Boiler Operation & Maintenance (10 CEP)

Duration: 8:30 AM - 5:00 PM (2 Days)
Venue: Four Points by Sheraton Puchong, Tower 3, Puchong Financial Corporate Centre, 1201, Jalan Puteri 1/2, Bandar Puteri Puchong, 47100 Puchong, Selangor.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas
Training Program Number: 10001589077

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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Topic

Introduction to Steam Boiler, Steam Boiler Operation, Steam Boiler Protection, Steam Boiler Essential Preventive Maintenance, Steam Boiler Inpection & Lay Up, and Boiler Water Treatment & Chemical Management.

Boiler Operator Essentials (10 CEP)

Duration: 8:30 AM - 5:00 PM (2 Days)
Venue: No. 11A & 11B, Jalan Puchong Permai 2, Taman Puchong Permai, 47100 Puchong, Selangor.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas
Training Program Number: 10001649164

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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Topic

Introduction to Steam Boiler, Steam Boiler Components & Parts, Steam Boiler Start Up, Steam Boiler Control, Steam Boiler Shutdown & Protection, and Steam Boiler Shutdown & Protection.

Boiler Inspection (10 CEP)

Duration: 8:30 AM - 5:00 PM (2 Days)
Venue: No. 11A & 11B, Jalan Puchong Permai 2, Taman Puchong Permai, 47100 Puchong, Selangor.
HRD Corp Claimable Courses - Skim Bantuan Latihan Khas
Training Program Number: 10001649787

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.

Topic

Codes, Standard For Boiler Inspection, Inspection, Methodology & Preparation, New Boiler Inspection, CF Renewal Inspection (Periodic Inspection), Special Inspection & Major Repair, and Common Boiler Defects & Root Cause.

HRSG Operation & Control (10 CEP)

Duration: 9:00 AM - 5:00 PM (2 Days)
Venue: No. 11A & 11B, Jalan Puchong Permai 2, Taman Puchong Permai, 47100 Puchong, Selangor.
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.

Topic

Introduction to HRSG, HRSG Major Components, HRSG Start Up, HRSG Controller, HRSG Protection, HRSG Shutdown, and Typical HRSG Startup Failures.

Modern Steam Plant (10 CEP)

Duration: 8:30 AM - 5:00 PM (2 Days)
Venue: No. 11A & 11B, Jalan Puchong Permai 2, Taman Puchong Permai, 47100 Puchong, Selangor.
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.

Topic

Introduction & Scope, Steam Header, Steam Turbine, Back Pressure Receiver, Steam Boiler Shutdown & Protection.

Steam Turbine Operation & Control (10 CEP)

Duration: 8:30 AM - 5:00 PM (2 Days)
Venue: No. 11A & 11B, Jalan Puchong Permai 2, Taman Puchong Permai, 47100 Puchong, Selangor.
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.

Topic

Introduction to Steam Turbine, Steam Turbine Major Components, HRSG Startup, Steam Turbine Controller, Steam Turbine Protection, Steam Turbine Shutdown.

Process Safety Management (10 CEP)

Duration: 9:00 AM - 5:00 PM (2 Days)
Venue: No. 11A & 11B, Jalan Puchong Permai 2, Taman Puchong Permai, 47100 Puchong, Selangor.
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:

• Understand the principles of Process Safety Management (PSM) and its link to Malaysian OSH and CIMAH requirements.
• Identify the key elements of a PSM programme and their application in industrial steam and process plants.
• Conduct and interpret basic Process Hazard Analysis (PHA) techniques for operational risk reduction.
• Develop and review safe operating procedures for critical process and boiler plant activities.
• Apply Management of Change (MOC) controls to prevent unintended hazards during plant modifications.
• Establish mechanical integrity practices for pressure vessels, piping, and safety-critical equipment.
• Investigate process safety incidents and implement corrective actions to prevent recurrence.
• Coordinate emergency preparedness and response for major accident hazard scenarios.

Topic

Introduction to Process Safety Management, Legal & Regulatory Framework, Elements of PSM, Process Hazard Analysis, Safe Operating Procedures, Pre-Startup Safety Review, Mechanical Integrity, Management of Change, Incident Investigation, and Emergency Planning.

Boiler Commissioning (10 CEP)

Duration: 8:30 AM - 5:00 PM (2 Days)
Venue: No. 11A & 11B, Jalan Puchong Permai 2, Taman Puchong Permai, 47100 Puchong, Selangor.
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:

• Plan and execute a structured boiler pre-commissioning inspection and documentation checklist.
• Apply relevant codes and DOSH requirements for new boiler registration and acceptance testing.
• Supervise hydrostatic pressure testing with correct safety isolation and stabilization procedures.
• Verify the functionality of critical safety devices including LWFCO, flame failure, and pressure interlocks.
• Commission burner and combustion systems for stable, efficient, and safe operation.
• Tune boiler control loops for drum level, pressure, and combustion stability beyond initial startup.
• Conduct performance testing, steam quality checks, and load acceptance trials.
• Prepare commissioning reports and handover documentation for operational teams and statutory authorities.

Topic

Introduction to Boiler Commissioning, Legislation & Standards, Pre-Commissioning Inspection, Hydrostatic Testing, Safety Device Verification, Burner & Combustion Tuning, Control System Commissioning, Performance Testing, Documentation & Handover.

Boiler Design Insight (10 CEP)

Duration: 8:30 AM - 5:00 PM (2 Days)
Venue: No. 11A & 11B, Jalan Puchong Permai 2, Taman Puchong Permai, 47100 Puchong, Selangor.
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:

• Explain the fundamental philosophy of boiler design and its relationship to operating limits and safety requirements.
• Describe the basic heat transfer mechanisms within a boiler and their impact on efficiency and performance .
• Understand the principles of boiler circulation and the importance of maintaining adequate flow conditions.
• Identify key pressure parts in a boiler and explain their role in maintaining pressure integrity.
• Recognize common damage mechanisms and relate them to deviations from design conditions.
• Evaluate the operational risks associated with exceeding design limits such as pressure, temperature, and flow.
• Apply practical reasoning to assess operating conditions and prevent potential boiler failures.

Topic

Boiler Design Philosophy & Operating Limit, Heat Transfer, Circulation & Flow, Pressure Part & Design Awareness Focus, Design Vs Damage Mechanism, Deviation from Design.