About the Boiler & Steam System Management Course

Time Training Center’s 5-day, 30-hour Boiler & Steam System Management course offers comprehensive insights into boiler design, operation, and performance optimisation. It provides theoretical knowledge and practical tools to cut operating costs, boost energy performance, and enhance safety across diverse plant setups.

The course uses a hands-on, application-based approach, covering all steam and condensate system components, including fuel combustion, burner efficiency, steam traps, and waste heat recovery. You can gain in-depth knowledge of performance evaluation, system integration, and troubleshooting techniques to improve plant reliability and performance. Emphasis is placed on identifying inefficiencies, implementing energy-saving strategies, and utilising advanced monitoring tools.

Through expert-led sessions, interactive workshops, and case studies, our course teaches standard plant calculations and boiler safety standards. You will learn 60+ proven methods to enhance boiler plant performance, reliability, and energy efficiency, enabling you to develop and implement effective optimisation plans.

Boiler & Steam System Management Course Objectives

​By the end of this Boiler & Steam System Management training course, participants will be able to:​

• Develop a comprehensive understanding of boiler and steam system components and their interdependencies.
• Conduct boiler performance assessments and identify inefficiencies through tuning and troubleshooting techniques.
• Apply effective strategies for energy savings using waste heat recovery systems and evaluate their return on investment.
• Utilise test instruments and data analysis tools to monitor key performance indicators and optimise operations.
• Perform plant-wide standard calculations, including steam flow, enthalpy, combustion efficiency, and boiler rating.
• Identify and address common operational issues related to steam distribution systems, including pressure drops, leaks, and losses.
• Assess and maintain the effectiveness of steam traps to reduce energy wastage and improve process efficiency.
• Apply boiler safety standards and implement effective control systems for safe, automated operations.
• Integrated computer-based solutions and software tools to reduce costs and enhance decision-making in boiler operations.
• Evaluate the impact of emissions and implement pollution control measures in compliance with environmental regulations.
• Identify 60+ proven methods to improve the overall performance, reliability, and energy efficiency of boiler plants.
• Prepare and implement boiler optimisation plans across various systems, from small industrial setups to large-scale facilities.

Training Methodology

We employ a comprehensive and applied learning strategy, integrating theory with real-world implementation:

• 30% Conceptual Learning: Expert-led sessions on catalytic theory and engineering principles
• 20% Interactive Workshops: Group exercises, presentations, and technical discussion forums
• 30% Case-Based Learning: Industry-specific examples and troubleshooting scenarios
• 20% Technology Integration: Digital tools, simulations, and catalyst modeling applications

Note: Instructors may adjust the training approach to fit technical requirements or participant engagement levels.

Course Instructor:

Our courses are delivered by highly qualified instructors with extensive experience in both industry and academia. With decades of hands-on expertise across a wide range of technical disciplines, our instructors are dedicated to providing high-quality, impactful training that equips participants with practical knowledge and skills they can immediately apply. Full instructor profiles are available upon request.

Course Fees

The course fee includes the following:

• Course Materials: Comprehensive participant materials, including lecture notes, slides, and case study documents. (Tablet or IPAD)
• Coffee/Tea: Provided on arrival and during morning and afternoon breaks to keep participants refreshed.
• Buffet Lunch: Served daily to ensure participants have an opportunity to network and recharge during lunch breaks.

Who Should Attend Our Boiler & Steam System Management Course?

This training course is highly beneficial for professionals involved in the operation, maintenance, and optimisation of boiler and steam systems, including:

• Facilities Engineers
• Operating Engineers
• Energy Engineers
• Maintenance Engineers
• Plant Managers and Supervisors
• System Designers and Inspectors
• Technical Consultants and Auditors

Course Outline

Module 1: Boiler System Tuning and Optimisation

• Pre-test assessment of existing knowledge
• Boiler components and performance indicators
• Step-by-step boiler tuning procedures
• Combustion adjustment techniques
• Indicators of inefficiency and energy losses
• Fuel types and their effect on combustion

Module 2: Troubleshooting and Operational Challenges

• Diagnosing boiler faults and failure modes
• Pressure, temperature, and flow abnormalities
• Burner malfunction, fouling, and water-side scaling
• Root cause analysis techniques
• Real-world troubleshooting scenarios

Module 3: Waste Heat Recovery Techniques

• Fundamentals of heat recovery systems
• Economizers, air preheaters, and condensate recovery
• Waste heat recovery steam generators (WHRSG)
• Energy recovery calculations and ROI assessments
• Integration with existing plant equipment

Module 4: Instrumentation and Cost-Saving Technologies

• Using test instruments for performance monitoring
• Steam quality testing, flow metering, and infrared thermography
• Computer-based optimization tools and software
• Case studies: Using technology to reduce fuel and water costs
• Maintenance strategies supported by diagnostics

Module 5: Plant Calculations & Boiler Performance Analytics

• Steam generation and enthalpy calculations
• Heat balance and efficiency computations
• Combustion air requirement calculations
• Boiler rating, blowdown rate, and feedwater analysis
• Energy loss diagnostics through mass-energy balances

Module 6: Boiler Plant Safety and Control Systems

• Boiler code requirements and safety standards
• Pressure relief systems and interlocks
• Control system types: on-off, modulating, flame safeguard
• Alarm systems and automatic shutdown protocols
• Operational best practices to ensure plant safety

Module 7: Steam Distribution, Traps, & System Losses

• Piping layouts, pressure drops, and condensate return
• Common issues in steam distribution networks
• Types of steam traps: types, their functions, and their diagnostics
• Trap testing, maintenance, and replacement criteria
• Condensate contamination and recovery options

Module 8: Environmental Compliance and Pollution Control

• Boiler emissions and regulatory requirements
• SOx, NOx, and CO2 reduction strategies
• Flue gas analysis and emissions monitoring systems
• Low-NOx burners and other emission control technologies
• Sustainable steam systems and ESG compliance

Module 9: System Optimisation & Performance Improvement

• 60 proven techniques for plant improvement
• Boiler efficiency checklists and audits
• Integrated system optimisation (boiler, distribution, return)
• Long-term energy management strategies
• Benchmarking and KPI tracking for continuous improvement

Module 10: Case Studies & Practical Implementation

• Real-life boiler failure and optimization case studies
• Hands-on performance improvement plan development
• Troubleshooting simulations and best-practice reviews
• Custom problem-solving workshops based on participant needs

Module 11: Capstone and Assessment

• Review of Core Topics and Key Learnings
• Final Group Discussion and Q&A
• Post-Test Evaluation
• Certificate Presentation

Course Completion Certificate

Upon completing your course at Time Training Center, you will be awarded an official Course Completion Certificate, recognising your achievement and the skills you've gained. This certificate validates your expertise and reflects the high standards of training you've undergone.