COURSE OVERVIEW:

Industrial boilers are high-energy assets that require precise management to ensure safety, efficiency, and longevity. This course provides a comprehensive examination of the mechanical operations and chemical processes that occur within steam generation systems. Participants will explore the critical relationship between combustion control, heat transfer, and pressure vessel integrity in modern industrial and utility boilers.

The scope of this training includes the technical procedures for startup, normal operation, and emergency shutdown, alongside rigorous maintenance protocols. A significant portion of the course is dedicated to the science of water treatment, explaining how to prevent scaling, corrosion, and carryover. We will analyze the internal and external water treatment methods necessary to protect the boiler’s heating surfaces and the downstream steam system.

Coverage extends to the inspection of boiler internals, the maintenance of burners, and the troubleshooting of control systems. Attendees will learn how to optimize boiler performance by managing fuel-to-air ratios and minimizing heat losses. By the end of this course, participants will be equipped with the knowledge to maintain high reliability and prevent the catastrophic failures associated with poor water quality or operational errors.

COURSE OBJECTIVES:

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

1. Explain the fundamental principles of heat transfer and steam generation.
2. Identify the major mechanical components of fire-tube and water-tube boilers.
3. Execute safe boiler startup and shutdown procedures according to industry standards.
4. Describe the chemical mechanisms of oxygen corrosion and scale formation.
5. Perform standard water quality tests and interpret the resulting data.
6. Manage internal water treatment programs using phosphates and polymers.
7. Understand the operation of external treatment systems such as softeners and deaerators.
8. Optimize combustion efficiency by monitoring flue gas composition and temperature.
9. Inspect and maintain burners, fuel trains, and ignition systems.
10. Identify the early warning signs of tube failure and refractory degradation.
11. Implement effective blowdown strategies to manage dissolved solids.
12. Diagnose malfunctions in boiler control loops and safety interlocks.
13. Develop a comprehensive preventive maintenance schedule for the boiler house.

TARGET AUDIENCE:

Boiler Operators, Plant Engineers, Maintenance Technicians, Water Treatment Specialists, and Facilities Managers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.