COURSE OVERVIEW:

The Boiler Operation and Control System Maintenance course is a practical, technical program designed to bridge the gap between day-to-day boiler house operations and the technical upkeep of automation hardware. Reliable steam production depends on both the skill of the operator and the precision of the control system. This course focuses on the operational procedures for safe startup, steady-state running, and controlled shutdown, while providing the technical skills necessary to maintain the transmitters, controllers, and final elements that regulate the process.

The scope of this training includes the management of water chemistry and its impact on control system sensors, such as conductivity and pH probes. Participants will explore the mechanical and electrical maintenance of boiler auxiliaries, including feed pumps, fans, and fuel delivery systems. The curriculum provides a detailed look at the preventative maintenance routines for pressure switches, level glasses, and automatic blowdown systems, ensuring that the physical hardware remains in peak condition to respond to control commands.

This coverage also addresses the diagnostic techniques required to identify deteriorating performance before it leads to a system trip or equipment damage. Attendees will learn how to interpret control loop trends to identify sticking valves, drifting transmitters, or failing sensors. By focusing on the synergy between operational best practices and systematic maintenance, the program ensures that participants can maximize boiler life, ensure personnel safety, and maintain the high efficiency required in modern industrial utility plants.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Execute safe boiler startup and shutdown procedures according to industry best practices.
• Monitor and interpret key boiler operating parameters for stability and efficiency.
• Perform routine maintenance on boiler water level control hardware.
• Manage boiler water chemistry through automated and manual blowdown control.
• Inspect and maintain fuel burners, igniters, and diffusers for clean combustion.
• Troubleshoot common control loop failures and instrument inaccuracies.
• Maintain and calibrate steam pressure and temperature transmitters.
• Inspect and test safety valves and low-water cutoff devices.
• Optimize fan and pump performance through the maintenance of variable speed drives.
• Perform internal and external boiler inspections for scale, corrosion, and leaks.
• Document operational logs and maintenance activities for regulatory compliance.
• Respond effectively to boiler emergencies and abnormal operating conditions.

TARGET AUDIENCE:

This course is designed for Boiler Operators, Maintenance Technicians, Facility Engineers, and Plant Supervisors who are responsible for the daily operation and technical maintenance of industrial and commercial boiler systems.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.