A Three Days Program on

STEAM BOILER ENGINEER (PART B & C) COURSE

DATES: 28th – 30th, July 2010 VENUE: Port Dickson, Negeri Semobilan BASIC FEE: RM2,900 per
participant (this includes course materials, meals, refreshment & certificate)

Objectives:
Objectives:
This program is a tremendous learning experience and is essential for each and everyone who are
involved in design, operation, inspection and maintenance of steam boilers or steam systems. This
course is also provides the practical knowledge for safe operation
operation and maintenance of boiler plant.
Participants will be introduced to related boiler legislation in Malaysia such as the Factories
F And
Machinery Act 1967 (Act 139), Regulations 1970. This course is endorsed by The Board of
Engineers Malaysia (BEM) under nder the Continuous Professional Development (16 ( CPD hours)
program.

Who should attend?

• New engineers, team leaders/coordinators, operations engineers, maintenance team
leaders, engineers, operations team leaders, inspection,
inspection, senior operations and
maintenance personnel.
• Experienced professionals who want to review or broaden their understanding of steam
boiler systems.
• Engineers who want to sit the Steam Engineer Certificate of Competency examination with
the Department of Occupational Safety and Health, Malaysia (DOSH).

At the end of the course, the delegates will be able to:

• Indentify the related laws, codes and standards for steam boiler design, installation,
fabrication, operation, inspection, repair and maintenance.
• Identify the major hazards that’s related to operation and maintaining the boiler and steam
systems.
• Operate the steam boilers and steam systems with the safe conditions.
• Describe the boiler commissioning, operations, trouble-shooting,
trouble shooting, inspections, repairs and
maintenance processes.
• Describe
ibe key parameters affecting boiler performance and efficiency.
• Describe the principles of thermodynamics of steam boiler and steam systems.
• Describe the uses of steam in process plant and power generation sector.
• Describe basic controls used in boiler operation.
ope
• Identify the boiler operation rules in safety from industrial combustion phenomena to feed
water quality.
• Sit for the examination of the Steam Engineer Certificate of Competency
ompetency (Part B & C) Grade
1 & 2 with the Department of Occupational Safety and and Health, Malaysia (DOSH).

Phone:: +6013-9278625
+6013 E-mail: bayubali@yahoo.co.uk
THE PROGRAMME

1. Factories and Machinery Act, 1967

• Overview of the Act 139 and Relevant Codes of Reference
• Steam Boiler and Unfired Vessels Regulations,1970,
• Person-in-charge
charge Regulations, 1970 and
• Notification, Certificate
Certificate of Fitness and Inspection Regulations, 1970
• Safety, Health And Welfare Regulations, 1970

2. Introduction to Steam Boilers

• Definition of the boiler,
• The Efficient Use of Steam,
• Boiler efficiency,
• Boiler Classifications,
• Boiler circulation,
• Principle of Fire Tube boilers,
• Principle of Water Tube Boilers
• Comparison between fire tube and water tube boiler, and
• Universal Pressure Boiler (Supercritical Boiler).

3. Steam Boiler Operations and Troubleshooting

• Fundamental Operational Responsibilities
• Operating Logs and General Checks Around the Boiler
• Boiler Plant Flow Diagram
• Start-up Guidelines,
• Boiler Operations,
• Boiler Trip and Protections,
• Water Level Controls,
• Boiler Operations Carry-over,
Carry
• Steam Temperature Control,
• Blowdown Requirements,
• Boiler Emergencies
rgencies and Safety,
• Idle Boiler (Boiler Storage),
• Returning Idle Boilers to Operation, and
• Commissioning Activities.

4. Safety Valve, Water Gauge Glass and Boiler Drums

• Pressure Safety Valve;
− Function of Safety Valves,
− Set Pressure,
− Closing pressure,
pressure
− Valve lift,
− Blowdown,
− Authorized Safe Working Pressure (ASWP),
− Setting Pressure Safety Valve,
− Safety valve testing,
− Troubleshooting of safety valve,

Phone:: +6013-9278625
+6013 E-mail: bayubali@yahoo.co.uk
 − Routine check/inspection, and
− Safety valve adjustment and setting.
• Water Gauge Glass;
− Function off Gauge glass,
− Installation of Water Gauge,
− Testing of Water Gauge and Repair.
• Boiler Drums
− Purpose of Boiler Drums,
− Equipments connected to boiler drums, and
− Equipments inside boiler drums.

5. Combustion Fundamental
• Introduction to combustions,
• Combustion
bustion Theory,
• Products of Combustion,
• Basic Combustion Equations,
• Flue Gas Analysis,
• General Considerations regarding safety,
• General Firing Practice For Boilers,
• Burners and Atomizer for fuel oil,
• Soot Blower
• Gas burners and Trial For Ignition Time
Ti (TFIT)

6. Boiler Water Treatment

• Introduction to boiler water treatments,
• Objectives of boiler water treatment,
• Types of water treatments,
• Raw Water System and filtration systems,
• Demineralization Water System,
• Membrane Technology,
• Deaerator Unit,
• Boiler Water Unit,
• Reliability of steam boiler system,
• Standard boiler water specifications,
• Water Treatment Concerns - Corrosion, Bio-fouling,
fouling, Deposition and Scaling.

7. Steam Turbines Fundamental

• Introduction of Steam Turbines
• Types of Steam Turbines
• Principle of Impulse and Reaction Turbines
• Start-up guidelines.
• Deposits problem on steam turbines.

8. Material Science and Engineering

• Classification of materials,
• Metallic Crystal Structures
• Imperfection in Solids

Phone:: +6013-9278625
+6013 E-mail: bayubali@yahoo.co.uk
 • Mechanical Properties of Metals
• Material
terial deformations,
• Engineering Stress-strain,
strain,
• materials testing,
• Correlation between Hardness and Tensile Strength
• Failure
ailure mechanism,
• corrosions,
• mechanical working of steel,
• heat treatments,
• Iron-carbon
carbon equilibrium diagram,
• Ferrous metals, and
• Boiler
oiler material specifications.

Non-Destructive Testing
9. Welding and Non-
• Basic principles and different types of welding,
• Weld joint and preparations,
• Heat Affected Zone
• Destructive test,
• Non-Destructive
Destructive Test (NDT) methods,
• Pre-heat
heat and Post Weld Heat Treatment
Tr (PWHT),
• Fundamental of Risk Based Inspection (RBI),
• Welding Procedure Specification (WPS)
• Welder Performance Qualification Test (WPQT), and
• Welding Qualification Test (WQT),

10.
10. Boiler Repairs and Maintenance
• Introduction to Boiler Maintenance,
• Maintenance Objectives
• Boiler Maintenance Program
• Inspections and Overhaul Procedures
• Boiler Inspections
• Maintenance of Valves and Fittings, and
• Repair
pair and Maintenance Procedures.

11. Boiler Failures

• Types of failure,
• Causes of failure, and
• Prevention from failures

12.
12. Review of DOSH Examination (Part B) and Interview (Part C)
Part C (Interview) and Part B (Written Examination)

Phone:: +6013-9278625
+6013 E-mail: bayubali@yahoo.co.uk
ABOUT THE INSTRUCTOR

Ir. Mohd Normarzuki Ya’acob,

Ya’acob, graduated with Bachelor (Honors) in Mechanical
Engineering from the the University of Malaya and is both a Registered
Professional Engineer (Mechanical) with Board of Engineer, Malaysia since
2000 and a Corporate Member, The Institution of Engineers, Malaysia. He is a
certified First Grade Engineer (Steam Boiler and Internal Combustion Engine)
by the Department of Occupational Safety and Health (DOSH).

He had working experiences with several company such as Equator Engineering Sdn Bhd,
Tenaga Nasional Berhad, Petronas Gas Berhad (Gas Processing Plant 5/6 and Centralised Centralise
Utilities
lities Facility) and currently he is holding the Technical Director with Bayubali Engineering Sdn
Bhd. Throughout his carrier he have extensive field experience in steam boiler operation, trouble-
trouble
shooting, inspection, maintenance and repair. He has also experience perience in project management,
design, selection, specification, installation, maintenance, operation, plant optimization and
trouble-shooting
shooting of oil, water and gas handling facilities in the oil and gas industry.

He is the co-author
author for An Introduction to Steam Machinery book published
blished by University of
Malaya Publisher.

BAYUBALI Engineering Sdn Bhd’s Series of Training Courses;

1. Steam Boiler Driver (Boilerman) Grade 1 & 2 (2

( days)
2. Steam Boilers – Operations, Troubleshooting, Inspection, Repair and Maintenance
Main (3 days)
3. Steam Boiler – Design, Inspection and Repairs (4
( days)
4. Pump Technology – Design and Applications (2 ( days)
5. Steam Turbine – Operation and Maintenance (2 ( days)
6. Combustion Fundamentals (2 ( days)
7. Gas Turbine Technology (3 3 days)
8. Risk Based Inspection
tion Fundamentals (3
( days)
9. Efficient Management of Electrical Energy in Malaysia (1
( day)
10. Plant Cost Management (3 days)
11. Hydraulic Systems (2 days)
12. Pneumatic Systems (2 days)
13. Condition Monitoring (2 days)

For further details, please do not hesitate to contact

contact En. Mohd. Rashidi bin Alias – Training
Manager at +6013 – 9278625

Phone:: +6013-9278625
+6013 E-mail: bayubali@yahoo.co.uk