Lesson 1Flue gas path and heat recovery: economisers, sootblowers, draft controls, flue inspection issuesCovers the flue gas path from furnace to stack, focusing on heat recovery, draft control, and cleanliness. Addresses economiser operation, sootblower use, inspection points, corrosion risks, and efficiency impacts of fouling.
Gas flow path: furnace, passes, breeching, stackEconomizer function, fouling, and leak detectionSootblower types, sequencing, and safe operationDraft fans, dampers, and draft control tuningFlue inspection, corrosion, and leakage issuesLesson 2Feedwater system: deaerator, feedwater tank, make-up water, condensate returnExplains the complete feedwater system from make-up water to steam drum, including deaerators, feed tanks, and condensate return. Focuses on oxygen removal, level control, venting, and how system design affects reliability.
Deaerator principles, venting, and pressure controlFeedwater tank layout, heating, and level controlMake-up water sources, metering, and valvesCondensate return lines, traps, and receiversFeedwater regulation valves and control schemesLesson 3Safety devices and controls: safety valves, pressure gauges, level switches, low-water cutoffs, interlocksExplains key boiler safety devices and control logic, showing how they prevent overpressure, low-water conditions, and unsafe startups. Emphasises inspection, testing intervals, failure symptoms, and documentation requirements.
Safety relief valves: sizing, testing, common faultsPressure gauges and pressure switches calibrationLevel controls, probes, and float switch maintenanceLow-water cutoffs: testing, failures, code rulesSafety interlocks and startup permissive logicLesson 4Pumps and piping: feedwater pumps, condensate pumps, seals, couplings, alignment and vibration basicsDetails boiler feedwater and condensate pumping systems, including pump types, NPSH, seals, and couplings. Emphasises alignment, vibration basics, lubrication, and routine checks that prevent cavitation, leaks, and premature failures.
Feedwater pump types, curves, and NPSH limitsCondensate pumps and receiver tank operationMechanical seals, packing, and leak controlCouplings, soft foot, and shaft alignment checksVibration symptoms, causes, and field checksLesson 5Boiler pressure vessel and steam drum: construction, materials, common failure modesDescribes the boiler pressure vessel and steam drum, including construction methods, materials, and internal components. Reviews common failure modes, inspection techniques, and code requirements that govern repairs and alterations.
Drum and shell construction, heads, and nozzlesMaterials selection, stress, and temperature limitsSteam drum internals: separators and dryersThermal fatigue, corrosion, and cracking modesInspection intervals, NDE methods, and repairsLesson 6Instrumentation and control systems: PID loops, pressure/level transmitters, flame safeguard, alarms and HMI basicsIntroduces boiler instrumentation and control architecture, including transmitters, control loops, and flame safety. Covers PID basics, alarm management, HMI displays, and how operators interpret signals for safe responses.
Pressure, level, and temperature transmittersPID loop terms, tuning impact, and stabilityBurner management and flame safeguard logicAlarm priorities, setpoints, and nuisance tripsHMI graphics, trends, and operator interfacesLesson 7Burner and combustion system: types, fuel train components, flame detection, combustion tuning fundamentalsExplores burner and combustion system components, fuel trains, and flame detection. Covers burner types, air–fuel ratio control, purge sequences, and basic combustion tuning to balance safety, efficiency, and emissions.
Burner designs for gas, oil, and dual-fuel serviceFuel train valves, regulators, and safety shutoffsIgnition systems and flame scanner technologiesAir–fuel ratio control and excess air effectsCombustion tuning steps and field test methodsLesson 8Water treatment equipment: hardness control, deaeration, chemical dosing, blowdown systemsFocuses on water treatment hardware that protects the boiler from scale, corrosion, and carryover. Explains hardness control, deaeration equipment, chemical dosing, and blowdown systems, linking test results to equipment settings.
Softening and hardness removal equipment basicsOxygen removal: mechanical and chemical methodsChemical dosing pumps, tanks, and injection pointsContinuous and intermittent blowdown hardwareMonitoring water quality and adjusting treatment
