COURSE OVERVIEW:

The operation of industrial boiler plants is a critical function that demands a sophisticated understanding of heat transfer, combustion chemistry, and pressure vessel safety. This course provides a comprehensive practical guide to the daily management of steam generation systems, focusing on the balance between maximizing thermal efficiency and ensuring the structural integrity of the boiler shell and tubes. Participants will explore the mechanics of fire-tube and water-tube boilers, understanding how feedwater quality and burner performance directly impact the reliability of the steam supply.

Maintenance of boiler plants involves a rigorous schedule of internal inspections, cleaning, and component testing to prevent catastrophic failures. This training emphasizes the identification of common degradation modes such as oxygen pitting, caustic embrittlement, and scale accumulation. The scope includes the servicing of critical auxiliary equipment, including deaerators, economizers, and soot blowers, ensuring that participants can manage the entire steam loop. By focusing on proactive maintenance, the course helps organizations reduce fuel consumption and extend the service life of expensive thermal assets.

Troubleshooting boiler malfunctions requires a systematic approach to diagnosing issues like unstable flames, poor steam quality, and erratic water levels. Coverage includes the analysis of combustion gases to optimize the air-to-fuel ratio and the testing of safety-critical devices such as low-water cutoffs and pressure relief valves. By the end of this program, attendants will be equipped with the diagnostic skills to resolve operational deviations quickly, maintaining a safe and continuous supply of high-quality steam for process requirements.

COURSE OBJECTIVES:

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

1.  Explain the fundamental thermodynamic principles of steam generation and heat transfer.

2.  Identify all primary and auxiliary components of a modern boiler plant system.

3.  Perform safe startup and shutdown procedures for both fire-tube and water-tube boilers.

4.  Interpret boiler water chemistry reports and adjust chemical dosing accordingly.

5.  Conduct internal and external inspections to detect signs of corrosion and scaling.

6.  Optimize burner performance by analyzing flue gas composition and stack temperature.

7.  Troubleshoot malfunctions in the feedwater system and deaerator operation.

8.  Test and calibrate safety-instrumented systems including low-water alarms.

9.  Evaluate the efficiency of heat recovery equipment such as economizers.

10.  Implement a comprehensive preventive maintenance program for boiler internals.

11.  Diagnose the root causes of carryover and poor steam purity.

12.  Manage the procedures for mechanical and chemical cleaning of boiler tubes.

13.  Execute emergency response protocols for tube ruptures or loss of flame.

TARGET AUDIENCE:

Boiler Operators, Plant Engineers, Maintenance Technicians, and Facility Managers responsible for the operation and upkeep of steam-generating facilities.

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.