Boiler Control and Maintenance Training Course

Course Overview:

This course is broad in scope and encompasses diverse fields such as boiler operation, maintenance, treatment of water, safety practices, and overall equipment efficiency.

Types of boilers, their functioning and the treatment of water in relation to tackling the problems of scale, corrosion, and carryover will also be covered Participants will be introduced to the principles of combustion, burner types and advanced control applications such as fuel/air control, level in drum control, and oxygen trim control. Fuel efficiency calculations and blowdown, non-destructive inspection will also be covered in the course. 

Aimed at boiler inspectors, operators or engineers, safety officers, this program is intended to provide the participants with necessary information and boost their knowledge on enhancing the boiler efficiency and safety while reducing the risks.

Course Objectives:

Upon completion of this course, participants will have an understanding of the chemistry of boiler water treatment for scale, corrosion, and carryover control, with external and internal water treatment The participant will have a strong understanding of efficiency calculation, boiler inspection either destructive or non-destructive test. The principal will have also a strong understanding of all control loops of boiler operation.

Who Should Attend?

• Boiler Inspectors
• Steam Plant Operators
• Maintenance Engineers / Managers
• Operation Managers
• Safety Officers
• Boiler Design Engineer

Course Outlines:

Introduction

• Fire-tube boilers
• Water-tube boilers

Boiler basics and steaming process

• Component of boiler
• Mass and energy balance
• Routing of combustion gas inside the boiler.

Heat transfer

• Conduction
• Convection
• Radiation
• Superheated steam
• Latent heat
• Sensible heat

Review of combustion Fundamentals

• Excess air & flue gases relation

Burners

• Selection of burners
• Atomizing of burners
• Oil burner
• Gas burner
• NOX burner
• Reduction of NOX emission

Boiler Operation

• Burner shutdown when steam pressure C.O.P is reached
• Boiler shutdown procedures
• Short-term shutdown
• Shutdown for cold Restart
• Safety system fuel and air supply control system
• Procedures for selection of burner control system

Basic instrumentation

• Pressure measurement
• Level measurement
• Temperature measurement
• Flow measurement

Boiler control application

Level drum control

• One element control
• Two element control
• Three element control

Generator control

• Level control
• Temperature control

Fuel/air ratio control

• Series limited control
• Parallel limited control
• Lead flag firing control
• Oxygen trim control
• Main header control
• Water treatment

The external water treatment process

• Ion exchange process
• Duration
• Evaporation

Internal water treatment

• lime soda process
• phosphate treatment
• feeding of chemical continuing treatment

Blowdown

• intermittent and continuous blowdown
• control of blowdown
• blowdown heat recovery

Efficient boiler operation

• Efficiency calculation
• Direct method
• Indirect method

Heat transfer calculation

Boiler & combustion systems hazards codes

Boiler inspection

• Destructive test
• Non-destructive test
• Preventation of boiler explosions / implosions NFPA8502 Troubleshooting