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01Thermodynamics Fundamentals 02Boiler Fundamentals 03Boiler Components and Mountings 04Fuels and Combustion 05Water Treatment 06Boiler Operation 07Steam Distribution 08Steam Traps and Condensate 09Heat Transfer and Process Heating 10Instrumentation and Controls 11Safety, Law and Environment 12Efficiency, Maintenance and Troubleshooting

01 · Thermodynamics Fundamentals

Heat and Energy

Units and temperature scales Sensible heat Latent heat Enthalpy Laws of thermodynamics Entropy

Saturation pressure and temperature Wet, dry and superheated steam Dryness fraction Reading steam tables Specific volume Flash steam

Steam Properties

Thermodynamics Fundamentals

Heat and Energy

Units and temperature scales Sensible heat Latent heat Enthalpy Laws of thermodynamics Entropy

Steam Properties

Saturation pressure and temperature Wet, dry and superheated steam Dryness fraction Reading steam tables Specific volume Flash steam

03 · Boiler Components and Mountings

Pressure Parts and Heat Recovery

Shell and drums Furnace and tubes Superheater Economizer Air preheater Refractory

Safety valves Water level gauge Pressure gauge Main steam stop valve Feed check valve Blowdown valve Fusible plug

Mountings and Fittings

Boiler Components and Mountings

Pressure Parts and Heat Recovery

Shell and drums Furnace and tubes Superheater Economizer Air preheater Refractory

Mountings and Fittings

Safety valves Water level gauge Pressure gauge Main steam stop valve Feed check valve Blowdown valve Fusible plug

04 · Fuels and Combustion

Fuels

GCV vs NCV Coal and lignite Biomass fuels Oil and gas Moisture and ash Fuel storage and handling

Air–fuel ratio Excess air Flue gas analysis Grate firing Fluidized bed combustion Burners and flame safety

Combustion

Fuels and Combustion

Fuels

GCV vs NCV Coal and lignite Biomass fuels Oil and gas Moisture and ash Fuel storage and handling

Combustion

Air–fuel ratio Excess air Flue gas analysis Grate firing Fluidized bed combustion Burners and flame safety

05 · Water Treatment

Feedwater

Raw water quality Softeners and RO Deaeration Feedwater temperature

Scale and its cost Corrosion and oxygen pitting TDS control and blowdown Chemical dosing Priming and carryover Daily water tests

Boiler Water

Water Treatment

Feedwater

Raw water quality Softeners and RO Deaeration Feedwater temperature

Boiler Water

Scale and its cost Corrosion and oxygen pitting TDS control and blowdown Chemical dosing Priming and carryover Daily water tests

06 · Boiler Operation

Start-up and Shutdown

Pre-start checks Cold start and warm-up Raising pressure Load changes Normal shutdown Emergency shutdown and banking

Log sheets Water level control Blowdown practice Draft control Reading the stack Shift handover

Daily Operation

Boiler Operation

Start-up and Shutdown

Pre-start checks Cold start and warm-up Raising pressure Load changes Normal shutdown Emergency shutdown and banking

Daily Operation

Log sheets Water level control Blowdown practice Draft control Reading the stack Shift handover

07 · Steam Distribution

Steam Mains

Sizing by velocity Pressure drop Drainage and drip legs Warm-up load Expansion and supports Insulation

Isolation valves Pressure reducing valves Control valves Separators and strainers Air vents Safety relief on the distribution side

Valves and Pressure Control

Steam Distribution

Steam Mains

Sizing by velocity Pressure drop Drainage and drip legs Warm-up load Expansion and supports Insulation

Valves and Pressure Control

Isolation valves Pressure reducing valves Control valves Separators and strainers Air vents Safety relief on the distribution side

08 · Steam Traps and Condensate

Steam Traps

Why traps exist Mechanical traps Thermostatic traps Thermodynamic traps Trap sizing Testing and failure modes

What condensate is worth Flash steam and flash vessels Return line sizing Condensate pumps Water hammer Contamination

Condensate Recovery

Steam Traps and Condensate

Steam Traps

Why traps exist Mechanical traps Thermostatic traps Thermodynamic traps Trap sizing Testing and failure modes

Condensate Recovery

What condensate is worth Flash steam and flash vessels Return line sizing Condensate pumps Water hammer Contamination

09 · Heat Transfer and Process Heating

Heat Transfer

Conduction, convection and radiation U-value and LMTD Fouling Heat loss from pipes Choosing a heating medium

Shell and tube exchangers Plate exchangers Jacketed vessels and coils Direct steam injection Dryers and hot air Stall

Heat Exchangers and Users

Heat Transfer and Process Heating

Heat Transfer

Conduction, convection and radiation U-value and LMTD Fouling Heat loss from pipes Choosing a heating medium

Heat Exchangers and Users

Shell and tube exchangers Plate exchangers Jacketed vessels and coils Direct steam injection Dryers and hot air Stall

10 · Instrumentation and Controls

Measurement

Pressure measurement Temperature measurement Level measurement Steam flow metering Conductivity and TDS Flue gas oxygen

On-off vs modulating PID basics Level control elements Firing-rate control Interlocks and trips Burner management

Control and Protection

Instrumentation and Controls

Measurement

Pressure measurement Temperature measurement Level measurement Steam flow metering Conductivity and TDS Flue gas oxygen

Control and Protection

On-off vs modulating PID basics Level control elements Firing-rate control Interlocks and trips Burner management

11 · Safety, Law and Environment

Indian Boiler Law

Boilers Act 2025 IBR 1950 IBR vs non-IBR Registration and certificates Inspection and hydro test Accidents and reporting Boiler attendant certification

Stack emission norms Particulate control Stack height Carbon market (CCTS)Ash handling and disposal Consent to operate

Emissions and Environment

Safety, Law and Environment

Indian Boiler Law

Boilers Act 2025 IBR 1950 IBR vs non-IBR Registration and certificates Inspection and hydro test Accidents and reporting Boiler attendant certification

Emissions and Environment

Stack emission norms Particulate control Stack height Carbon market (CCTS)Ash handling and disposal Consent to operate

12 · Efficiency, Maintenance and Troubleshooting

Efficiency and Audits

Efficiency testing Cost of steam Blowdown heat recovery Economizer and APH payback Condensate and flash recovery Insulation economics

Preventive maintenance schedule Annual inspection preparation Tube failures Low efficiency diagnosis Pressure not building Carryover and water hammer diagnosis

Maintenance and Troubleshooting

Efficiency, Maintenance and Troubleshooting

Efficiency and Audits

Efficiency testing Cost of steam Blowdown heat recovery Economizer and APH payback Condensate and flash recovery Insulation economics

Maintenance and Troubleshooting

Preventive maintenance schedule Annual inspection preparation Tube failures Low efficiency diagnosis Pressure not building Carryover and water hammer diagnosis

A Free Boiler Engineering Course, From Steam to Troubleshooting

01 · Thermodynamics Fundamentals

Thermodynamics Fundamentals

Heat and Energy

Steam Properties

02 · Boiler Fundamentals

Boiler Fundamentals

How a Boiler Works

Boiler Types

03 · Boiler Components and Mountings

Boiler Components and Mountings

Pressure Parts and Heat Recovery

Mountings and Fittings

04 · Fuels and Combustion

Fuels and Combustion

Fuels

Combustion

05 · Water Treatment

Water Treatment

Feedwater

Boiler Water

06 · Boiler Operation

Boiler Operation

Start-up and Shutdown

Daily Operation

07 · Steam Distribution

Steam Distribution

Steam Mains

Valves and Pressure Control

08 · Steam Traps and Condensate

Steam Traps and Condensate

Steam Traps

Condensate Recovery

09 · Heat Transfer and Process Heating

Heat Transfer and Process Heating

Heat Transfer

Heat Exchangers and Users

10 · Instrumentation and Controls

Instrumentation and Controls

Measurement

Control and Protection

11 · Safety, Law and Environment

Safety, Law and Environment

Indian Boiler Law

Emissions and Environment

12 · Efficiency, Maintenance and Troubleshooting

Efficiency, Maintenance and Troubleshooting

Efficiency and Audits

Maintenance and Troubleshooting