Workshop on Boiler Plant: Start-Up, Operations, Maintenance & Troubleshooting

Program Overview:

This is a practical maintenance engineering training course enabling delegates from technical and production disciplines to understand the rudiments of functional responsibilities that guarantees high level of Boiler Plant availability and reliability. This 5-Day Course teaches the practicality of Boiler Maintenance in a most suitable manner ready for implementation and monitoring.

For Whom:

This course is designed for all levels of Technical Personnel in the oil & Gas Industry as well as in Chemical and Process Industries but will greatly benefit Technical Personnel in charge of Production, Maintenance & Operations Engineers, Boiler Operators, Supervisors and Engineering Managers

Learning Objectives:

At the end of the program, participants will be able to:

• explain the concept of Boiler Plants and their applications;
• comprehend the derivation, calculation & application of reliability centered maintenance to Boiler Plants;
• measure the effectiveness and efficiency of Boiler Plant Maintenance functions;
• evaluate investment opportunities in maintenance engineering vis-a-vis Boiler Plants;
• ensure Boiler Plant availability and reliability based on production planning models;
• ensure cost-benefit analysis of Boiler maintenance activities with respect to production high level timing goals; and
• have a good overview of uncertainty and risk in the maintenance of Boiler Plants.

Course Outline:

DAY 1 – 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

DAY2 – 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

DAY 3 – 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

DAY 4 – Operation and Safety of Steam Boilers

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

DAY 5 – Maintenance Management and

Troubleshooting of Boilers

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

      Approaches to Boiler Plant Maintenance

• Systematic Approach to Boiler Plants Maintenance:

MTTR, MTBF, FTE, etc. analysis

• Planning & Implementation of RCM for Boiler Plant
• Cost-Benefit Analysis of RCMS in Boiler Plant

Training Methodology

Lectures, discussions, exercises, case studies, audio-visual aids will be used to reinforce these teaching/learning methods.