Steam Engineer Preparatory Course

Steam Engineer Preparatory Course

Boiler operation requires a competent person to be operated and monitored by a steam engineer and boiler man as prescribed in Malaysian Regulations. Based on the Factory and Machinery Act, every certificated machinery requires a competent person, where process and operation safety are an important element to ensure the machine is in good operating condition.

Steam Engineer Grade 1 must understand the elements below.

Section 1 - Acts, Regulations and Standards

1. Occupational Safety and Health Act 1994 (OSHA 1994) and Regulations
2. OSHA 1994 Amendments
3. Occupational Safety and Health (Use and Standard of Exposure Chemical Hazardous to Health) Regulations 2000 (USECHH Regulations)
4. Industry Code of Practice 
1. The Industry Code of Practice For Safe Working In A Confined Space 2010
2. Industry Code of Practice for Management of Occupational Noise Exposure and Hearing Conservation 2019
5. Guidelines
1. Guidelines On Heat Stress Management At Workplace 2016
2. Guidelines On Ergonomics Risk Assessment At Workplace 2017
6. Other related rules and regulations
7. Steam engineer roles and responsibilities.
8. Plant safety, management and maintenance policy
9. Boiler house management

Section 2 - Boiler Design

1. Applicable codes & standards
2. Steam plant conceptual design
3. Boiler design
4. Boiler component
5. Parts, essentials fittings and safety devices

Section 3 - Boiler Operation

1. Fundamental operational responsibilities
2. Starting cold boiler (Precaution - Furnace explosion, Dust explosion)
3. Connecting of more than one boiler
4. Operating under emergency situations, idling procedure and maintenance (tubes, shell, drums, headers, superheater, economiser, furnace, air heater, pumps, fans, and stacks)
5. Uses of low pressure steam and hot water boiler for process heating
6. Special type of boiler for high pressure and temperature steam
7. Steam management
8. Boiler efficiency and burner efficiency

Section 4 - Inspection, Maintenance, Repair and Alteration

1. Boiler defect & potential root cause
2. Materials, creep and fatigue, corrosion and control
3. Welding and welding mechanical failure
4. Non-destructive examination or non-destructive test

Section 5 - Machine Integrity

1. Fit for services
2. Process safety management elements