BOILER PLANT OPERATOR POSITION DUTIES ‐ ABERDEEN Proving Ground, MD: Plant operators start, operate, adjust, stop, maintain, and perform various operational repairs on single or multiple fuel 500 or more horsepower boilers to include a cogenerating heat and power turbine and associated auxiliary and pollution control equipment. Boilers use oil and gas to produce steam or high temperature water required for heating operations. Boilers operated require constant attention to maintain efficiency and control the formation of pollutants. Operators maintain efficient combustion levels and ensure compliance with air pollution laws or regulations. Through the use of manual, automatic, or microprocessor controls or control systems, boiler plant operators monitor, adjust, and control all phases of boiler plant operations. Incumbent use electronic, hydraulic, and pneumatic controls, and zone charts in conjunction with meters, gauges, and computer‐generated date to determine adjustments or corrections necessary for proper boiler operations or changing load requirements. They operate, adjust, and maintain auxiliary and pollution control equipment such as electrical or steam driven pumps. Forced and induced draft fans, air compressors, deaerating equipment, feed water heaters, economizers, fuel heaters and delivery equipment, and demineralizing systems. They adjust fuel feeds and the volume and velocity of draft and other fire box variables to achieve maximum combustion efficiency with changing load demands or variations in fuel quality. They regularly observe and note readings on gauges, meters, detectors, recorders, boiler water level indicators, and computer generated and analog displays to detect danger signals in operations. They analyze test feedwater, boiler water, and condensate using standard chemical tests. The operator determines the treatment and chemicals to be used to control chemical concentrations, remove impurities and entrapped gases, or stabilize fluctuating water conditions in the boiler. In some work situations, due to operating pressures or user requirements, they are required to maintain low water cutouts, high pressure cutouts, and purge type combustion safeties.
They perform operational maintenance (e.g., lubricate equipment and power clean water tubes) and repairs of limited to moderate complexity (e.g., replace or repair valves, Gauges, and pumps) on mechanical parts and systems and may be required to perform limited or basic electrical repairs. They may operate emergency electrical generators to meet plant electrical requirements when the main electrical source is unable to provide the necessary power. During the non‐ heating season, the incumbent will be responsible for performing preventative maintenance to heating, ventilation, air conditioning and refrigeration equipment. 55%
Maintains surveillance over the Energy Management and Control System (EMCS) by monitoring the central console (computer terminal). Presses appropriate functions keys to: (1) obtain status of control points on each boiler and air conditioning system, which is linked to the EMCS computer central terminal. (2) To activate or shut down elements of the system by temperature and/or time set point override per direction, of the supervisor (EMCS System Manager). Detects normal and fault conditions through the alarm system; interprets the codes produced by the system to determine the point or points in alarm and thus, the nature of the problem. When possible performs emergency correction of faulty operating condition and takes necessary action to correct or neutralize the alarm conditions. When a malfunction cannot be corrected from the central console, incumbent notifies the supervisor or other designated personnel under emergency conditions, takes any possible action to ensure prompt dispatching of maintenance mechanics. Assists EMCS field mechanics by relaying information (by two
way radio) from peripheral display as to equipment status/operability. May be necessary to notify supervisor during off duty hours when information on alerts supplied by the EMCS system warrants for mechanics personnel response.
Incumbent must be able to determine whether he can make an emergency correction of the malfunction correct or neutralize the alarm condition or, if the malfunction cannot be corrected from the central console contacts the supervisory or designated mechanic or mechanics. 25%
Performs the following boiler plant equipment mechanic duties: Installs, maintains, and repairs large complex boilers, heating plants and systems having complicated, when provide heat and hot water. Performs visual and operational tests to trouble shoot and diagnose the cause of malfunction. In addition to standard equipment in complicated systems, incumbent services the large complex systems complicated components such as preheaters, superheaters, baffles, economizers, and breechings. Repairs valves by repacking, replacing, and/or grinding seats. Perform a major overhaul of oil fired installations including soot removal, replacement of filters and filter elements, cleaning and replacement of nozzles and electrodes, and chemical cleaning of boiler waterside. May be required to correct samples of boiler feedwater and perform a variety of tests by using prescribed chemical reagents, color slides, and related equipment; determines and adds the prescribed amount and type of chemicals to the feedwater for proper equipment care. 10%
On second and third shift, on weekends or holidays, when the regular work force is not on duty, receives trouble calls or emergency calls relating to a variety of trades and crafts. Logs in information and relays request to designated personnel capable of responding to the call(s). On the more serious cases, notifies the appropriate off duty supervisor. Receives incoming calls relating to contract fuel oil deliveries and dispatches trucks to proper plant location for unloading. Required to maintain all required logs and reports to include, but is not limited to, boiler plant logs and state reports. 10% Performs other duties as assigned.
Skill and knowledge: Boiler plant operators apply a comprehensive knowledge of all operational phases of power boiler plant operations (e.g. water treatment, fuel systems, steam generation, and pollution control) and their interrelationships for efficient and economical generation of steam or high temperature hot water (HTHW).
Operators apply knowledge of the principles and theories pertaining to combustion, heat transfer, and steam or HTHW generation in the operation of power boiler plants. In addition, they apply a thorough knowledge of the structural and operating characteristics of single and multiple fuel power boilers. Associated auxiliary and pollution control equipment or systems (e.g., computerized or microprocessor control systems, fuel handling and distribution equipment and systems, fuel firing mechanisms, feedwater and boiler water treatment systems, steam and electrical pumps, pressurization systems, compressors, and flue gas desulfurization systems) to properly operate, adjust, troubleshoot, and maintain the equipment and systems. They apply a thorough knowledge of chemical tests. They have a thorough knowledge of water treatment procedures and water analysis, using standard chemical tests. They have a thorough knowledge of water treatment procedures and water analysis, using standard
chemical tests. They have a thorough knowledge of treatment equipment and systems (e.g., cation/ion exchange units for demineralization of feedwater). They have a thorough knowledge of chemical and physical aspects of sulfur containing fuels of oil, the chemical reactions involved in combustion, and the relationship between fuel quality and combustion efficiency. They have a practical knowledge of environmental law and a thorough knowledge of procedures or adjustments during combustion to control pollutants in flue emissions (e.g., control combustion time, stack temperature, and excess airflow). Operators have thorough knowledge of the steam or HTHW distribution systems, user requirements, casualty control procedures, and how to bypass a section of the steam system to maintain service. They are knowledgeable of maintenance requirements (e.g., cleaning fuel guns, lubricating equipment, and power cleaning water tubes) and procedures necessary to perform operations repairs of limited to moderate complexity (e.g., repair or replace valves, gauges, water pipes, and refractory linings). In some work situations, operators may have basic knowledge of electricity to test and replace wires, switches, and other basic electrical components.
Boiler plant operators have the skill in procedures and adjustments necessary to start, operate, and maintain a power boiler facility (i.e., power boilers, cogenerating heat and power turbines and auxiliary and pollution control equipment) to meet load demands and maintain efficient levels of combustion and compliance with pollution laws. They have skill in operating power boilers from cold starts through normal operation and hot or emergency shutdowns. Operators can stabilize boilers in a closed system when one boiler starts to go down while maintaining safe levels and efficient combustion. They have skill in reading and analyzing information from gauges, meters, recorders, analog displays, and computer generated data to determine the operational status of the facility and necessary adjustments. They can make individual and sequential adjustments to a variety of controls and equipment to achieve and maintain maximum efficiency of equipment and systems being operated. They are skilled in specialized combustion techniques and adjustments to firebox variable such as fuel flow or feed, fuel air ratio, temperature, combustion time, and over air or under air feeds to control chemical pollution in flue gas emissions and maintain combustion efficiency. They apply skill in setting and adjusting flame patterns in power boilers with single or multiple burners to ensure safe and efficient combustion. They have skill in adjusting various combustion settings to compensate for varying qualities or conditions of fuels.
Responsibility: Boiler plant operators receive work assignments from a supervisor who is in charge of the facility or work shift. They provide written or oral instructions, which may be accompanied by diagrams, drawings, operating manuals, or special facility procedures to be followed during emergencies, equipment failure, or system malfunction. They are familiar with the total plant layout including drawings and circuit diagrams of the boilers and auxiliary and pollution control equipment, in order to locate problems and determine appropriate action necessary to maintain adequate steam or high temperature, hot water production. Boiler plant operators make more independent decisions and judgments regarding boiler plant operations (e.g., combustion and pollution control adjustments, troubleshooting techniques, and equipment maintenance and repair procedures). In maintenance and repair operations, they complete all work in accordance with required specifications and use a variety of standard mechanical and basic
electrical processes. Boiler plant operators typically have primary responsibility for checking boilers and auxiliary and pollution control equipment to insure the operational efficiency of equipment and safety of personnel. They take immediate action to prevent interruptions to plant operations and report all emergencies or dangerous conditions. The supervisor is usually available to provide technical assistance on difficult or unusual problems. Work is checked through occasional observation of operational efficiency, production reports, and adherence to established operating techniques and procedures.
Physical Effort: Boiler plant workers frequently work in confined areas in and around boilers and support equipment (i.e., auxiliary and pollution control equipment). The work required moderate to strenuous effort and long periods of walking, standing, climbing, bending, and crouching. Workers frequently lift and carry boiler parts and chemical supplies weighing up to 23 kilograms (50 pounds) unassisted and occasionally items weighing over 23 kilograms (50 pounds) with assistance of other workers or weight handling equipment.
Working Conditions: Boiler plant workers work indoors and occasionally work outside for short periods where they are subject to prevailing weather conditions. Workers are subject to high temperatures, constant noise, rotating machinery, soot, dirt, grease, chemicals, oil, and fumes in the work area. Boiler plant workers at this level are subject to cuts and abrasions from the use of tools and equipment and burns from acids, caustics, hot water, steam, and contact with piping and boilers. In addition, they work on catwalks and ladders.
CONDITIONS OF EMPLOYMENT & NOTES: 1. Must possess (before appointment) and maintain a Grade 1 Maryland State Stationary Engineer License. 2. Must obtain a Boiler Optimization Certification within one year of appointment. 3. Must pass a pre‐appointment and annual physical. 4. Must possess and maintain a valid State driver’s license and be able to obtain and maintain an Army Motor Vehicle operator’s permit. 5. Employee will be a part of an Emergency Workforce and is required to have his/her name on a call out list and be called back to work during non‐duty hours (including weekends) to support emergency situations or make emergency repairs.
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