Boiler Operations Maintenance and Steam Management

Boiler Operations Maintenance and Steam Management

Date/Time: Date(s) - 01/02/2023 - 03/02/2023( 8:00 am - 5:00 pm )
Location: Malaysia, Kuala Lumpur


Boilers are an important asset used for various purposes in different industrial plants. It’s one of the main application to produce high-pressure steam for process applications and power generation. Operation and maintenance of Boilers are critical to ensure a safe and efficient plant environment. This training ensures participants gain a comprehensive understanding of commercial, industrial, and utility boiler systems. This training covers the principle of operation of steam boilers, types and the main components of steam boilers. It will also focus on the study of correct operation and routine maintenance and safety. Participants will also learn how to improve boiler efficiency, energy cost saving methods, and maximize safety.


  • Steam Plant Management
  • Boiler Construction
  • Boiler Operation Start/ Stop
  • Understanding of Water Treatment in Steam Plant
  • Routine Inspection/ DOSH Inspection
  • Operate and supervise steam plant
  • Explain the importance of the components used in steam plant
  • Describe the principles of operation and maintenance of steam plant
  • Understand the concepts of water treatment, combustion system and materials used in
  • Know some proper guidelines and procedures in maintaining the boilers
  • Combustion System/ Fuel
  • Factories and Machinery Act
  • Steam Traps Operation and Maintenance
  • Boiler Efficiency
  • Boiler Maintenance and Repairs

Who Should Attend?

  • Practicing boiler operators, technicians and engineers of plant where boilers and steam turbine form an integral component
  • Mechanical engineers and mechanical supervisors


Introduction to steam boilers fuel combustion and the steam generation process

  • Influence of the fuel type on the boiler design operation
  • Firing appliances and Thermal efficiency

Boiler auxiliary plant

  • Water treatment plant and dosing
  • Feed water pumps, Valves, steam traps, piping and fans
  • Economisers and heat recovery equipment
  • Economisers and heat recovery equipment Economisers and heat recovery equipment Economisers and heat recovery equipment

Design and Construction of Boilers

  • Materials Used in Boiler Construction
  • Stresses in Tubes and Drums
  • Drum Construction
  • Welded Construction
  • Structural Support Components
  • Manholes, Handholes, and Fittings
  • Boiler Assembly
  • Heating Surface and Capacity
  • Boiler Capacity Calculation

Operation and controls

  • Boiler instruments and their purpose
  • Typical P&I diagrams for coal and oil/gas fired units
  • Control systems and system operating philosophy
  • Operational sequences and procedures
  • Typical operational problems, the reason for the problems and ‘trouble shooting’

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
  • Critical importance of maintenance policies and programs
  • Setting up an inspection program
  • Types of boiler inspections
  • Maintenance information and procedures
  • In-house verse Contractor repair maintenance

Operation and Maintenance of Boilers

  • Boiler Startup
  • Normal Operation
  • Operating Characteristics of Fluidized Bed Boilers
  • Abnormal Operation
  • Idle Boilers
  • Maintenance
  • Boiler Internal Inspection
  • Evaluating the Condition of a Boiler
  • Making Repairs
  • Inspection and Maintenance Requirements of Heat Recovery Steam Generators (HRSGs)

Managing boiler repairs and modifications

  • When does a boiler repair become a boiler modification?
  • Understanding the legislative requirements
  • Steps to be taken when a ‘defect’ is identified
  • The AIA and their inspection points

Storage period and critical preservation steps

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

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
  • What emission levels are specified in international standards or legislation?

Introduction to boiler control & instrumentation

  • Objectives of Boiler Control
  • Basic Control loops and their interconnections
  • Feedforward plus feedback controls
  • Cascade/ratio controls
  • Process Dynamics – generic control response
  • Factors affecting control system or loop applications

Boiler fuel combustion controls for

  • Liquid Fuels
  • Gaseous Fuels
  • Solid Fuels both graded and pulverised
  • Combustion Chemistry and products of combustion
  • Stoichometric Air and Excess Air Requirements

Control principles and design concepts

  • Boiler Water Level Indicators & Measuring Devices
  • Associated problems and refinements
  • Steam demand and firing rate control relationships
  • Steam demand and firing rate control relationships
  • Relationship between boiler load and temperature
  • Temperature of and strategies for superheated steam
  • Measurement of furnace draft
  • Feedforward/feedback controls
  • Impact of dew point and nitrous oxides & sulphur oxide pollutants
  • Protection against implosion
  • Pros and cons of Measurement methods and gases selected
  • Digital Interlocks within control systems

Training Methodology

  • Case Studies.
  • Individual and group discussions and exercises.
  • Intensive training by using templates, diagrams, and charts.
  • Planning activities and presentations.
  • Self-assessments.
  • Action plan.

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Bookings are closed for this course.

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