COURSE OVERVIEW:

Industrial boilers are the heart of process utility systems, providing the high-pressure steam necessary for heating, power generation, and mechanical drives. This course provides a comprehensive exploration of the critical operational phases of boiler management, focusing on the complex thermal and mechanical stresses encountered during transient states. Participants will examine the physical principles of steam generation, water circulation, and combustion control to ensure that start-up and shutdown procedures are executed without compromising equipment longevity.

The scope of this training covers the systematic preparation of the boiler system, including feed water conditioning, furnace purging, and burner management system checks. Attendees will learn the detailed sequence for cold, warm, and hot start-ups, emphasizing the importance of managing drum metal temperatures and expansion rates to prevent thermal shock. The course also details the controlled shutdown process, highlighting the preservation techniques required to protect internal surfaces from corrosion during standby or maintenance periods.

A primary focus is placed on the rapid identification and mitigation of operational upsets such as drum level fluctuations, flame failure, and tube leaks. Participants will be trained in the diagnostic logic required to handle emergency scenarios like "black-plant" restarts and fuel system failures. By integrating process safety principles with hands-on operational logic, this course empowers boiler operators and engineers to maintain steam reliability while preventing catastrophic vessel or furnace incidents.

COURSE OBJECTIVES:

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

1.  Identify the primary components of water-tube and fire-tube industrial boilers.

2.  Execute a rigorous pre-start-up checklist including valve alignments and safety interlocks.

3.  Manage the furnace purging process to prevent the accumulation of combustible gases.

4.  Perform controlled cold start-ups while monitoring thermal expansion and metal stress.

5.  Regulate the boiler drum level and feed water chemistry during pressure ramping.

6.  Implement safe ignition sequences according to burner management system logic.

7.  Execute controlled shutdown procedures for both short-term and long-term outages.

8.  Apply wet and dry preservation methods to prevent internal oxygen corrosion.

9.  Diagnose the causes of drum level "swell" and "shrink" during load changes.

10.  Respond effectively to emergency upsets such as loss of draft or flame-out.

11.  Troubleshoot burner instabilities and fuel-to-air ratio imbalances.

12.  Manage boiler water quality to prevent scale formation and carryover.

13.  Formulate an emergency response plan for boiler tube ruptures and pressure loss.

TARGET AUDIENCE:

Boiler Operators, Utility Engineers, Maintenance Supervisors, and Shift Leads responsible for steam generation and plant utilities.

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.