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 Operations and Maintenance of Boiler and Heater E1221364 QR Code
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Operations and Maintenance of Boiler and Heater



Boilers and steam generating systems are considered highly complex elements of equipment
which operate at very high pressures and temperatures. These demanding operating conditions
require good quality of construction materials and professional fabrication. Safe and efficient
operation of boilers requires that a special attention to be given to the reliability of equipment for
steam generation as well as efficient steam system management.
This course is intended to introduce delegates to safe operation of boiler units and the
associated equipment for steam generation and steam distribution. Methods and techniques of
energy saving related to efficient steam distribution system management will be explained in
detail. The course will be primarily focused on practical aspects related to operation, control,
maintenance and troubleshooting of problems encountered in boiler systems. The course will
also cover reliability of boiler units, as well as on efficient management of the entire steam
system. Practical examples and workshop exercises from real life industrial practice will be
utilized throughout the training course to emphasize the key learning points.

Course Objectives:

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

  • Combustion process and draft system for steam boilers
  • Boilers types, components and functions
  • Understand the importance of the draft system for proper operation
  • Improve understanding of control and protection system
  • Understand the best practice operation procedures
  • Safety valve & burner management System
  • Routine operation and emergency procedures
  • Understand NDT and maintenance procedures
  • Gas Quality
  • Function & Purpose
  • Main components
  • Operation & settings
  • Maintenance

Target Audience

This course is designed for:

  • Mechanical engineers and mechanical supervisors
  • Inspection engineers and inspectors
  • Mechanical technicians
  • Field Operators and Technicians
  • Facilities and process engineers
  • Maintenance & planning managers
  • Planning & integrity engineers
  • Electrical engineers
  •  Anyone involved in steam generation and water treatment Process Engineers who are new to the profession


Gas Engines & Power Generation

Unit 1: Internal Combustion Engine “ICE” Basic Design

  • Brief History of ICE & Types& Cycles
  • Guascor Engine Layout and Configuration
  • Guascor Gas Engine Main Systems
  • Gas Engine Vs Diesel Engine
  • Ratings definitions

Unit 2: AC Alternators Basics

  • Principle of operation
  • Major components (field coils, commutator, DC output, regulator, armature, rotating diodes)
  • Generator Design & Performance characteristics
  • Insulation system
  • Thermal Deterioration
  • Design consideration
  • Gen Sets Faults & Protection Standards, IEC & NEC & NEMA Standards

Unit 3: Synchronization Introduction

  • Paralleling & Synchronization Condition
  • Synchronization Types
  • Governor Types
  • Synchronization Application

Unit 4: Gen Sets Installation

  • Foundation
  • Vibration
  • Noise
  • Ventilation

Unit 5: Gas Engine Main Systems

  • Model View Illustration
  • Specifications
  • Gas Basics & Characteristics
  • Engine Design
  • Fuel System Operation
  • Air Intake & Exhaust System Operation
  • Lubrication System Operation
  • Cooling System Operation
  • Air starting System Operation
  • Safety Signs & labels
  • Protection Devices

Boiler Operation, Maintenance and Troubleshooting

Unit 6: - Combustion Process and Heat Transfer Fundamentals

  • Basics of Thermodynamics
  • Heat Transfer and Combustion
  • Introduction to Steam Boilers
  • Latent Heat & Sensible Heat
  • Steam Properties
  • Purity of Steam
  • Mass and Energy Balance
  • Conduction, Convection, and Radiation
  • Combustion Fundamentals
  • Excess Air & Flue Gases Relation

Unit 7: - Boiler Types & Operational Overview

  • Classifications of Steam Boilers
  • Boiler Functional Overview
  • Main Pressure Parts Components of Steam Boilers
  • Burners Types & Operational Controls
  • Low NOx Burners
  • Draft System of Steam Boilers
  • Water Treatment System

Unit 8: - Boiler Control Systems & Protection Mechanisms

  • Boiler Control and Protection
  • Safety Valves and Flame Safeguard
  • Oxygen Trim
  • Burner Management System
  • Continuous Blowdown Control
  • Drum Level Control

Unit 9: - Operation and Safety of Steam Boilers

  • Boiler & combustion systems hazards codes
  • Principles of Boiler Operation
  • Pre-startup procedures
  • Start-up & Shut down Procedures
  • Routine Operation during Boiler Service
  • Emergency Procedures

Unit 10: - Maintenance Management of Boilers

  • Problems of Steam Boilers
  • Preventive Maintenance Program
  • Destructive Test of Steam Boilers
  • NDT of Steam Boilers
  • Steam Boiler Repair

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