Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Engineers and technicians working in power generation, chemical, petrochemical, and manufacturing industries.
• Maintenance professionals who are responsible for the operation and troubleshooting of furnaces and boilers.
• Operators who need to enhance their technical skills in furnace and boiler systems.
• Plant supervisors and managers looking to improve their teams’ performance in furnace and boiler operations.

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants will be able to:

• Understand the principles of furnace and boiler operation and their components.
• Operate and maintain different types of furnaces and boilers safely and efficiently.
• Recognize common issues and failures in furnace and boiler systems.
• Diagnose problems and implement appropriate troubleshooting techniques.
• Understand control systems used in furnace and boiler operations.
• Apply best practices to optimize furnace and boiler performance.

DAY 1

Introduction to Furnace and Boiler Systems

• Welcome and introduction
• Pre-test
• Overview of Furnace and Boiler Systems

• Types of furnaces and boilers
• Key components and functions
• Boiler cycles and furnace operation

• Principles of Heat Transfer in Furnaces and Boilers

• Conduction, convection, and radiation
• Efficiency considerations
• Combustion process basics

• Introduction to Fuel Types and Combustion

• Solid, liquid, and gaseous fuels
• Combustion air requirements
• Combustion analysis and control

DAY 2

Furnace and Boiler Operation

• Operation Principles

• Fuel supply systems
• Air supply and combustion controls
• Burner and ignition system functions

• Start-up and Shutdown Procedures

• Pre-start checks and system testing
• Start-up sequence for boilers and furnaces
• Shutdown protocols and safety considerations

• Monitoring and Controlling Furnace and Boiler Systems

• Pressure, temperature, and flow measurements
• Control systems: Basic and advanced
• Use of control panels and SCADA systems

DAY 3

Furnace and Boiler Control Systems

• Control Loops and Automation

• Basic control theory (PID, ON/OFF, etc.)
• Boiler and furnace automation technologies
• Role of sensors and actuators in automation

• Instrumentation and Control Systems

• Pressure, temperature, and flow measurement instrumentation
• Control valves and actuators
• Use of programmable logic controllers (PLC) in control

• Safety Systems and Regulations

• Key safety systems in furnace and boiler operations
• Industry standards and compliance (ASME, OSHA, etc.)
• Safety interlocks and emergency shut-off systems

DAY 4

Troubleshooting Furnace and Boiler Systems

• Common Issues in Furnace and Boiler Operations

• Combustion problems (flame failure, burner misfire)
• Pressure and temperature fluctuations
• Water chemistry issues and scaling

• Diagnostic Techniques

• Visual inspection and system checks
• Analyzing control system errors and alarms
• Troubleshooting using instrumentation and diagnostic tools

• Root Cause Analysis

• Identifying underlying causes of recurrent issues
• Methods for preventing future problems
• Importance of regular maintenance schedules

DAY 5

Advanced Troubleshooting and Performance Optimization

• Advanced Troubleshooting Techniques

• Boiler tube leaks and failures
• Furnace refractory issues
• Electrical and control system failures

• Optimizing Furnace and Boiler Efficiency

• Fuel optimization and air-to-fuel ratio management
• Enhancing heat transfer efficiency
• Load management and energy conservation

• Maintenance Best Practices

• Preventative maintenance planning
• Predictive maintenance using advanced tools
• Troubleshooting case studies and group discussions

• Post-test
• Certificate ceremony