Topic 1 Watertube Boilers (Heating, Power, and Tubular)

Learning Outcome

Describe the various types of watertube boilers used in small industrial and heating systems.

Learning Objectives

1. Describe the construction of watertube and copper‐tubular boilers.
2. Describe the water circulation in a longitudinal drum straight tube boiler.
3. Describe two‐drum bent tube boilers, and the advantages of a bent tube boiler compared to a straight tube boiler.
4. Describe the construction of the “A” type, “D” type, and “O” type and the advantages of packaged watertube boilers.

 

Topic 2 Cast-Iron Sectional and Modular Boilers

Learning Outcome

Describe and explain the uses of cast‐iron boilers.

Learning Objectives

1. Describe the general construction of cast‐iron sectional boilers.
2. List the advantages of cast‐iron sectional boilers over watertube and firetube boilers.
3. Describe the arrangement of equipment in a multiple cast‐iron sectional boiler heating plant.
4. Describe the construction and operation of cast‐iron modular boilers.

 

Topic 3 Firetube Boilers (Heating and Power)

Learning Outcome

Describe the various types of firetube boilers used in power and heating systems.

Learning Objectives

1. Explain the difference between power and heating boilers.
2. Describe the historical significance, the construction, and application of the early types of firetube boilers: the HRT, or horizontal return tubular, locomotive, and firebox boilers.
3. Describe the construction and application of wetback and dryback Scotch boilers.
4. Describe the construction and application of vertical firetube boilers and tubeless boilers used in heating plant service.
5. Describe the construction of packaged firetube boilers.

 

Topic 4 Electric Boilers

Learning Outcome

Describe electric boilers with regard to their use and general design.

Learning Objectives

1. Compare electric boilers to fuel‐fired boilers.
2. Describe the construction and operating principle of electrode‐type electric boilers.
3. Describe the construction and operating principle of immersion‐type electric boilers.

 

Topic 5 Basic Fittings for Steam Boilers

Learning Outcome

Name, identify, and explain the operating principles and the differences, if any, between the following low and high pressure boiler fittings: pressure gauges, gauge siphons, safety valves, gauge glasses and water columns, safety shutoff valves, quick opening valves, stop valves, check valves, and vent valves.

Learning Objectives

1. Describe the construction, purpose, and operation of pressure gauges and gauge siphons (pigtails).
2. Describe the testing of pressure gauges.
3. Describe the construction, operation, installation, and testing of low‐pressure (safety relief) and high‐ pressure (safety or pop) valves.
4. Describe the purpose, function, and testing of gauge glasses and water columns.
5. Explain how to change a gauge glass.
6. Describe the construction, operation, and purpose of the following valves: gauge glass safety shutoff valves, gauge glass quick closing valves, stop valves, check valves, blowoff (blowdown) valves, and vent valves.

 

Topic 6 Basic Fittings for Hot Water Boilers

Learning Outcome

Name, identify and explain the operating principles of the following hot water boiler fittings and equipment: pressure, altitude or combination gauges, thermometers, safety relief valves, temperature relief devices, stop valves or drain valves, backflow preventers, and expansion tanks.

Learning Objectives

1. Identify the required instruments, fittings, and controls on a hot water boiler system.
2. Explain how to change a gauge glass on an expansion tank.
3. Describe the construction and operation of the “auto fill valve.”
4. List the usual devices and fittings that are used in hot water heating boiler systems.

 

Topic 7 Low Water Fuel Cut-Offs and Feedwater Controls

Learning Outcome

Discuss the design, operation and testing of low‐water fuel cutoffs and describe feedwater control methods and devices used on low‐pressure boilers.

Learning Objectives

1. Describe the construction and operation of float and electrode low water level fuel cut‐off equipment.
2. Describe the testing and maintenance of float and electrode low water level fuel cut‐offs.
3. Describe the operation of a feedwater float switch operating a valve and a float switch operating a pump.
4. Explain the purpose and function of heating boiler feedwater and condensate piping connections.

 

Topic 8 Heating Boiler Operating Controls

Learning Outcome

Name and describe the various operating controls found on low‐pressure boilers.

Learning Objectives

1. Describe the operation of the on‐off control, the high‐low fire control, the modulating control, and the high limit control found on low‐pressure steam boilers and hot water heating boilers.
2. Explain the operation of the common control switches found on a low‐pressure heating boiler.
3. Describe the operation of the safety switches or interlocks found on the fuel supplies of low‐pressure heating boilers.
4. Explain the required testing and maintenance of heating boiler controls.

 

Topic 9 Boiler Combustion Controls‌

Learning Outcome

Explain the design and operation of various combustion controls on heating boilers.

Learning Objectives

1. List and discuss the various types of boiler flame failure detectors.
2. Describe the testing of boiler flame failure safety devices.

 

Topic 10 Boiler Programming Controls

Learning Outcome

Describe the basic operation of boiler programming controls.

Learning Objectives

1. Describe the operation of equipment that is used to automatically start up and shut down boilers.
2. List a typical sequence of startup and shutdown events.
3. Describe common 5th Class Power Engineer responses to a boiler programmer startup or shutdown.

 

Topic 11 Basic Boiler Operation

Learning Outcome

Describe the preparation, start‐up and shutdown, abnormal conditions, and routine operational checks in the operation of steam and hot water boilers.

Learning Objectives

1. Explain the preparation required before starting a steam or hot water boiler.
2. Explain the startup steps once the boiler has been prepared.
3. State possible abnormal conditions during startup and the cautions required to avoid uneven expansion and thermal shock.
4. Describe the procedure required when “cutting in” an additional boiler.
5. Describe the operating conditions for hot water and steam boilers that must be checked daily, and state the required monthly checks.
6. Explain the procedure for removing a hot water boiler from service.
7. Describe the procedure for removing a steam boiler from service.
8. Explain the emergency conditions that can occur during the operation of a steam boiler. Explain the causes and prevention of furnace and pressure explosions.
9. Explain the reasons for boiler accidents, and describe the role and design of operating logs in the safe operation of a boiler.
10. Operator traits, good operating practice, curiosity, using your senses, (sense‐interpret‐analyze‐perform = SIAP), trusting your instincts, experience and due diligence.

 

Topic 12 Routine Boiler Maintenance and Inspection

Learning Outcome

Describe the service and maintenance required for boilers. Discuss the procedure for preparing a boiler for inspection and cleaning, and describe mechanical boiler cleaning methods.

Learning Objectives

1. Describe the general servicing and routine maintenance of packaged firetube and cast‐iron sectional boilers.
2. Explain the importance of layups and state the procedures to be followed for wet and dry boiler layups.
3. Describe the symptoms of a leaking firetube.
4. List the steps and precautions to be taken to prepare a boiler for inspection.
5. Describe the inspection of a boiler.
6. Describe the methods and tools used for mechanical and chemical cleaning of a boiler.
7. Discuss the standard procedure for a hydrostatic test and the reason for doing the test.

 

Topic 13 Combustion and Draft‌

Learning Outcome

Discuss the characteristics of common fuels used in heating boilers, conditions for complete and incomplete combustion, draft methods, and the application of flue gas analysis.

Learning Objectives

1. Explain natural and mechanical draft arrangements.
2. Describe draft measurement using U‐tube and inclined draft gauges.
3. Describe the use, advantages, and characteristics of common boiler fuels.
4. State the requirements and reactions for complete and incomplete combustion.
5. Explain the difference between a pressure explosion and a furnace explosion.

 

Topic 14 Burners for Boilers

Learning Outcome

Describe the operation of the various types of gas and oil burners used on boilers.

Learning Objectives

1. Describe the operation of atmospheric and ring gas burners.
2. Describe the construction and operation of automatic valves.
3. Describe the principle of oil atomizing burners for boilers.
4. List and describe the auxiliary equipment needed for an oil combustion system.
5. Describe the overall components and operation of fuel oil systems.

 

Topic 15 Piping Materials and Connections

Learning Outcome

Discuss the various construction materials, size classification, and connection methods for the piping in a plant.

Learning Objectives

1. Explain the characteristics and applications of the various materials used to manufacture piping and fittings.
2. Explain pipe size, schedules, and classifications.
3. Identify screwed, flanged, and welded pipe connections.

 

Topic 16 Piping Expansion, Support, and Insulation

Learning Outcome

Discuss piping expansion, support, and insulation.

Learning Objectives

1. Explain pipe expansion and the principle of expansion bends and joints.
2. Explain the purpose of pipe supports and describe various pipe support designs.
3. Explain the purposes for pipe insulation and describe the use of the common insulation materials.

 

Topic 17 Steam Traps

Learning Outcome

Explain the purpose of steam traps and describe the installation and operating principles of the various steam traps found on piping systems.

Learning Objectives

1. Describe the designs and operating principles of mechanical traps.
2. Describe the designs and operating principles of thermostatic steam traps.
3. Describe the correct piping arrangement and procedures for a steam trap.
4. Explain the purpose and design of a strainer.
5. Explain the causes, effects, and prevention of water hammer.

 

Topic 18 Introduction to Valves‌

Learning Outcome

Discuss the design, application, and maintenance of common types of valves used in piping systems.

Learning Objectives

1. Describe five standard valve designs: gate, globe, butterfly, ball, and plug.
2. Describe the design and operation of check and non‐return valves.
3. Describe the function of a pressure‐reducing valve.
4. Describe valve identification markings.
5. Describe typical valve maintenance requirements.

Topic 1 Steam Heating Equipment

Learning Outcome

Describe the operating principles of steam heating equipment and components.

Learning Objectives

1. Describe the construction and operation of steam heating system devices used to transfer heat from the steam to a heated space.
2. List and describe the auxiliary equipment used in a steam heating system, including air vents, radiator valves and traps, and condensate return equipment.

 

Topic 2 Steam Heating Systems

Learning Outcome

Describe the operating principles and maintenance procedures of steam heating systems and the components of these systems.

Learning Objectives

1. Describe standard types of piping and equipment layout for steam heating systems.
2. Describe the general operation and maintenance of steam heating systems.
3. Apply a steam heating system troubleshooting guide.

 

Topic 3 Hot Water Heating Systems

Learning Outcome

Describe the various designs of hot water heating systems.

Learning Objectives

1. Describe the standard piping and circulation layouts of hot water heating systems.
2. Compare the advantages and disadvantages of hot water and steam heating systems.
3. Describe radiant panel and snow melting hot water systems.

 

Topic 4 Hot Water Heating System Equipment and Operation

Learning Outcome

Describe accessories, operation and troubleshooting of a hot water heating system.

Learning Objectives

1. Describe the purpose and function of standard hot water heating system components such as diverter fittings, air vents, air separators, flow control valves, balancing valves and fittings, riser stop valves, pressure reducing valves, circulating pumps, expansion tanks, and steam to hot water converters.
2. Explain how the location of the hot water circulating pump and the expansion tank are determined.
3. Describe the cleaning, filling, starting, routine operation, and troubleshooting of hot water heating systems.
4. Apply a hot water heating system troubleshooting guide.

 

Topic 5 Warm Air Heating System Equipment

Learning Outcome

Describe the operating principles of warm air heating sources.

Learning Objectives

1. Compare the advantages and disadvantages of forced air and gravity warm air systems.
2. List and describe the common sources of warm air heat.
3. List and describe the operational characteristics of directly fired space heaters.

 

Topic 6 Warm Air Furnace Components and Maintenance

Learning Outcome

Describe the components and maintenance requirements of typical warm air heating and ventilating systems.

Learning Objectives

1. Describe the operation of furnace components.
2. Describe and discuss the relative merits of three types of air distribution and duct systems.
3. Describe the recommended maintenance procedures for warm air heating and ventilating systems.
4. Apply a troubleshooting guide for forced warm air systems and components.

 

Topic 7 Ventilation and Air Filters

Learning Outcome

Describe the various ventilation systems found in buildings, as well as describe the various types of air filters used in these systems.

Learning Objectives

1. Explain the difference between natural and mechanical ventilation.
2. Describe the types of contaminants found in air.
3. Describe the types of air cleaning devices used in buildings.

 

Topic 8 Electric Controls for Heating Systems

Learning Outcome

Describe and explain the function of the various components of an electric control circuit.

Learning Objectives

1. Discuss the various terms associated with electric control systems.
2. Describe the basic construction and operation of electric thermostats, humidity controllers, and pressure controllers.
3. Describe the function and operation of the controlled devices in electric control systems.
4. Explain the operating sequence of a basic electric control circuit.

 

Topic 9 Refrigeration Theory‌

Learning Outcome

Explain the theory and terms associated with refrigeration.

Learning Objectives

1. Explain the fundamentals of refrigeration.
2. Describe the practical cycle of operations in a vapor compression refrigeration system.
3. State how the capacity of a refrigeration system is described and how refrigeration tables are used to calculate system performance.

 

Topic 10 Air Compression

Learning Outcome

Describe the operating principles of the different types of air compressors.

Learning Objectives

1. Describe the main classifications and types of air compressors.
2. Describe air compressor auxiliary equipment, including capacity control systems.
3. Discuss preventive maintenance for reciprocating air compressors.

 

Topic 1 Watertube Boiler Designs

Learning Outcome

Describe common designs, configurations and circulation patterns for modern bent‐tube watertube boilers and steam generators and explain how boilers are rated.

Learning Objectives

1. Explain the difference between packaged, shop assembled, and field‐erected watertube boilers. Explain how boilers are rated.
2. Explain the process of water circulation in a watertube boiler and the factors that influence circulation.
3. Identify examples of and describe the A, O, and D design configurations and explain the water and gas circulation patterns for each. Define integral furnace.
4. Define a steam‐generating unit, identify oil and gas‐fired units, and explain the components, heating surfaces, and flow patterns through a typical unit. State typical temperatures throughout the unit.
5. Differentiate between critical and super‐critical boilers.
6. Explain the purpose and advantage of forced circulation and describe the flow through a typical controlled circulation boiler.
7. Explain the purpose and design of a once‐through boiler.

 

Topic 2 Special Boiler Designs

Learning Outcome

Describe the designs, components, firing methods, and operating considerations for some special boilers used in industry.

Learning Objectives

1. Describe typical designs, components and operating strategies for once‐through, steam flood boilers.
2. Describe typical designs, components and operating strategies for Fluidized Bed boilers.
3. Describe typical designs, components and operating strategies for Heat Recovery Steam Generators.
4. Describe typical designs, components and operating strategies for Black Liquor Recovery boilers used in pulp mills.
5. Describe typical designs, components and operating strategies for Refuse boilers used in waste disposal.
6. Describe typical designs, components and operating strategies for waste heat, biomass boilers.

 

Topic 3 Boiler Construction

Learning Outcome

Explain Code requirements, in general terms, and describe construction and assembly methods for the major components of a large boiler.

Learning Objectives

1. Explain top and bottom support and describe the support techniques for various components of a large boiler, including lateral supports for furnace walls. Explain allowances for expansion.
2. Explain the purpose, design, locations and installation methods for boiler casing insulation, refractory, and cladding.
3. Describe the methods used to fabricate boiler tubes.
4. Describe the preparation, fabrication, and testing of boiler drums.
5. Describe methods of attaching tubes to drums and headers, including expanding and welding, and explain where each method would be used.
6. Explain code requirements/sizes for, and describe the designs and installation of, manholes and handholes, including welded handholes. Explain procedures for removing and installing covers.
7. Describe the field assembly of a large boiler or steam generating unit.

 

Topic 4 Boiler Heat Transfer Components

Learning Outcome

Explain the purpose, location, design and operating conditions for the major heat transfer components of a large watertube boiler or steam generator.

Learning Objectives

1. Describe baffle designs and locations and explain their significance to boiler heat transfer.
2. Describe the designs of integral furnace sidewall and header arrangements, including tube‐and‐tile, tangent tube, and membrane.
3. Define primary, secondary, convection, radiation, platen, and pendant as they apply to superheaters. Describe the locations of superheaters within a steam generator and state the operating characteristics of convection and radiant superheaters.
4. Explain the purpose and design of a separately‐fired superheater.
5. Explain the purpose and describe the locations of reheaters. Explain the position of and flow through the reheater in relation to the superheaters.
6. Describe designs and locations for integral and separate economizers.
7. Describe the designs, operation, and location of plate, tubular, and rotary regenerative air heaters.
8. Explain operating care and considerations that must be given to the various heat transfer sections of the boiler.
9. Explain a typical water and gas temperature profile through a large steam generating unit.

 

Topic 5 High Pressure Boiler Fittings

Learning Outcome

Describe the design and operation of common external and internal fittings attached to the pressure side of a high‐ pressure boiler.

Learning Objectives

1. Describe the design, installation, operation, and setting of a high‐pressure pressure relief valve. Explain the Code requirements for size, capacity and locations of the pressure relief valves on a boiler.
2. Describe the code requirements for boiler pressure gages, including attachment and locations.
3. Describe common designs, connections and components of high‐pressure water columns and flat gage glasses, including illumination and quick shut‐off devices and bulls‐eye glasses. Explain testing and maintenance of a high‐pressure gage glass.
4. Describe the float and probe designs for low‐water fuel cutoffs and explain how these are tested.
5. Describe boiler steam outlet arrangements and fittings including gate, angle, and globe stop valves and globe, Y, angle, and spring‐cushioned non‐return valves.
6. Describe manual blowoff piping arrangements. Describe the design and operation of sliding disc, seatless sliding plunger, seat and disc, and combination valves. Explain manual blowoff procedures. Describe the requirements for a blowoff tank.
7. Explain the components of the steam drum internals of a watertube boiler. Describe the design and operation of various steam separation devices, including baffles, primary and secondary separators, and scrubbers.

 

Topic 6 Boiler Draft and Flue Gas Equipment

Learning Outcome

Explain boiler draft systems and fans and describe the equipment used to remove ash from flue gas.

Learning Objectives

1. Define and explain the applications and designs of natural, forced, induced and balanced draft.
2. Explain how draft is measured, monitored, and controlled in a large, balanced draft boiler. Explain the position of control dampers.
3. Describe typical draft fan designs, single and double inlet arrangements, and explain methods used to control fan output.
4. Explain the start‐up and running checks that must be made on draft fans.
5. Describe typical windbox and air louver arrangements and distinguish between primary and secondary air.
6. Describe the design and operation of flue gas particulate clean‐up equipment, including mechanical and electrostatic precipitators and baghouse filters.
7. Describe the design and operation of ash handling systems, including hydro and air systems, bottom ash systems, and scraper conveyor systems.
8. Describe the designs and operation of SO2 recovery systems, including lime and wet gas scrubbing.

 

Topic 7 Fuels, Combustion, and Flue Gas Analysis

Learning Outcome

Explain the properties and combustion of common fuels and the analysis of combustion flue gas.

Learning Objectives

1. Explain/define complete combustion, incomplete combustion, combustion products, and write balanced combustion equations.
2. Explain the purpose and benefits of excess air and calculate the theoretical and excess air required for the complete combustion of a given fuel.
3. Explain proximate analysis, ultimate analysis, and heating value of a fuel and describe the use of calorimetry to determine heating value. Explain higher and lower heating values.
4. Given the ultimate analysis of a fuel, use Dulong’s Formula to calculate the heating value of the fuel.
5. Describe the properties, classifications and combustion characteristics of coal.
6. Describe the properties, classifications and combustion characteristics of fuel oil.
7. Describe the properties and combustion characteristics of natural gas.
8. Explain the use and combustion characteristics of alternatives to traditional fossil fuels, including biomass, coke and oil emulsions.
9. Explain the analysis of flue gas for the measurement of O2, CO, and CO2 in relation to combustion efficiency. Describe typical, automatic flue gas analyzers.
10. Explain the formation, monitoring and control of nitrogen oxides (NOX), sulfur dioxide, and particulates.

 

Topic 8 Control Loops and Strategies

Learning Outcome

Explain the operation and components of pneumatic, electronic and digital control loops, and discuss control modes and strategies.

Learning Objectives

1. Describe the operation, components and terminologies for a typical control loop.
2. Describe the operation and components of a purely pneumatic control loop. Explain the function of each component.
3. Describe the operation and components of an analog/electronic control loop. Explain the function of each component.
4. Describe the operation and components of a digital control loop. Explain the function of each component.
5. Explain the purpose, operation, and give examples of on‐off, proportional, proportional‐plus‐reset, and proportional‐plus‐reset‐plus‐derivative control. Define proportional band and gain.
6. Describe and give typical examples of feed forward, feed back, cascade, ratio, split‐range, and select control.
7. Explain, with examples, the purpose and incorporation of alarms and shutdowns into a control loop/ system.
8. Explain the interactions that occur and the interfaces that exist between an operator and the various components of a control loop/system, including the components of a controller interface.

 

Topic 9 Instrument and Control Devices

Learning Outcome

Explain the operating principles of various instrument devices that are used to measure and control process conditions.

Learning Objectives

1. Describe the design, operation and applications for the following temperature devices: bimetallic thermometer, filled thermal element, thermocouple, RTD, thermistor, radiation and optical pyrometers
2. Describe the design, operation and applications for the following pressure devices: bourdon tubes, bellows, capsules, diaphragms, and absolute pressure gage.
3. Describe the design, operation and applications for the following flow devices: orifice plate, venturi tube, flow nozzle, square root extractor, pitot tube, elbow taps, target meter, variable area, nutating disc, rotary meter and magnetic flowmeter.
4. Describe the design, operation and applications for the following level devices: atmospheric and pressure bubblers, diaphragm box, differential pressure transmitter, capacitance probe, conductance probes, radiation and ultrasonic detectors and load cells.

 

Topic 10 Distributed and Logic Control

Learning Outcome

Explain the general purpose, design, components and operation of distributed and programmable logic control systems.

Learning Objectives

1. Explain distributed control and describe the layout and functioning of a typical distributed control system. Explain the function of each major component of the system.
2. Identify and explain the functions of the major components of the operator interface unit (OIU), including controller interfaces, displays, alarms and shutdown.
3. State typical applications and explain the purpose and functioning of a programmable logic controller, including the operator interfaces. Explain a ladder logic diagram.
4. State the purpose and explain the general functioning of a communication and data acquisition system (eg. SCADA) as it relates to process control.

 

Topic 11 Boiler Control Systems

Learning Outcome

Explain the components and operation of automatic control systems for boiler water level, combustion, steam temperature, and start‐up.

Learning Objectives

1. Describe on‐off and single element control of boiler feedwater.
2. Explain swell and shrinkage in a boiler. Describe the components and operation of a two‐element feedwater control system, explaining the interaction of the controllers.
3. Describe the components and operation of a three‐element feedwater control system.
4. Describe the components and operation of a direct combustion control system.
5. Describe the components and operation of a ‘steam flow – airflow’ combustion control system.
6. Describe the components and operation of a ‘fuel flow – airflow’ combustion control system.
7. Describe the components and operation of an ‘airflow – fuel flow’ combustion control system.
8. Describe the components and operation of a multi‐element combustion control system.
9. Describe steam temperature control methods and equipment, including attemperation (desuperheating), gas recirculation, gas bypass, and tilting burners.
10. Describe the automatic, programmed start‐up sequence for a gas‐fired boiler.

 

Topic 12 Boiler Procedures

Learning Outcome

Describe common procedures in the operation and maintenance of high pressure boilers.

Learning Objectives

1. Explain the steps involved in the commissioning of a new boiler or before starting a boiler after major repairs, including:
1. hydrostatic test
2. external and internal inspections
3. drying out refractory
4. boiling out
5. testing shutdowns and safety devices
2. Describe the wet and dry methods when laying up a boiler for an extended time, including nitrogen blanketing.
3. Describe the proper shut down and preparation of a boiler for internal inspection.
4. Describe a thorough inspection of the water and furnace sides of a boiler.
5. Describe typical equipment and procedures for cleaning the water side of a boiler:

   1. mechanically

   2. chemically

6. Explain routine tasks and visual monitoring that the operator must perform on a large operating boiler.
7. Explain the procedures and precautions that an operator must exercise to avoid furnace and pressure‐ side explosions.
8. Describe sootblowing systems and describe the procedures for operating sootblowers.

 

Topic 13 Internal Water Treatment for Boilers

Learning Outcome

Discuss internal water treatment methods and systems for the control of scale, corrosion, and carryover and explain testing and monitoring strategies.

Learning Objectives

1. Explain the causes and effects of boiler scale; explain the most common internal methods of scale control, including phosphate treatment, chelate treatment, sludge conditioning and dispersion.
2. Explain the causes and effects of boiler and condensate return line corrosion; explain treatment methods for acidic, caustic, oxygen, and carbon dioxide corrosion, including sulphite, hydrazine, and amine treatment.
3. Explain the mechanical and chemical causes, effects and types of carryover; explain methods of carryover control, including the use of antifoam and blowdown.
4. Describe the design and explain the operation of simple blowdown, heat recovery, and automatic blowdown systems.
5. Explain, in general terms, the sampling and testing strategies for boiler internal conditions; describe typical sampling and automatic monitoring equipment.
6. Describe typical chemical feed systems, including pot feeders, continuous feed with day tanks, and continuous feed with pump tanks.

 

Topic 14 Boiler Water Pretreatment

Learning Outcome

Explain the purpose, principles, equipment, and monitoring of boiler water pretreatment processes.

Learning Objectives

1. Describe the design and explain the terms, purpose and operation of a clarifier, using coagulation, flocculation, and subsidence.
2. Describe the design and explain the terms, purpose and operation of gravity and pressure filters.
3. Describe the design and explain the terms, purpose and operation, including chemical reactions for a cold lime softener.
4. Describe the design and explain the terms, purpose and operation of a hot lime softener.
5. Explain the principles of ion exchange softening in general, identifying the common anions and cations in untreated water.
6. Describe the design, components, and operation of a sodium zeolite softening system including chemical reactions.
7. Describe the design, components, and operation of a hydrogen zeolite softening system including chemical reactions.
8. Describe the design, components, and operation of a dealkalization system including chemical reactions.

7 Describe the design, components, and operation of a demineralizer system, including mixed bed and degasification.

1. Explain the principle and operation of a reverse osmosis system.
2. Describe the design, principle, and operation controls of a typical deaerator.

 

Topic 15 Welding Procedures and Inspection

Learning Outcome

Explain the processes and applications of different welding techniques and describe the testing of welds and procedures.

Learning Objectives

1. Describe the equipment, procedure and applications of shielded metal arc welding (SMAW). Explain the classification of arc welding electrodes.
2. Describe the equipment, procedure and applications of submerged arc welding (SAW).
3. Describe the equipment, procedure and applications of gas tungsten arc welding (GTAW).
4. Describe the equipment, procedure and applications of gas metal arc welding (GMAW).
5. Explain weld preparation and terminology of a butt weld; explain preheating and post‐weld heat treatment.
6. Describe common defects in welds, including undercut, lack of penetration, porosity, slag inclusion, and cracking; explain how each occurs and its effect on the integrity of the weld.
7. Explain the equipment and procedures for dye penetrant, magnetic particle, radiographic, and ultrasonic inspection of a weld; explain the potential weld defects revealed by each test.
8. Explain the requirements and process for Weld Procedure and Welder Performance qualification, per the ASME Code, Section IX.

 

Topic 16 Pressure Vessels

Learning Outcome

Explain pressure vessel design, stresses, and operating considerations.

Learning Objectives

1. Define “pressure vessel” and explain, in general terms, how pressure vessels are regulated in design, construction and repair (including purpose of Section VIII, ASME).
2. Explain the stamping/nameplate requirements for pressure vessels and identify terms and specifications on a typical nameplate.
3. Describe the weld locations on a typical pressure vessel and identify head designs, including ellipsoidal, torispherical, hemispherical, conical, and toriconical.
4. Describe acceptable nozzle attachment methods, including reinforcements; describe inspection openings.
5. Explain the loads that contribute to stresses in pressure vessels, including pressure, thermal, attachments, static, wind, seismic, and cyclic loads.
6. Explain the components and fittings of a typical pressure vessel.
7. Explain operating and maintenance considerations for the safe operation of pressure vessels, including the appropriate use of hydrostatic and pneumatic testing.

Topic 1 The Cost and Effects of Workplace Injuries

Learning Outcome

Describe the cost and effects of workplace injuries on the individual worker and the business.

Learning Objectives

1. Describe the financial cost of injuries and the impact an injury has on the injured person.
2. Discuss the social and legal implications of injuries.
3. List the steps that can be taken by management to minimize the effects of workplace injuries.

 

Topic 2 Personal Protective Equipment

Learning Outcome

Describe the use, selection and care of personal protective equipment.

Learning Objectives

1. Describe the basic types of personal protective equipment available.
2. Describe the various types and the training, care and maintenance of respiratory protection.

 

Topic 3 Isolation of Mechanical and Electrical Equipment

Learning Outcome

Describe the general procedures involved in the isolation of plant equipment.

Learning Objectives

1. Discuss the general considerations required for the mechanical and electrical isolation of equipment.
2. Describe the typical safe isolation of various pieces of plant equipment.

 

Topic 4 Confined Space Entry

Learning Outcome

Describe procedures needed to enter into and work safely within confined spaces.

Learning Objectives

1. Define and describe the hazards of being in a confined space.
2. Describe procedures to be used when performing a confined space entry, including completion of an entry checklist.

Topic 5 Introduction to Boilers

Learning Outcome

By using common terms relating to boilers discuss the historical developments of, and the general requirements for proper boiler design.

Learning Objectives

1. Apply common terminology used in the description of boilers.
2. Describe early boiler designs and explain developments that improved boiler operation.
3. List the general requirements for proper boiler design.

 

Topic 6 Firetube Boilers‌

Learning Outcome

Discuss the design, components and characteristics of HRT, locomotive, firebox, Scotch and packaged firetube boilers.

Learning Objectives

1. Describe horizontal return tubular and locomotive type boilers.
2. Describe firebox, scotch and heating boilers.
3. Describe vertical and packaged firetube boilers.

 

Topic 7 Watertube Boilers‌

Learning Outcome

Describe various watertube boiler designs, including large generating units.

Learning Objectives

1. Describe the operating principle and design of watertube boilers.
2. Explain the design and application of packaged watertube boilers.
3. Describe the design, construction and components of large scale steam generating units.
4. Describe the design of watertube and copper‐tubular heating boilers.

 

Topic 8 Electric Boilers

Learning Outcome

Describe electric boilers in regard to their use and general design.

Learning Objectives

1. Describe the construction and operating principle of electric boilers.

    

   Topic 9 Basic Boiler Construction

   Learning Outcome

   Describe fabrication and general construction features of watertube and firetube boilers.

   Learning Objectives

   1. Describe the design and manufacturing of boiler shells and drums.
   2. Describe the standard types of welded joints, heat treatments and welding inspection used in the construction of pressure vessels.
   3. Describe the general design of riveted joints.
   4. Describe the tools and standard methods used to attach boiler tubes to tubesheets, headers and drums.
   5. Describe the need for, and application of, boiler stays.
   6. Describe boiler access and inspection openings and drum connections.
   7. Identify the different types of internal firetube furnace designs.
   8. Describe boiler foundations and supports.
   9. Describe the design and construction of water‐cooled furnace walls in watertube boilers.

Topic 10 Boiler Draf t Equipment‌

Learning Outcome

Discuss draft and describe the basic equipment used to supply combustion air to a boiler furnace.

Learning Objectives

1. Describe the forced, induced and balanced methods of mechanical draft.
2. Discuss the common methods of controlling combustion air flow.
3. Discuss the common methods of measuring furnace pressures.

 

Topic 11 Introduction to Boiler Combustion‌

Learning Outcome

Discuss the basic theory of combustion in a boiler, and the equipment used to provide proper combustion conditions.

Learning Objectives

1. Describe the principles of combustion, combustion equations and the relationships between theoretical and excess air.
2. Describe the three general classes of boiler fuels.
3. Describe the firing methods used in the combustion of various fuels, the effects of combustion on refractory and how the flow of fuel is controlled.
4. Describe flue gas analysis and its relationship to boiler efficiency.

 

Topic 12 Fluidized Bed Combustion

Learning Outcome

Discuss the basic theory and design of a fluidized bed steam generator and describe the special operational and control aspects of fluidized bed combustion.

Learning Objectives

1. Define and discuss the history and benefits of “fluidized bed combustion”.
2. Explain the types and operation of fluidized bed combustion units.
3. Discuss the advantages and disadvantages of fluidized bed combustion.
4. Discuss two start‐up strategies and explain bed expansion.

 

Topic 13 Safety and Relief Valves

Learning Outcome

Discuss the design and operation of safety valves for power and heating boilers.

Learning Objectives

1. Describe the ASME code requirements and the construction and operation of high pressure safety valves.
2. Describe the ASME code requirements for the construction and operation of low pressure heating boiler safety valves.
3. Describe the testing and repair of safety valves.
4. Describe the construction and operation of a temperature relief device.

 

Topic 14 Water Columns and Gage Glasses‌

Learning Outcome

Describe different types of direct and inferential level gages or indicators.

Learning Objectives

1. Describe direct type water level indicators.
2. Describe indirect type water level indicators.

 

Topic 15 Drum Internals

Learning Outcome

Describe typical internal components of a boiler steam drum.

Learning Objectives

1. Describe the purposes of and the general principles and equipment used to separate steam and water in a steam drum.
2. Describe steam drum internal feedwater, continuous blowdown and chemical feed pipes.

 

Topic 16 Sootblowers

Learning Outcome

Discuss the design and operation of sootblowers.

Learning Objectives

1. Describe the construction and operation of retractable and stationary sootblowers.
2. Describe an arrangement for shot cleaning.

 

Topic 17 Continuous and Intermittent Blowdown

Learning Outcome

Describe the purposes, equipment and operation of continuous and intermittent blowdown.

Learning Objectives

1. Describe the equipment and processes involved in continuous and intermittent blowdown systems.

    

   Topic 18 Boiler Preparation, Start-up and Shutdown

   Learning Outcome

   Describe the basic preparation of a boiler for start‐up and shutdown procedures.

   Learning Objectives

   1. Describe the steps that must be taken to prepare a boiler for start‐up.
   2. Describe a typical boiler start‐up procedure.
   3. Describe the boiler and steam header warm‐up procedures.
   4. Describe the procedure for shutting down a boiler.

 

Topic 19 Routine and Emergency Boiler Operation

Learning Outcome

Discuss routine and emergency practices for operation of a packaged boiler.

Learning Objectives

1. Describe the proper routine care and operation of a boiler.
2. Describe emergency conditions in boilers and the required responses.
3. List types and causes of boiler accidents and explosions.
4. Discuss the need for boiler operating and maintenance logs and the type of information that should be recorded.

Topic 20 Basic Electricity

Learning Outcome

Describe the concepts of basic electricity and perform simple calculations using voltage, current, resistance and power.

Learning Objectives

1. Describe the atomic structure of matter and its relationship to electricity.
2. Describe basic electrical circuits.
3. State Ohm’s Law and apply it to single resistor circuits.
4. Apply Ohm’s Law to series resistance circuits.
5. Apply Ohm’s Law to parallel resistance circuits.
6. List the factors affecting resistance.
7. Calculate the power developed in an electrical circuit.

 

Topic 21 Magnetism and Electromagnetism

Learning Outcome

Describe the basic principles of magnetism.

Learning Objectives

1. Describe magnetism and the relationship between magnetism and electricity.
2. Describe the relationship between electricity and magnetism in an electrical generator.
3. Describe the relationship between electricity and magnetism in an electric motor.

 

Topic 22 Electrical Metering Devices

Learning Outcome

Discuss the designs and uses of electrical metering devices.

Learning Objectives

1. Describe how voltage, current and resistance are measured in an electric circuit.
2. Describe the construction and operation of a kilowatt hour meter.

 

Topic 23 Motors and Generators

Learning Outcome

Describe the operating principles of the various types of AC and DC motors or generators.

Learning Objectives

1. Describe the construction and operation of DC generators and motors.
2. Describe the construction and operation of AC generators (alternators) and motors.
3. Interpret the information on a motor nameplate.
4. Discuss and perform basic calculations relating to power factor and power factor correction.

 

Topic 24 Transformers

Learning Outcome

Describe the operating principle of transformers.

Learning Objectives

1. Describe the principle of operation of transformers.
2. Describe the construction and operation of single phase transformers and perform basic transformer calculations.
3. Describe the construction and operation of three‐phase transformers.
4. Discuss transformer maintenance and cooling.

 

Topic 25 Electrical Distribution Circuits

Learning Outcome

Describe an electrical distribution system.

Learning Objectives

1. List and describe the standard types of electrical voltage systems.
2. Interpret electrical circuit symbols as used in building systems.
3. Describe the major components of an electrical distribution system.
4. Describe the function and operation of alternate power supply system equipment.

Topic 26 Introduction to Instrumentation Learning Outcome

Describe the overall purpose and function of plant instrumentation systems.

Learning Objectiv1e.s Describe the concept and basic components of a control loop.

1. Describe the various means by which control signals are transmitted.

2. Describe the function of transducers.
3. List and describe the types of instrumentation which are not necessarily part of a control loop.

 

Topic 27 Introduction to Process Measurement‌

Learning Outcome

Describe the construction and operation of common devices used to measure pressure, level, temperature, flow, and composition.

Learning Objectives

1. Describe the standard types of pressure measuring devices.
2. Describe the standard types of level sensing and measuring devices.
3. Describe the standard types of flow sensing and measuring devices.
4. Describe the standard types of temperature sensing and measuring devices.
5. Describe the principle and basic operation of a chromatograph.

 

Topic 28 Basic Control Loop Components

Learning Outcome

Describe the basic types and functions of transmitters, recorders, controllers and control valves.

Learning Objectives

1. Describe the principle, construction and operation of instrumentation transmitters.
2. Describe the principle, construction and operation of instrumentation indicators and recorders.
3. Describe the principle, construction and operation of instrumentation controllers and control valves.

 

Topic 29 Boiler Water Level and Combustion Controls‌

Learning Outcome

Describe specific types of instrumentation and controls used on boilers.

Learning Objectives

1. Describe the construction and operation of boiler low water level fuel cutoff equipment.
2. List the ASME code regulations regarding low water fuel cutoffs.
3. Describe the testing and maintenance of boiler low water level fuel cutoffs.
4. Describe the components and component functions of boiler water level control systems.
5. Describe basic boiler combustion control systems.

 

Topic 30 Boiler Programming Controls‌

Learning Outcome

Describe the operation of programming controls for boilers and discuss testing and maintenance procedures for these controls.

Learning Objectives

1. Describe the operation of equipment that is used to automatically start up and shut down boilers.
2. Interpret operating sequence bar graphs and provide a typical sequence of start up and shutdown events.
3. Apply a boiler start up and shutdown programmer troubleshooting guide.

 

Topic 31 Introduction to Process Computer Applications

Learning Outcome

Describe the major components of process computers, their basic functions and the types of tasks performed by the computer systems.

Learning Objectives

1. Define the types of computer systems, components and peripherals used in process control.
2. Describe basic computer working principles.
3. Describe the application of computers to process control.

Topic 32 Cast Iron Sectional and Modular Boilers

Learning Outcome

Describe cast iron boilers and explain their uses.

Learning Objectives

1. Describe the general construction and the advantages of cast‐iron sectional heating boilers over watertube and firetube boilers.
2. Describe the arrangement of equipment in a multiple, cast‐iron sectional boiler heating plant.
3. Describe the construction and operation of cast‐iron modular heating boilers.

 

Topic 33 Oil Burners for Heating Boilers

Learning Outcome

Describe the various oil burners used on heating boilers.

Learning Objectives

1. Describe air, steam and mechanical oil atomizing burners for boilers.
2. Describe the auxiliary equipment needed for an oil combustion system.
3. Describe the design and operation of fuel oil systems, including storage.

 

Topic 34 Gas Burners for Heating Boilers

Learning Outcome

Describe the operation of the various types of gas burners used on heating boilers.

Learning Objectives

1. Describe the operation of various types of gas burners.
2. Describe the construction and operation of automatic gas valves.

 

Topic 35 Basic Fittings for Low Pressure Steam Boilers

Learning Outcome

Describe, and explain the operating principles of pressure gages and safety valves found on low‐pressure steam boilers.

Learning Objectives

1. Describe the code requirements for pressure gages on low‐pressure steam boilers.
2. Describe the code requirements for the boiler connections and valves on low‐pressure steam boilers.

 

Topic 36 Basic Fittings for Hot Water Boilers

Learning Outcome

Describe the purpose and operating principles of basic boiler fittings on hot water boilers.

Learning Objectives

1. Describe the code requirements for the required fittings on hot water heating boilers.
2. Discuss the types of non‐required fittings that are used on hot water heating boilers.

 

Topic 37 Hot Water and Steam Heating Boiler Operation

Learning Outcome

Describe the specific safe and efficient operational procedures that relate to automatically‐fired, low‐pressure hot water and steam heating boilers.

Learning Objectives

1. Describe the general preparation and start‐up of a hot water heating boiler.
2. Describe the operation of a hot water heating boiler under routine conditions, including removal from service.
3. Describe the preparation, start‐up, routine operation and removal from service of a steam heating boiler.

Topic 38 Heating Boiler Feedwater Controls

Learning Outcome

Describe the various feedwater control methods and devices used on low‐pressure steam boilers.

Learning Objectives

1. Describe the operation of a feedwater float switch operating a valve and a pump.
2. Describe how condensate is collected and returned to the boiler.
3. Explain the purpose and function of heating boiler feedwater and condensate piping connections.

 

Topic 39 Heating Boiler Operating Controls

Learning Outcome

Name and describe the various operating controls found on low‐pressure heating boilers.

Learning Objectives

1. Discuss the various operating controls for low‐pressure steam and hot water heating boilers.
2. Describe the operation of the control and safety switches found on the fuel supplies of low‐pressure heating boilers.
3. Explain the required testing and maintenance of boiler controls.

 

Topic 40 Heating Boiler Combustion Controls

Learning Outcome

Explain the design and operation of various combustion controls on heating boilers.

Learning Objectives

1. Describe the construction and operation of heating boiler flame failure detectors.
2. Describe the testing of hot water heating boiler flame failure safety devices.

Topic 41 Powerhouse Maintenance I

Learning Outcome

Describe the safe use of common hand tools in the powerhouse.

Learning Objectives

1. List the general safe working practices identified by the Workers’ Compensation Board.
2. Describe the types and proper use of hacksaws, files, chisels, hammers, screwdrivers and wrenches.
3. Describe the types and proper use of hand threading tools.
4. Describe the types and proper use of measuring tools.
5. Describe the proper layout of work and the use of layout tools.
6. Describe the types and proper use of portable and fixed grinders, hand drills, drill presses and the care of drill bits.

 

Topic 42 Powerhouse Maintenance II

Learning Outcome

Discuss and describe the safe and proper setup of equipment for hoisting and working above ground.

Learning Objectives

• Describe the requirements for setting up work platforms in general and ladders and scaffolding in particular.
• Describe the general safety precautions and calculations used when rigging equipment.
• Describe the general safety precautions used when hoisting equipment.

 

Topic 43 Powerhouse Maintenance III

Learning Outcome

Discuss the designs and safe applications and attachment of lifting cables and ropes, and the designs and uses of metal fasteners.

Learning Objectives

1. Discuss the correct use and limitations of wire cable and rope, including cable attachments and rope knots.
2. List and describe common types of metal fasteners, such as screws, bolts, studs, nuts and washers.

 

Topic 44 Boiler Maintenance‌

Learning Outcome

Describe the service and maintenance required for boilers.

Learning Objectives

1. Describe the general maintenance and servicing of packaged firetube and cast‐iron sectional boilers.
2. State the procedures to be followed for wet and dry boiler lay‐ups.
3. Describe the causes and symptoms of a leaking firetube and the procedure for removing a firetube fromservice.
4. Describe two methods of detecting cracks in firetube ends and tube sheets.
5. Describe the general procedure for the removal and replacement of a defective firetube.

 

Topic 45 Boiler Cleaning

Learning Outcome

Discuss the procedure for preparing a boiler for inspection and cleaning, and describe mechanical and chemical boilercleaning methods.

Learning Objectives

1. List the steps and precautions to be taken to prepare a boiler for inspection.
2. Describe the internal inspection of a boiler.
3. Describe the methods and tools used for mechanical cleaning of a boiler.
4. Describe two methods used for the chemical cleaning of a boiler.