COURSE OVERVIEW:

Industrial boilers are the primary source of thermal energy for countless manufacturing and refining processes, functioning as high-pressure vessels that convert water into steam through controlled combustion. This course provides a comprehensive technical exploration of boiler architecture, including fire-tube and water-tube designs, and the thermodynamic principles that govern their operation. Participants will examine the relationship between fuel systems, combustion air, and feed water chemistry, ensuring they understand how to maintain stable steam production while maximizing fuel efficiency and minimizing emissions.

The scope of the training focuses on the critical balance of the "Steam-Water Circuit." We will address the importance of drum level control, deaeration, and blowdown procedures in preventing scale formation and oxygen pitting.

Coverage includes an in-depth look at burner management systems (BMS), focusing on the safety interlocks and sequences required to prevent furnace explosions and ensure reliable ignition. Participants will learn to interpret flue gas analysis data to optimize the air-to-fuel ratio and reduce the environmental footprint of the plant.

Troubleshooting forms the core of the practical instruction, addressing common operational challenges such as foaming, priming, and water hammer. Attendees will study the diagnostic steps required to identify the root causes of low steam quality, tube leaks, and refractory failure. By mastering these troubleshooting techniques, participants will be equipped to respond decisively to abnormal conditions, execute safe emergency shutdowns, and implement preventive maintenance tasks that extend the service life of the boiler pressure parts and auxiliary equipment.

COURSE OBJECTIVES:

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

1.  Identify the major components and types of industrial boilers.

2.  Interpret boiler piping and instrumentation diagrams (P&IDs).

3.  Manage the feed water treatment process to prevent internal scaling.

4.  Execute safe boiler startup and shutdown sequences.

5.  Regulate combustion parameters to optimize thermal efficiency.

6.  Troubleshoot drum level instability and "shrink and swell" phenomena.

7.  Perform effective bottom and continuous blowdown procedures.

8.  Monitor and interpret flue gas temperature and composition.

9.  Identify the signs of oxygen corrosion and caustic embrittlement.

10.  Manage burner management systems (BMS) and safety interlocks.

11.  Troubleshoot steam trap failures and condensate return issues.

12.  Implement emergency procedures for "low-water" and "flame-out" events.

13.  Conduct visual inspections of furnace refractory and tube surfaces.

TARGET AUDIENCE:

Boiler Operators, Maintenance Engineers, Process Technicians, Utilities Supervisors, and Safety Officers are responsible for steam plant operations.

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.