practices and completion of technical reviews/audits.
