Boiler Operation & Maintenance (10 CEP)

Duration: 9:00 AM - 6:00 PM (2 Days)
Venue: 468A, Jalan Persiaran Scientex Utama 1, Taman Scientex Utama, 81400 Senai, Johor, Malaysia.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas

Training Outcomes

Upon completion of this training, participants will be equipped to immediately implement best practices and:

• State the basic purpose and operating principles of industrial steam boilers
• Differentiate the fundamental construction of steam boilers.
• Identify key boiler terminology used in daily logging and documentation
• Execute a safe, controlled boiler start-up and normal shutdown procedure.
• Accurately monitor and log critical operating parameters on a shift basis.
• Describe the function of the main control loops.
• Explain the operating principle of all major safety and protection devices.
• Immediately respond to and reset common safety trip alarms.
• Demonstrate the proper testing procedure for the Low Water Alarm & Cut-Off device.
• Perform routine daily and weekly Preventive Maintenance checks on boiler systems.
• Identify early signs of mechanical failure.
• Execute minor maintenance tasks like cleaning the flame scanner and checking pump gland seals.
• Prepare a boiler safely and thoroughly for internal inspection by statutory authorities.
• Implement the correct Wet or Dry Lay-up procedure based on the planned shutdown duration.
• Understand the legal requirements for operating logbooks and mandatory inspection intervals.

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Boiler Inspection (10 CEP)

Duration: 9:00 AM - 6:00 PM (2 Days)
Venue: 468A, Jalan Persiaran Scientex Utama 1, Taman Scientex Utama, 81400 Senai, Johor, Malaysia.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas

Training Outcomes

Upon completion of this training, participants will be equipped to immediately implement best practices and:

• Identify the specific roles and legal responsibilities of Competent Persons (Boilerman and Steam Engineers) during the inspection lifecycle.
• Apply international design codes such as ASME Section I and BS EN 12952/12953 to verify boiler structural integrity.
• Execute a comprehensive pre-inspection preparation plan, including cooling, isolation (LOTO), and confined space safety protocols.
• Determine the most effective Non-Destructive Testing (NDT) methods for detecting subsurface cracks, wall thinning, and weld defects.
• Assess the physical condition of internal boiler components through systematic visual inspection (VT) techniques.
• Manage the documentation and technical requirements for the registration and commissioning of new boiler units.
• Supervise a statutory Hydrostatic Pressure Test while adhering to precise safety and stabilization parameters.
• Prepare the steam plant for a successful Certificate of Fitness (CF) renewal visit by a DOSH Inspector.
• Verify the functionality of critical safety automation, including Low Water Fuel Cut-Off (LWFCO) and high-pressure alarms.

Modern Steam Plant (10 CEP)

Duration: 9:00 AM - 6:00 PM (2 Days)
Venue: 468A, Jalan Persiaran Scientex Utama 1, Taman Scientex Utama, 81400 Senai, Johor, Malaysia.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas

Training Outcomes

Upon completion of this training, participants will be equipped to immediately implement best practices and:

• Design steam header configurations that act as a buffer against pressure fluctuations.
• Execute flawless steam turbine startup and shutdown sequences according to OEM standards.
• Optimize the BPR to absorb load swings and ensure consistent exhaust pressure.
• Minimize energy loss and water hammer risks through effective trapping and distribution.
• Maintain precise steam parameters (Pressure & Temp) as required by the end user or process.
• Ensure steam quality (Dryness/Superheat) for maximum heat transfer at the customer's end.
• Apply preservation techniques to prevent internal corrosion during standby periods.
• Develop emergency response protocols for sudden pressure surges or steam trips.

Boiler Operator Essentials (10 CEP)

Duration: 9:00 AM - 6:00 PM (2 Days)
Venue: 468A, Jalan Persiaran Scientex Utama 1, Taman Scientex Utama, 81400 Senai, Johor, Malaysia.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas

Training Outcomes

Upon completion of this training, participants will be equipped to immediately implement best practices and:

• State the purpose of and basic operating principles of a steam boiler.
• Differentiate between common steam boiler types.
• Recognize common industry terminology related to steam boiler.
• Identify the main functional groups of steam boiler components.
• Explain the function of critical components like the burner, drum, and superheater.
• Locate and describe the function of key safety fittings.
• List the necessary pre-start checks to ensure safe operation.
• Follow the step-by-step procedure for a safe boiler light-off.
• Interpret basic steam boiler control panel indicators and alarms.
• Execute a safe, controlled normal shutdown procedure.
• Identify the symptoms of key operating problems and initiate corrective action.
• Explain the function of all major safety and protection devices.
• Identify the contaminants in boiler feedwater and their negative effects.
• Explain the purpose of both external and internal water treatment.
• Interpret basic water test results and adjust blowdown accordingly.

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HRSG Operation & Control (10 CEP)

Duration: 9:00 AM - 6:00 PM (2 Days)
Venue: 468A, Jalan Persiaran Scientex Utama 1, Taman Scientex Utama, 81400 Senai, Johor, Malaysia.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas

Training Outcomes

Upon completion of this training, participants will be equipped to immediately implement best practices of:

• Analyze the unique design characteristics of Heat Recovery Steam Generators (HRSG) and their role in combined cycle power plants.
• Execute precise Cold, Warm, and Hot startup sequences to minimize thermal stress and fuel consumption.
• Optimize HRSG Control Systems including Drum Level, Steam Temp, and Swell Management for stable operations.
• Implement best practices for safe and efficient HRSG shutdown and preservation
• Identify and mitigate the root causes of typical startup failures and "trip" scenarios.
• Master HRSG Protection logic, including Drum Level, Furnace Purge, and Temperature interlocks.
• Manage the "Swell and Shrink" phenomena effectively during load changes and transient periods.
• Evaluate Heat Transfer efficiency across Economizers, Evaporators, and Superheaters.
• Formulate emergency response protocols for critical HRSG failures to ensure personnel and asset safety.

Steam Turbine Operation & Control (10 CEP)

Duration: 9:00 AM - 6:00 PM (2 Days)
Venue: 468A, Jalan Persiaran Scientex Utama 1, Taman Scientex Utama, 81400 Senai, Johor, Malaysia.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas

Training Outcomes

Upon completion of this training, participants will be equipped to immediately implement best practices and:

• Analyze the fundamental principles of the Rankine Cycle and how steam turbines convert thermal energy into mechanical power.
• Identify the mechanical functions and material constraints of major turbine components, including rotors, casings, and blading.
• Execute standardized startup sequences (Cold, Warm, and Hot) while managing thermal expansion and eccentricity.
• Master the operation of the Turbine Control System (Governor) for precise speed and load management.
• Evaluate the critical role of auxiliary systems, such as Lube Oil, Gland Steam, and Vacuum systems, in turbine reliability.
• Implement safe shutdown and cooldown protocols, including the strategic use of turning gears to prevent rotor bowing.
• Identify and mitigate the root causes of turbine trips through a deep understanding of the Protection Matrix.
• Optimize turbine efficiency by monitoring exhaust vacuum, steam quality, and extraction parameters.
• Apply advanced preservation techniques for turbines in standby mode to prevent internal corrosion and pitting.
• Formulate emergency response strategies for critical scenarios such as overspeed, high vibration, or loss of vacuum.