Lesson 1Flue gas path and heat recovery: economizers, sootblowers, draft controls, flue inspection issuesWe cover the path of flue gas from the fire box to the stack, looking at getting back heat, controlling the pull of air, and keeping clean. It talks about how economizers work, using sootblowers, places to check, risks of rust, and how dirt cuts down on good work.
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 returnWe explain the full feedwater setup from added water to the steam drum, with deaerators, feed tanks, and coming back of condensate. Focus on taking out oxygen, watching levels, letting out air, and how the setup design helps it last long.
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, interlocksWe explain main safety tools and control ways on the boiler, showing how they stop too much pressure, low water, and bad starts. Stress on checking, testing times, signs of breaking, and papers needed.
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 basicsWe detail pumping for feedwater and condensate, types of pumps, NPSH, seals, and couplings. Stress on lining up straight, vibration starts, oiling, and regular looks that stop sucking air, leaks, and early breaks.
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 modesWe describe the boiler pressure container and steam drum, building ways, materials, and inside parts. Look at usual break ways, check methods, and rules for fixes and changes.
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 basicsWe bring in boiler tools and control build, with senders, control rounds, and flame safety. Covers PID starts, alarm handling, HMI screens, and how workers read signs for safe moves.
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 fundamentalsWe look into burner and burning setup parts, fuel lines, and flame finding. Covers burner kinds, air-fuel mix control, clean out steps, and basic tuning for safety, good use, and low smoke.
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 on water clean tools that guard the boiler from hard scale, rust, and carry over. Explain hard water control, air removal gear, chemical adding, and blowdown setups, tying test results to tool 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
