Lesson 1Flue gas path and heat recovery: economizers, sootblowers, draft controls, flue inspection issuesCover di flue gas path from furnace to stack, focusin pon heat recovery, draft control, an cleanliness. Address economizer operation, sootblower use, inspection points, corrosion risks, an 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 returnExplain di full feedwater system from make-up water to steam drum, includin deaerators, feed tanks, an condensate return. Focus pon oxygen removal, level control, ventin, an how system design affect 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, interlocksExplain key boiler safety devices an control logic, showin how dem prevent overpressure, low-water conditions, an unsafe startups. Emphasize inspection, testin intervals, failure symptoms, an 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 basicsDetail boiler feedwater an condensate pumpin systems, includin pump types, NPSH, seals, an couplings. Emphasize alignment, vibration basics, lubrication, an routine checks dat prevent cavitation, leaks, an 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 modesDescribe di boiler pressure vessel an steam drum, includin construction methods, materials, an internal components. Review common failure modes, inspection techniques, an code requirements dat govern repairs an 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 basicsIntroduce boiler instrumentation an control architecture, includin transmitters, control loops, an flame safety. Cover PID basics, alarm management, HMI displays, an how operators interpret signals fi 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 fundamentalsExplore burner an combustion system components, fuel trains, an flame detection. Cover burner types, air–fuel ratio control, purge sequences, an basic combustion tunin to balance safety, efficiency, an 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 systemsFocus pon water treatment hardware dat protect di boiler from scale, corrosion, an carryover. Explain hardness control, deaeration equipment, chemical dosin, an blowdown systems, linkin test results to equipment settins.
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
