Practical Boiler Plant: Operations, Maintenance and Troubleshooting

Objectives

• Recognize and solve boiler problems simply, easily and with confidence

Gain the most up-to-date information and practical understanding of the installation, operation, maintenance and management of boiler plants

Outline

DAY 1:  INTRODUCTION

• Types of package boilers and their applications
• Boiler components, terminology, and definitions​

FUEL COMBUSTION AND THE STEAM GENERATION PROCESS

• Overview of the boiler heating and steam generation process
• Influence of the fuel type on the boiler design operation
• Firing appliances
• Basics to the theory of combustion
• Thermal efficiency
• Fireside deposits and corrosion​

DAY 2: BOILER AUXILIARY PLANT

• Water treatment plant and dosing
• Feed water pumps
• Valves and steam traps
• Piping
• Fans
• Economizers and heat recovery equipment
• Flue gas cleaning and dust removal​

OPERATION AND CONTROLS

• Boiler instruments and their purpose
• Typical P&I diagram for coal and Oil and Gas fired units
• Control systems and system operating philosophy
• Operational sequences and procedures
• Safety equipment and interlocks
• Safety procedures and emergencies
• Operating records and logs
• Typical operational problems, the reason for the problems and troubleshooting​

Day 3: PRESSURE CONTAINING COMPONENTS

• Basics to codes calculation theory and assumptions
• Overview of design parameters for shell, furnace, plates, and tubing
• Importance of pressure part inspection​

PLANNING AND MANAGING BOILER MAINTENANCE

• The critical importance of maintenance policies and programs
• Setting up an inspection program
• Types of boiler inspections
• Involvement of the Authorized Inspection Authority (AIA)
• Maintenance information and procedures
• Developing a preventive maintenance program
• In-house verse contractor repair maintenance​

DAY 4: MANAGING BOILER REPAIRS AND MODIFICATIONS

• When does a boiler repair become a boiler modification?
• Importance of historical records
• Understanding the legislative requirements
• Steps to be taken when a ‘defect’ is identified
• Responsibility of the boiler owner
• Responsibility of the boiler repair contractor
• The AIA and their inspection points​

COLD STORAGE OF A BOILER

• Clearly establishing the storage period
• Storage period and critical preservation steps
• Storage instructions and procedures
• Consequences of no storage plan​

DAY 5: CONTROL PRINCIPLES AND DESIGN CONCEPTS

• Water level indicators and measuring devices
• Draft and its function in the combustion process, draft types, and measurement
• Protection against implosion​

EMISSION CONTROLS AND ENVIRONMENTAL CONSTRAINTS

• Types of emissions for different fuels fired
• Methods used for controlling boiler flue gas emissions
• Effectiveness of various types of cleaning equipment

Who Should Attend ?

This course is intended for all Boiler Plant Construction Managers, Consulting Engineers, Design Engineers, Insurance Company Inspectors, Mechanical Engineers and Technicians, Operation, Maintenance, Inspection and Repair Managers, Supervisors and Engineers, Plant Engineers, Senior Boiler Plant Operators, Repairers, and Installers.