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Boilers: Operation, Maintenance, Inspection, Control and Troubleshooting



The boiler is an essential component of the modern power plant as well as in any process and petrochemical plant. A modern boiler has to produce steam in an efficient and safe manner with the lowest operational cost that is practical. The safety of steam production and boiler operation presents an important element in the overall steam production management. Boiler operation has to be in an environmentally acceptable way, including the aspects of combustion, but also chemical water treatment and other safety considerations.

This training course will cover many important aspects of boiler operation, combustion control, and feed water management. Methods of efficiency improvement of the boiler operation will be explained and discussed. Best practices for preventive and corrective maintenance based on inspection according to Codes & Standards will be explained and discussed. Problems in boiler operation will be discussed and problem-solving and troubleshooting will be illustrated through several real-world case studies and presented in the form of training courses. Maintenance and repair of the auxiliary mechanical equipment such as fans and pumps will be explained in detail.

Course Objectives:

At the end of this course, the participants will be able to:

  • Identify the appropriate boiler feedwater treatment methods
  • Identify the important steps in the inspection of cooling towers
  • Know how to apply effective inspection and discover weakness points
  • Recommend the best practice for condition monitoring
  • Explain functions of controls, safeguards, interlocks and alarm systems
  • Describe correct procedures for boiler starting up and shutdown
  • Explain the malfunctions that can cause boiler shutdown

Targeted Audience:

  • Technicians and Engineers in charge of Boiler Operation
  • Technical Personnel dealing with Boilers Maintenance
  • Boiler Inspectors and Contractors
  • Technical Personnel in charge of Steam Generation and Distribution Systems

Course Outlines:

Unit 1: Overview of Steam Generation and Use:

  • Overview of Boiler Types and Industrial Steam Generators
  • Elements of Boiler Plant: Fired Tube Boilers and Water Tube Boiler
  • Steam Generation Basics
  • Generation operation parameters
  • Power types - KW, KVAR, KVA
  • Synchronization techniques and basic conditions
  • Flame Characteristics
  • Products of Combustion and Environmental Regulations

Unit 2: Boiler Efficiency and Performance:

  • Boiler Efficiency: Economic and Environmental Aspects
  • Boiler Feed Water Preheating Train
  • Air Economizers and Waste Heat Utilization
  • Boiler Performance and Specifications
  • Evaluating Boiler Efficiencies
  • Boiler Blow-Down Control Recovery
  • Steam Distribution System Losses

Unit 3: Boiler Safety Operation and Control:

  • Boiler Control Strategies: Safeguards, Interlocks, and Alarm Systems
  • Explain PLC for boiler controls (practical)
  • Burner Management System (BMS)
  • Safe Start-Up and Shutdown Procedure
  • Scale and Corrosion Control
  • Chemical & Physical Treatment of Feed Water
  • De-aeration of Feed Water: Removing of Oxygen and CO2

Unit 4: Boiler Inspection, Maintenance, and Repairs:

  • Routine & Periodic Boiler Inspections: Risk-Based Inspection (RBI)
  • Common Boiler Problems in Operation
  • Abnormal Operating Conditions and Operator Actions
  • Maintenance Work Done Periodically
  • Checklist for Maintenance of Fuel Supply System
  • Maintenance of Condensate Recovery and treatment
  • Using CMMS (computer managed maintenance systems)

Unit 5: Boiler Troubleshooting and Accident Prevention:

  • Boiler Failures and Accidents: Root Cause Analysis
  • How to apply FMEA (Failure Mode Effective Analysis)
  • Boiler Troubleshooting Guide
  • Applying RBI (Risk-Based Inspection techniques)

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