The Slurry Treatment Plant (STP) Manager is responsible for the planning, setup, commissioning, operation, maintenance, optimization, and demobilization of the Slurry Treatment Plant and associated support systems for major tunnel boring operations. This role ensures that slurry separation, filtration, water treatment, chemical dosing, spoil handling, and related plant operations are performed safely, efficiently, and in alignment with TBM production requirements.
The STP Manager will lead plant operations to maintain continuous TBM advancement, optimize slurry performance based on ground conditions, reduce downtime, manage plant crews and vendors, and ensure compliance with project specifications, environmental permits, safety standards, and operational KPIs.
The STP Manager’s key responsibilities are:
- Lead the setup, commissioning, operation, maintenance, troubleshooting, and demobilization of the Slurry Treatment Plant and associated systems, including pumps, screens, shakers, hydrocyclones, centrifuges, filter presses, tanks, pipework, conveyors, controls, and water treatment systems.
- Manage multi-stage separation and filtration processes to continuously remove excavated material from bentonite/water slurry mixtures and maintain required production throughput.
- Monitor and control slurry properties, including density, viscosity, sand content, bentonite concentration, chemical dosing, and water quality, to support tunnel face stability and TBM performance.
- Optimize chemical dosing programs, including bentonite, polymers, coagulants, flocculants, lime milk, and other additives based on ground conditions, production requirements, and cost efficiency.
- Coordinate closely with TBM operations, mud pump systems, conveyor systems, grout batch plant operations, construction teams, and engineering staff to avoid production bottlenecks and maintain uninterrupted excavation cycles.
- Review and interpret geotechnical data, TBM production forecasts, process flow diagrams, P&IDs, technical specifications, method statements, and operational requirements to identify risks and optimization opportunities.
- Establish and maintain operating procedures, start-up/shut-down sequences, emergency response plans, contingency plans, risk assessments, and safe work procedures for STP operations.
- Lead troubleshooting and root-cause analysis for plant performance issues, including pump cavitation, pipeline blockages, screen blinding, centrifuge performance, chemical treatment inefficiencies, excessive wear, water treatment challenges, and reduced throughput.
- Track and report key performance indicators, including plant availability, slurry quality, throughput, water reuse, waste volumes, chemical consumption, equipment downtime, MTBF/MTTR, maintenance performance, and cost trends.
- Manage preventive and corrective maintenance programs, including lubrication, inspection schedules, critical spares, repairable-spares loops, replacement parts, and vendor/OEM support.
- Oversee procurement and inventory of critical plant components, including slurry pumps, screens, cyclones, filter press components, pipework, valves, sensors, instrumentation, chemical additives, and consumables.
- Manage and mentor plant operators, mechanics, electricians, technicians, and specialist subcontractors, ensuring proper staffing, training, shift coverage, and adherence to operational procedures.
- Prepare and maintain plant documentation, including SOPs, inspection records, maintenance records, commissioning documentation, KPIs, lessons learned, training materials, and regulatory reporting.
- Ensure compliance with all applicable safety, environmental, and quality requirements, including OSHA, MTA, NYC, project-specific procedures, water discharge permits, waste disposal protocols, dust/noise controls, and confined space/LOTO requirements.
- Support continuous improvement initiatives to increase reliability, improve maintainability, reduce waste, optimize chemical consumption, improve plant layout, and reduce operating costs.
- Coordinate with project leadership, engineering, EHS, quality, procurement, and construction teams to support safe and efficient tunneling operations.
EDUCATION AND QUALIFICATIONS
- Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Civil Engineering, Environmental Science, Industrial Engineering, or a related technical discipline preferred. Equivalent hands-on experience in tunneling, slurry treatment, wastewater treatment, or industrial plant operations may be considered.
- 10+ years of experience in heavy civil, tunneling, mining, mineral processing, wastewater treatment, or industrial plant operations, with direct experience managing Slurry Treatment Plants preferred.
- 5+ years of supervisory or management experience leading plant operators, mechanics, technicians, electricians, subcontractors, vendors, or multidisciplinary production teams.
- Strong technical knowledge of slurry treatment systems, separation technology, slurry pumps, hydrocyclones, screens, centrifuges, filter presses, conveyors, tanks, pipework, water treatment systems, and chemical dosing systems.
- Experience supporting TBM tunneling operations, including slurry TBMs, slurry circuits, spoil processing, bentonite management, mud pumping systems, and production coordination.
- Experience with commissioning, startup, plant optimization, preventive maintenance, troubleshooting, and demobilization of heavy industrial or tunneling plant systems.
- Strong understanding of slurry chemistry, water treatment, geotechnical interface considerations, chemical performance, and process optimization in variable ground conditions.
- Demonstrated ability to manage budgets, procurement, spare parts, maintenance planning, vendors, OEM coordination, and cost-control initiatives.
- Familiarity with CMMS, KPIs, method statements, risk assessments, SOPs, lift plans, LOTO, confined space work, hot work, and hazardous energy control.
- Proficiency with Microsoft Office required; experience with Microsoft Project, AutoCAD, SolidWorks, SCADA/HMI, PLC/MCC systems, or other plant monitoring tools is preferred.
- Strong leadership, communication, decision-making, and problem-solving skills in a fast-paced, 24/7 tunneling or heavy industrial environment.
JOB REQUIREMENTS
- Ability to coordinate STP operations with TBM advancement and other project activities to maintain continuous production.
- Ability to work effectively in a high-pressure tunneling environment with rotating shifts, nights, weekends, and critical production windows as needed.
- Strong field presence with the ability to provide hands-on troubleshooting, crew leadership, and technical direction.
- Ability to interpret technical documents, drawings, process flow diagrams, equipment manuals, operational data, and project specifications.
- Knowledge of environmental compliance requirements related to water treatment, slurry disposal, spoil management, discharge criteria, dust/noise controls, and waste streams.
- Commitment to safety, quality, environmental stewardship, operational excellence, and continuous improvement.
WORK ENVIRONMENT
- Work will be performed across surface plant areas, shafts, tunnel headings, maintenance areas, and project offices.
- Frequent field supervision is required, including walking, standing, climbing ladders/scaffolds, accessing platforms, and navigating uneven terrain around heavy equipment.
- Exposure to noise, vibration, dust, water, slurry, chemicals, moving equipment, confined spaces, variable temperatures, and active construction operations.
- Consistent use of PPE is required.
- Flexibility is required to support continuous excavation, commissioning activities, plant shutdowns, maintenance windows, and emergency response needs.
FCC is dedicated to creating an inclusive workplace where diversity is valued and respected. As an Affirmative Action/Equal Opportunity Employer, we do not discriminate against any applicant for employment or employee because of race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, protected veteran status, genetics, creed, veteran status, military status, or any other characteristic protected under Federal, State, or local laws.
Reasonable accommodation will be provided to qualified individuals with disabilities in accordance with applicable law.
