FIRETUBE BOILERS – OPERATION AND MAINTENANCE COURSE

FIRETUBE BOILERS – OPERATION AND MAINTENANCE COURSE

Course Description

DURATION

14 hours (Two (2) days)

 

TARGET GROUP

New engineers, team leaders/coordinators, operations engineer, maintenance team leaders, engineers, operations team leaders, inspection, senior operations and maintenance personnel that working with firetube boilers.

 

TARGETED INDUSTRY/INDUSTRIES

Oil & Gas, Petrochemicals, Power Plant, Renewal Energy Plant, Co-Generation Plant, Palm Oil Mills and Refineries, Plywood Industries, Hotels and all industries that using steam for heating and mechanical driven.

 

CERTIFICATION

This course can be certified under the Continuing Professional Development (CPD) Program by the Board of Engineers, Malaysia (BEM).

 

COURSE OVERVIEW

Fire-tube boiler is an essential component of any process plant. Fire-tube 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 fire-tube boiler operation presents important element in the overall steam production management.

 

COURSE OBJECTIVE

The objectives of the course are to give the participants an understanding for the works related to fire-tube steam boilers such as boiler safety, legislation and regulations, commissioning of new boilers, operation, trouble-shooting, inspection, maintenance and repairs.

Participants will be introduced to related boiler legislation in Malaysia such as the Factories and Machinery Act 139, Steam Boiler and Unfired Pressure Vessel 1970.

 

COURSE OUTCOMES

At the end of the course, the delegates will be able to: –

  • Describe the principles of thermodynamics of steam boiler and steam systems.
  • Describe key parameters affecting boiler performance and efficiency.
  • Identify the related laws, codes and standards for steam boiler design, installation, fabrication, operation, inspection, repair and maintenance.
  • Identify the major hazards that’s related to operation and maintaining the firetube boiler and steam systems.
  • Operate the firetube steam boilers and steam systems with the safe conditions.
  • Describe the firetube boiler commissioning, operations, trouble-shooting, inspections, repairs and maintenance processes.

 

COURSE CONTENTS

Laws, Applicable Codes & Standards

  • Selection of a Steam Boiler
  • Factory and Machinery 1967 (Act 139) and Its Regulations

 

Thermodynamics of Steam

  • Properties of Steam
  • Temperature-Enthalpy Diagram
  • Introduction to Vapor and Steam
  • Performance and Factors Affecting Efficiency
  • Application of Various Types of Steam

 

An Introduction to Steam Boilers

  • The Efficient Use of Steam
  • Steam Boiler Definitions and Classifications
  • Basic Steam process
  • Heat Transfer in Steam Boiler Systems
  • Boiler Circulation Process
  • Types of Steam Boilers

 

Firetube Steam Boiler Operations and Trouble-shootings

  • An Introduction to operations and trouble shootings
  • Basic boiler controls
  • Boiler operation and trouble-shootings
  • Boiler storages
  • Commissioning activities
  • Safety valves
  • Water gauge glasses

 

Boiler Water Treatments

  • Introduction to boiler water treatment
  • Objective of boiler water treatment
  • Types of boiler water treatments
  • Water treatment concerns
  • Scale formation
  • Boiler water guides (applicable codes and standards)

 

Combustion Fundamentals

  • Combustion theory
  • Products of combustion
  • Flue gas analysis
  • General firing practice for boilers
  • Burners (gas and liquid)
  • Atomizer for fuel oil
  • Trial for Ignition Time (TFIT)
  • Safety aspects during burner ignition

 

Materials Testing and Boiler Maintenance

  • Introduction Non-Destructive Testing
  • Welding Processes
  • Heat treatments
  • Material testing
  • Introduction to Boiler Maintenance
  • Boiler maintenance program
  • Boiler-internals inspection
  • Repair Procedures
  • Case study of boiler repairs

 

Steam Boiler Failures

  • Types of failures
  • Causes of failures
  • Prevention from failures