© 2001-2008
AESYS Technologies, LLC

Booth #5036

Educational Services, Division of AESYS Technologies, LLC offers the Boiler Training Program to provide an intense hands-on comprehensive experience for service, maintenance and operating personnel of any experience level.

Although a Boiler Operator Certification is not available through this Program, this Program does help develop the skills, knowledge and core competency necessary to qualify for such certification through fundamental and practical examinations. The Program is designed to prepare participants to develop the capability required for a certification examination.
Operator certification is generally a requirement of Authority Having Jurisdiction (AHJ). The AHJ would be mandated by each State’s or Province’s legislation to require such certifications. Please check with your State’s, or Province’s, Department of Labor or Occupational Safety, for performance and examination requirements within your jurisdiction.

BTP Course No. 1, the Safety and Theory module, a 1-day classroom session, provides for approximately 8 hours of instruction. Course No. 2, the Boiler Operations module, primarily a 2-day classroom session, provides for approximately 4 hours of hands-on application. Course No. 3, the Advanced Boiler Operations module, a 2-day operations workshop, provides for approximately 12-16 hours of hands-on application.

The Program is provided in a relaxed and informal environment, however with certain and clear focus towards development of the service, maintenance and operating personnel capabilities. It is designed for experienced operating, technical service and maintenance personnel requiring further education of core competency, or desire to qualify for Boiler Operator Certification, Plant managers, field inspectors, design/project management personnel, as well as beginners and apprentices seeking to ensure a career path within the industry. All experience levels will benefit from this unique, fast paced and comprehensive Program.
Key Benefits of the Program
- Learn to properly select operating control set points to minimize boiler cycles
- Understand correct shutdown procedures that will ensure efficient operating periods
- Methods of performing weekly routine combustion checks to reduce periods of inefficient combustion
- Preventative maintenance that will reduce unplanned outage time
- Water chemistry control for the non-chemist to improve boiler performance and save money
- Master the linkage mystery
- Understand common sense methods to manage water and chemical makeup for improved operating efficiency
Who Should Attend:
- Boiler Service and Maintenance Contractors
- Mechanical and Plumbing Contractors
- Plant Operators and Maintenance Staff
- Building Inspectors & Administrators
- Design and Operating Engineers
- Facility Agents & Owners
Program Objectives :
- Obtain a better understanding of basic boiler theory, including design and operating principles
- Using the supplied text books, participate in discussions including boiler construction, components, flow paths and thermodynamics
- Learn to save money and time through safe, efficient boiler room operations

Course 1 - .8 CEU
Boiler Theory and Safety

A one-day program provides an overview of basic packaged boiler theory and safety. Topics covered include boiler construction, fluid paths, major control components, instrumentation, boiler feed water control, basic thermodynamics and principles of operation.

Basic Packaged Boiler Description
Firetube Boiler
Watertube Boiler
Boiler Construction
Advantages/Disadvantages

Combustion
Fuel, Heat, Oxygen
Products of Combustion

Boiler Fluid Flow Paths
Water, Fuel, Combustion Air

Thermodynamics
Water Reactions
Heat Transfer

Boiler Components
Forced Draft Fan
Forced Draft Damper
Firetubes
Reversing Chamber (Arch)
Fuel Supply Regulator
Main Fuel Valves
Fuel Butterfly Valve
Feedwater Control Valve
Miscellaneous Valves

Instrumentation
Pressure and Temperature, Level, Flow

Control
Feedwater Control
Burner Controls
Flame Safety Control

Principles of Boiler Operation
Boiler Prerequisites
Boiler Start-up
Boiler Normal Operation
Boiler Shutdown

Boiler Safety
Safety Resources
Safety Rules

Boiler Chemistry
Chemical Maintenance
Open Loop Steam Boiler
Chemicals
Scaling Control/Production
Basic Tests

Course 2 – 1.6 CEU
Boiler Operations

Program features two days of in-depth study about the design, operation and maintenance of packaged boilers. Topics include control systems, water chemistry control and maintenance, gas pressure regulators, oil pumps, air compressors start-up and adjustment, combustion testing, maintenance and operating procedure, as well as burner controls and adjustment.

Boiler Control Systems
Principles of Control
Flame Monitoring Devices
Honeywell and Fireye Flame Safeguard Burner Control Systems

Water Chemistry Control
and Maintenance
Introduction to Boiler Water
Working Fluid Properties
Corrosion and Scale Formation
Boiler Water Treatment

Fuel Oil Pumps
Pump Classification and Terminology
Positive Displacement Pumps

Air Compressors
Air Compressor Principles
Reciprocating Compressors
Sliding Vane Compressors
Compressor Installation
Air Compressor Troubleshooting

Gas Regulators

Start-Up and Adjustment
Initial Line-up Check
Initial Start-up Check
Gas Start-up
Normal Operation
Field Linkage Adjustment

Combustion Testing
Oil Fired Testing
Gas Fired Testing

Boiler Operations and Maintenance
Boiler Start-up
Boiler Shut-down
Boiler Lay-up
Periodic Inspections and
Maintenance

Course 3 – 1.6 CEU
Advanced Operations

Demonstrate
- Walk down of the boiler and auxiliary equipment
- Check rotation of motors, manual resets, locate and state function of operating and safety limit devices
- Water level

Locate
- Bottom blowoff, surface blowdown, feedwater supply valves, steam line drain, burner and boiler observation ports, water level gauge glass, water stopcocks, hand holes, pressure and temperature controls, high pressure trip, low fire hold pressure switch, modulating pressure controller

Identify Burner Components
- Forced draft damper, draft fan, draft fan motor, damper drive linkage, modulation controls, drive motor, jack shaft, fuel valve control linkage, ignition pilot fuel train, ignition transformer, flame scanner sight tube, fuel oil gun, fuel gas train, operating controls

Conduct Anomaly-Free Boiler Startup
- Name each stage including expected indications, place operating control in TEST position and discuss the outcome of each stage of operation
- Identify safe stable flame and describe visual indications
- Perform pilot ignition turndown test
- Identify fuel type characteristic of flame

Monitor Combustion Points
- Connect the fuel gas and windbox manometers, stack thermometer, stack gas sample port, flue gas smoke tester, stack temperature, Fyrite CO2 Gas Analyzer, CO, NOx, Hayes Chart, Calibrate boiler efficiency, perform combustion test, potential problems, adjustments for highest possible turndown, troubleshoot, calculate gas flow, drain water column, verify boiler trips, setup on low water cutout, perform bottom blowoff

Perform Complete Boiler Shutdown
Troubleshooting and Maintenance
In addition to boiler theory and operational safety instruction, participants will also learn about select troubleshooting tips, maintenance procedures and record keeping skills.
Troubleshooting Tips
- Discover seven basic parameters that indicate trouble
- Learn to draw your own wiring diagram and troubleshoot a controller without power supplied
- Learn to make minor adjustments to water levels, and make-up tank pressure, to eliminate feedwater supply pump cavitation and improve boiler efficiency
- Review methods of adding chemicals to reduce equipment failures
- Understand how to reroute cabling to cure nuisance flame scanner problems and flame failures
- Discover six different ways to cure flame sighting problems
Maintenance Procedures and Record Keeping:
- Discover how to monitor stack temperature trends to reduce forced boiler outages
- Learn how to consistently maintain higher flame quality and lower NOx emissions
- Find out what a clean air compressor inlet filter can do for flame atomization and fuel efficiency