STEAM BOILER DRIVERS (BOILERMAN) COURSE

STEAM BOILER DRIVERS (BOILERMAN) COURSE

Course Description

DURATION

21 hours (Three (3) days)

 

TARGET GROUP

  • New technician, operation technician, operation team leader/coordinator, maintenance and inspection technicians.
  • Technicians who want to sit the Steam Boiler Driver (Boilerman) Certificate of Competency examination with the Department of Occupational Safety and Health, Malaysia (DOSH).

 

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 is suitable for boiler technicians that are willing to sit for the Steam Boiler Driver’s Certificate of Competency examination with the Department of Occupational Safety and Health, Malaysia (DOSH).

 

COURSE OBJECTIVE

The course is to enhance boiler driver’s knowledge and understanding of the requirements for operation, and maintenance of steam boilers in accordance to the best practices and Laws in Malaysia (such as Occupational Safety and Health Act 1994, Factories and Machinery Act 1967 (Act 139), Regulations 1970 and Regulations 2014).

This course also is suitable for engineers that are willing to sit the Steam Boiler Driver’s Certificate of Competency examination with the Department of Occupational Safety and Health, Malaysia (DOSH).

 

COURSE OUTCOMES

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

  • Identify the major hazards that’s related to operation and maintaining the boiler and steam systems.
  • Operate the steam boilers and steam systems with the safe conditions.
  • Describe the boiler commissioning, operations, trouble-shooting, inspections, repairs and maintenance processes.
  • Describe key parameters affecting boiler performance and efficiency.
  • Describe the principles of thermodynamics of steam boiler and steam systems.
  • Describe the uses of steam in process plant and power generation sector.
  • Describe basic controls used in boiler operation.
  • Sit for the examination of the Steam Boiler Driver’s Certificate of Competency Grade 1 or 2 with the Department of Occupational Safety and Health, Malaysia (DOSH).

 

TRAINING METHODOLOGY

  • Lecture
  • Pre- and Post-Test
  • Classroom discussions
  • Short video presentation
  • Case study

 

COURSE CONTENTS

Laws Related to Steam Boilers

  • An overview of Occupational Safety and Health Act (1994)
  • An overview of Factories and Machinery Act, 1967
  • Factories and Machinery, Regulations 1970: –
    • Steam Boiler and Unfired Pressure Vessel
    • Certificates of Competency – Examinations
  • Factories and Machinery, Regulations 2014: –
    • Person-In-Charge
  • Regulations 10 – Essential Fittings

 

Introduction to Steam Boilers

  • Definition – definition of the boiler, radiation process, conduction process, convection process and ideal design of the boiler system
  • Boiler Classifications;
    • Use of boiler,
    • Pressure,
    • Heat source,
    • Types of fuel,
    • Furnace,
    • Circulation of water, and
    • Tubes (tube content).
  • Principle of Fire Tube and Water Tube Boilers;
    • Design criteria,
    • Construction, and
    • Comparison of Fire and Water Tube Boilers
  • Universal Pressure Boiler (Supercritical Boiler)

 

Steam Boiler Operations and Trouble-shootings

  • Operating Logs
  • Boiler Operations;
    • Pre shift assumption checks,
    • Pre operational checks,
    • Lining up the system,
    • Operating procedures,
    • Operating checks, and
    • Securing procedure.
  • Boiler Emergencies and Safety
  • Boiler Inspection.
  • Boiler Storage.
  • Commissioning Activities;
    • Inspection,
    • Hydrostatic test,
    • Slow firing and blow-down
    • Boiling out,
    • Steam blowing, and
    • Safety valve setting.

 

Boiler Water Treatment

  • Introduction to boiler water treatments
  • Raw Water System and filtration systems
  • Pressurized filters and Types of media.
  • Demineralization Water System.
  • Reverse osmosis.
  • Deaerator Unit
  • Boiler Water Unit
  • Boiler feed water,
  • Boiler water
  • Steam condensate return.
  • Water Treatment Concerns.

 

Combustion Fundamentals

  • Combustion Theory;
    • Perfect combustion,
    • Complete combustion (Excess air control), and
    • Incomplete combustion.
  • Products of Combustions
  • Basic Combustion Equations;
    • Perfect combustion,
    • Complete combustion, and
    • Incomplete combustion.
  • Flue Gas Analysis
  • General Considerations regarding safety
  • General Firing Practice for Boilers
  • Burners Atomization;
    • Atomizer for fuel oil,
    • Pressure atomizer, and
    • Steam atomizer.
  • Gas burners

 

Steam Turbines Fundamentals

  • Introduction of Steam Turbines
  • Impulse Turbines
  • Reaction Turbines
  • Principle of Impulse and Reaction Turbine
  • Factors affecting turbines problem

 

Steam Boiler Maintenance

  • Introduction to Boiler Maintenance
  • Preventive Maintenance;
    • Waterside inspection and cleaning,
    • Steam drum inspection,
    • Fireside inspection,
    • External inspection, and
    • Maintenance and Precautions.
  • Repair procedures.

 

Steam Boiler Failures

  • Types of failure
  • Cause of failure
  • Prevention of failure

 

Test Questions and Answers

Discussion of the frequent questions asked by the Department Occupational Safety and Health (DOSH) during examination.