Learn Boiler Operation Skills in 2-Years

Boiler Operator (2-Years) 1
TRAINING OBJECTIVES
This program has been designed to give the attendee a broad introduction to the
most common and important components, principles, and concepts used in boiler
systems. Safe operation practices and boiler efficiency issues will be discussed, as
well as the rules and regulations that govern the workplace. The Trainee will learn
how to perform proper maintenance procedures for the system and how to conduct
vessel inspections. The topics presented in this course are designed to help the
trainee become a better operator, troubleshooter, and maintenance technician.
Upon completion of this course, the passouts will have a solid knowledge of basic
boiler systems, the components and accessories used in these systems, how and
why boiler systems work, and an understanding of present dangers if not operating
the system safely.
CURRICULUM SALIENT’S
Entry Level Matric with Science having 2nd Division
Duration of course 2 – Years
Total Training Hours 3200
Training Hours Per Day 7 Hours Per Day
5 Hours Friday
Training Hours Per Week 40 Hours
Training Methodology Practical 80%

Theory 20%
Medium of Instruction: English / Urdu

Boiler Operator (2-Years)
SKILL PROFICIENCY DETAILS: -
After completion of course the trainees will be able to:
 Recognize the different electrical components used in electricity.

 Use the analog and digital instruments for taking measurements.
 Perform the chipping and cutting operations by using different tools.
 Weld the different jobs by using ARC & Gas welding techniques.
 Prepare different joints by using brazing.
 Operate the steam generation equipment and control the process.
 Perform the different machine operations like thread cutting, forging, riveting etc.
 Perform the different hydraulic test, steam test, destructive & non destructive
steam generation.
 Operate the different mechanical machines used in the mechanical workshop for
preparation of different jobs.
 Inspect the whole process of steam generation including boiler and other
equipments.
 Take the measurements by using different measuring instruments i.e Micrometer
& Gauges.
 Perform the grinding operations by considering ISO Fits & Tolerance.
 Draw the different views of different objects as per technical drawing
requirements.
 Draw the different shapes relating to the technical drawing.
 Draw the different objects by using 1st angle & 2nd angle projection method.
 Make the drawings of different models by using the CAD, 2-D / 3-D concepts.
 Prepare the different drawings through computer aided design (CAD).
 Calculate the volume of parallel, engineering solids.
 Solve the problems relating to the technical math.
 Take the measurements of different angles.
 Calculate the surface areas of different shape objects.
 Calculate the area of composed figures, volume, quantity of liquid and weights.
Page 2 of 43
KNOWLEDGE PROFICIENCY DETAILS
After completion of course the trainees will be able to:
 Understand the whole process of steam generation-I at an ordinary stage.

 Enumerate the different types of the boilers.
 Explain the working principle of boiler.
 Explain the electricity pertaining to DC fundamentals, Transformers, power
factors and instruments.
 Understand the basic technological aspects required for initial work.
 Learn about the Gas and ARC welding along with brazing.
 Learn about steam generation-II including design factor and material.
 Learn thread cutting, riveting, forging, iron and steel.
 Explain the steam generation-III.
 Describe the pipe fitting, fastening and lathe machine operations.
 Know how to perform boiler inspections, boiler material, boiler fuels, boiler
operations and safety appliances.
 Understand measuring, sheet metal work, grinding, fits and tolerance.
 Describe the basic technical terminologies used in technical drawings.
 Know the dimensioning, views, tolerance and measuring of sizes.
 Understand the first and third angle projection, drawing of difficult models and
CAD 2-D / 3-D concepts.
 Understand the basics of technical math i.e. whole numbers, fractions, decimal
system of measuring, percentage, average and surface area etc.
 Describe the volumes, quantity and weight.
 Calculate the equations and surface area.
 Calculate the volumes, weight and area of composed figures.
Page 3 of 43
Curriculum Delivery Structure
1ST SEMESTER
Curriculum Co- curricular
Test Total
Delivery activities / Vacations
1-20 21-25 26
Week
26
20 5 1
2ND SEMESTER
Test Total
1-20 21-25 26
Week
26
20 5 1
3RD SEMESTER
Test Total
1-20 21-25 26
Week
26
20 5 1
4TH SEMESTER
Curriculum Co- curricular Final
Total
Delivery activities / Vacations Test
1-20 21-25 26
Week
26
20 5 1
Page 4 of 43
SCHEME OF STUDIES
1st SEMESTER
Sr. Theory Practical Total
Main Topics
No Hours Hours Hours
1. Steam Generation – I 40 200 240
2. Technical Mathematics – I 20 - 20
3. Technical Drawing and Drafting– I 20 - 20
4. Electrical – I 20 200 220
5 Workshop Practice – I 40 200 240
6 Functional English 20 20 40
7 Work Ethics - 20 20
Total 160 640 800
2nd SEMESTER
Sr. Theory Practical Total
Main Topics
No Hours Hours Hours
1 Steam Generation-II 40 200 240
2 Technical Drawing and Drafting-II 20 - 20
3 Technical Mathematics-II 20 - 20
4 Workshop Practice – II 40 200 240
5 Welding-I 20 200 220
Total 160 640 800
Page 5 of 43
3rd SEMESTER
Theory Practical Total
Sr.No Main Topics
Hours Hours Hours
1 Steam Generation-III 30 140 170
2 Water Treatment-I 30 160 190
3 Plumbing & Pipe fitting 20 100 120
4 Welding-II 10 100 110
5 Workshop Practice–III 10 100 110
6 Technical Mathematics-III 20 - 20
7 Technical Drawing & Drafting-III 20 - 20
Total 160 640 800
4th SEMESTER
Theory Practical Total
Sr.No Main Topics
Hours Hours Hours
1 Steam Generation-IV 40 165 205
2 Water Treatment-II 40 155 195
3 Industrial Boiler Automation 30 145 175
4 Workshop Practice – IV 10 135 145
5 Technical Mathematics-IV 10 - 10
6 Technical Drawing & Drafting-IV 10 - 10
Total 160 640 800
Page 6 of 43
st
1 Semester
Page 7 of 43
DETAIL OF COURSE CONTENTS

Boiler Operator (2 – Years)
1st Semester
Steam Generation-I
Sr. Theory
Detail of Topics Hours
No.
1. Explain Boiler 5
2. Types of Boiler 15
2.1 Vertical Boiler
2.2 Lancashire Boiler
2.3 Locomotive Boiler
2.4 Cochran Boiler
2.5 Scoth Marine
2.6 Package type Boiler
2.7 Water Tube Boiler
2.8 Parallel Drum Boiler
2.9 Straight Tube boiler
2.10 Bend Tube Boiler
3. Working Principle of Boiler 20
Total 40
Sr.
Practicals Hours
No.
1 Boiler operator 10
2 Gases route of boiler (different boilers) 10
3 Water back / dry back boiler 10
4 Water tube boiler working / routes 10
5 Ignition rod setting 20
6 Lead play clearing / filling 10
7 Gauge glass fitting steam cock water cock 20
8 Gauge glass / washer fitting 20
9 Pressure gauge reading / working 10
10 Temperature gauge reading 10
11 Feed check valve fitting / working 20
12 Stop valve working / fitting 20
13 Blow down valve working / fitting 15
14 Safety valve working setting (different types) 15
Total 200
Page 8 of 43
Technical Mathematics-I
Sr. Theory Practical

Detail of Topics Hours Hours
No.
1. Whole Number
1.1 Addition, Subtraction 03
1.2 Multiplication and Division
2. Fractions
2.1 Addition Subtraction of common Fraction
2.2 proper Fraction, Multiplication and Division of 03
Fraction
3. Decimal System of Measuring

3.1 F.P.S, C.G.S, M.K.S, S.I units system
3.2 Conversion of System
03
(F.P.S to M.K.S to C.G.S, M.K.S to S.I etc) to
each other
4. Percentage
4.1 Calculation of Percentage
4.2 Changing the Decimal to Percentage
4.3 Changing the Percentage to Decimal and
03
Common Fraction
4.4 Calculation of Rate, the Base and the
Percentage
5. Angles
5.1 Angle Measurement and its Units System
(Degree, Minute, Second)
5.2 Types of Angles (Acute, Right, Obtuse,
04
Straight, Reflex, Full)
5.3 Calculation of Angles
5.4 (Addition, Subtraction, Multiplication Division)
Page 9 of 43
6. Surface Area-I
6.1 Surface Area of Square, Rectangle, Triangles
etc
04
6.2 Calculation Area of Trapezium
6.3 Area of Circle, Semi Circle, and Sector of
Circle.
Total 20
Technical Drawing and Drafting-I

No.
1 1.1 Introduction to Technical Drawing 01
1.2 Kinds of Lines 01
1.3 Drawing Instruments 01
1.4 Lettering 02
1.5 Views (introduction and Types) 02
1.6 Representation in Three Views 02
1.7 Assembling Bodies 02
1.8 Completion of Views Visible Edges 02
1.9 Work Pieces with Cover Edges 02
1.10 Dimensioning 01
1.11 Draw True Scale 02
1.12 Drawing of Circle and Radius 02
Total 20
Page 10 of 43
Electrical
No.
1. DC Fundamentals 4 30
1.1 Ohm’s Law
1.1.1 Definition of Ohm’s Law
1.1.2 Problems of Ohm’s Law
1.2 Laws of Restriction
1.2.1 Specific Resistance and Conductivity
1.3 Effects of Temperature on Resistance
and Temperature Coefficient of
Resistance
1.3.1 Problem on R=p*L/A and Rt =Ro (1+at)
1.3.2 Resistance in series, Parallel and series
Parallel
1.3.3 Calculations on combination of resistance
and cells in series, parallel and series-
parallel combinations
1.3.4 Power and Energy their units and
calculations
1.3.5 Power dissipation in Resistors
1.4 Batteries
1.4.1 Types of DC sources
1.5 Brakers / Types
1.5.1 AC Current
1.5.2 DC Current
1.6 Single Phase Motor
1.7 Three Phase Motor
2. Transformer
2.1 Principal of Transformer, Manual Indicator
Coefficient of Mutual Inductance
4 60
2.2 Various System of Power Transmission
2.2.1 DC System
2.2.2 DC Two Wire
Page 11 of 43
2.2.3 DC Three Wire

2.2.4 Single Phase AC System
2.2.5 Single Phase Two Wire
2.2.6 Single Phase Three Wire
2.2.7 Three Phase Three Wire
2.2.8 Three Phase Four Wire
3. Power Factor
3.1 Insulators
3.1.1 Insulator Materials
3.1.2 Types of Insulators
3 50
3.2 Conductors
3.2.1 Introduction
3.2.2 Types of Conductors With Respect Material
3.2.3 Conductor Advantages
4. Under Ground Cables
4.1 Types of Cables 3 20
4.2 Construction of Cables
5. Digital Instruments
5.1 Digital Voltmeter 3 20
5.2 Digital Multimeter
6. Miscellaneous Test Instruments
6.1 Wattmeter, Electro-Dynamometer Type
3 20
6.2 Energy Meter, Induction Type
6.3 Watt Meter, RF
Total 20 200
Workshop Practice-I
No.
1. Introduction of Work Shop, Work Place Tools
1.1 Work Shop, Work Place, Tools
1.2 Characteristics of Metal 5 20
1.3 Work Shop Tools
1.4 Power
1.5 Machine Power
Page 12 of 43
2. Measuring-1
2.1 General Introduction
2.2 Units Steel Rule (Length +Angle)
2.3 Calipers, Gauges 20
5
2.4 Vernier Caliper
2.5 Micro-meter
2.6 Care of Instruments
3. Hand Operation Technicque-1
3.1 Marking
3.2 Chipping and Cutting
3.3 Sawing
3.3.1 Chiseling 10
80
3.3.2 Shearing
3.3.3 Filling
3.3.4 Scraping
3.3.5 Tapping
3.3.6 ISO-Fits
4. Drill Machine Operation Techniques
4.1 Drilling (Types)
4.2 Counter Sinking
10 50
4.3 Counter Boring
4.4 Reaming
4.5 Tapping by Machine
5. Fastening Methods
5.1 Introduction of Fastening
5.2 Joining of Parts with Screw
5.3 Types of Screw
30
5.4 Riveting 10
5.5 Size of Screw, Bolt and Nut
5.6 Thread Cutting Tools
5.7 Types of Threads
Total 40 200
Page 13 of 43
nd
2 Semester
Page 14 of 43
2nd Semester
Steam Generation-II
Sr. Theory
Detail of Topics
No. Hours
1. Define /Explain Steam 4
2. Types of Steam 4
3. Boiler Stays 4
4. Boiler Mounting Fitting & Auxiliaries 10
4.1 Safety Valve
4.2 Blow Down Valve Types /Working Principal
4.3 Feed Check Valve
4.4 Lead Plug
4.5 Super Heater
4.6 Super Heater Types
4.7 Advantages / Disadvantages
4.8 Design Factors
5. Economizer 8
6. Types /Design Factors / Material 10
6.1 Soot Blower
6.2 Types /Soot Blowing Methods /Safety
Precautions
6.3 Air Preheater
6.4 Attemperator
6.5 Steam Traps Types
Total 40
Sr.
Practical’s Hours
No.
1 Boiler Burner Working / Operation 30
2 Gas Regulatory Valve Working / Setting / Fitting 40
3 Gas Slow Opening Valve Working / Fitting 30
4 Gas Pressure Switch / Air Pressure Switch Working 30
5 Pump Fitting 40
6 Gland Packing Of Different Valves 30
Total 200
Page 15 of 43
Technical Drawing-II
No.
1. 1.1 Inclined Surface 20
1.2 Cylindrical Work Pieces
1.3 Centre line Dimensioning
1.4 Draw Three Views
1.5 Surface Symbols
1.6 Assembling of Two Parts
1.7 Tolerance (entry of Tolerance in Drawing)
1.8 Measuring of Sizes
Total 20
Technical Mathematics-II
No.
1. Pythagorean Proposition 4
1.1 Definition
1.2 Derivation of Formula
1.3 Practice of Solving Problems
2. Calculating Area of Composed Figures 4

2.1 Calculating Area and Perimeter of Composed
Figures
3 Volume 4
3.1 Volume and Units of Volume
3.2 Volume of Solids and Hollow Objects
3.3 Calculation of Volume of Cone and Pyramid
3.4 Volume of Composed Engineering Solids
4 Quantity of Liquids 4
4.1 Units of Liquids
4.2 Calculating Quantity of Liquid in Containers
4.3 Practice of Solving the Problems about Volume
and Quantity
Page 16 of 43
5 Weights 4
5.1 Weight and Its Units
5.2 Specific Gravity
5.3 Calculating the Weight on the Basis of Volume
5.4 Calculating the Weight on the Basis of Length,
Area and Thickness
5.5 Practice of Solving the Problems
Total 20
Workshop Practice-II
No.
1. Thread Cutting by Hand
1.1 Methods of Cutting Threads
(External and Internal Threads)
1.2 Threading Tools (Tap, Die)
1.3 Selection of Core and Out Side Diameter. 6 30
1.4 Clamping of Taps and Dies
1.5 Pipe Die
1.6 Cutting , Measuring and Checking of Threads
2. Riveting
2.1 Process of Riveting
2.2 Effects of Up-Setting 6
2.3 Types of Rivet and their Uses 30
2.4 Types of Riveted Joints
2.5 Standardization of Rivet
2.6 Riveting Tools
3. Forging by Hand
3.1 Forging Process
3.2 Up Setting of Material
3.3 Fire Required Purging
30
3.4 Energy (Kinetic Energy) 7
3.5 Forging Tools
(Anvil, Swag Block, Hammers, Tongs)
3.6 Handling of Fire
Page 17 of 43
3.7 Burning Process

3.8 Selection and Blowing of Hammer
3.9 Cutting the Material of the Job
3.10 Drawing Down, Up-Setting, Bending and
Punching.
4. Fastening Methods (Permanent) Gas Welding
4.1 Gas Welding Process
4.2 Melting and Solidification Process Gases
4.3 Behavior of Gases
4.4 Air Pressure
7
4.5 Gas Welding Equipments 30
(Torch, Cylinders, Regulator)
4.6 Types of Flames
4.7 Burning of Torch
4.8 Preparation of Job
5. Electric Arc Welding

5.1 Electric Arc Welding Process
5.2 Movements of Electric Arc
5.3 Expansion and Shrinkage of Materials
5.4 Electric Arc Welding Equipments 40
7
5.5 Selection of Voltage
5.6 Selection of Electrode
5.7 Testing of Welding Joints
5.8 Safety During Welding
6. Iron and Steel
6.1 Production of Pig Iron
6.2 Blast Furnace
40
6.3 Ferrous and Non- Ferrous Metals and Alloys 7
6.4 Properties of Materials
6.5 Low, Medium and High Carbon Steel and Uses
Total 40 200
Page 18 of 43
Welding ARC &GAS

No.
1. Introduction of Bench Working Tools
1.1 Bench Vice
1.2 Kinds of File
3.1.1 Flat File Rough
3.1.2 Half Round File
3.1.3 Round File
3.1.4 Triangle File 30
3.2 Hammer
2
3.3 Steel Foot Rule
3.4 Scriber
3.5 Centre Punch
3.6 Try Square
3.7 Hand Saw
3.8 Chisel
2. Safety and Holding Bench Working Tools
2.1 Tool Safety
2 20
2.2 Use
2.3 Personal Safety
3. Flat Filing Ex 1
3.1 Flat Filling
2 30
3.2 Squaring
3.3 Sizing
4. Measuring
3.1 Steel Rule
3.2 Vernier Caliper 2 20
3.3 Inside Caliper
3.4 Outside Caliper
5. Welding Defects
2 20
Total 10 120
Page 19 of 43
Brazing

No.
1. Brazing
1.1 Brazing Process
1.2 Tools and Equipment 2 20
1.3 Type of Splatter
1.4 Type of Flux
1.5 Views Finding
2. Lap Joint Brazing
2.1 Preparation
20
2.2 Practice 3
2.3 Job Safety
3. Butt Joint
3.1 Preparation
3 20
3.2 Practice
3.3 Safety
4. Double Lap Joint 2 20
Total 10 80
Page 20 of 43
rd
3 Semester
Page 21 of 43
3rd Semester
Steam Generation-III
Sr. Theory
No.
1. Hydraulic Test 3
2. Steam Test 3
3. Destructive & Nondestructive Test 4
4. Boiler Pumps 3
5. Feed Water Injector 3
6. Boiler Draught 4
7. Draught Fans 3
8. Oil Heaters /Strainer /Filters 3

Water Treatment
9.1 P.M Plant
9.2 Zeolite Water Softing Plant
9. 4
9.3 R.O Plants
9.4 Boiler Water Treatment Chemicals
9.5 Scale / Sledge /Pitting /Grooving /Corrosion
Total 30
Sr. No. Practicals Hours

1 Tube Welding 20
2 Tube Expanding 10
3 Tube Bedding 10
4 Tube Seal Welding 15
5 Water mobbery float & Prob Rod Setting / Fitting 15
6 Anti Claps Ring Fitting 15
7 Reinforce Ring Fitting 15
8 Admission Ring Fitting 20
9 Wash Out Plug Fitting 20
Total 140
Page 22 of 43
Water Treatment-I
No.
1. 1.1 Water Treatment 30 160
1.1.1 Soft Water
1.1.2 Hard Water
1.1.3 PH Water
1.2 External / internal water treatment
1.2.1 External
1.2.2 Deactivation
1.2.3 Deaeration
1.2.4 Deoxygination
1.2.5 Filtration
1.2.6 Sedimentation
1.2.7 Zeolite water safety plant
1.2.8 DM plant
1.2.9 R.O plant
1.2.10 Lime Water Treatment
1.2.11 Internal Method
1.2.12 Chemical Dosing
1.2.13 Blow Down Method
1.3 Concentration of Solids
1.3.1 Carry over
1.3.1.1 Causes of Carry Over
1.3.1.2 Presentation / Control
1.3.1.3 Disadvantages
1.3.1.4 Primary / Causes
/Prevented
1.3.1.5 Foaming Causes
Presentation
1.4 Steam Purification
1.4.1 Antiprimiry Pipe
1.4.2 Drum Internals
1.4.3 Steam Cyclone
1.4.4 Steam Washing
1.4.5 Steam Scrubbing
Total 30 160
Page 23 of 43
Plumbing & Pipe Fitting

No.
1. 1.1 Advantages / Disadvantages 20 100
1.2 Plastic Pipes
1.3 Ferrous / Non Ferrous Material
1.4 Kinds of Pipes
1.5 Materials, Normal Sizes
1.6 Pressure / Drainage Fittings
1.7 Fitting Specifications
1.8 Properties
1.9 Rust / Corrosion
1.10 Expansion / Heat Resistance
1.11 Definition, Importance of Pipe Symbols
1.12 Threads Tapers, Threads Angle
1.13 Steep Pipes, Cast Iron, Copper Plastic & AC
Pipes
1.14 Installation Supporting
1.15 Hangers and Devices
1.16 Protection of Steel Pipes
1.17 Pipe Fitting Exercise
1.18 Measuring, Marking, Cutting & Reaming
Total 20 100
Page 24 of 43
GAS WELDING
No.
1. Oxyacetylene Equipment & Tools
1.1 Oxyacetylene Cylinders
1.2 Oxyacetylene Gauges
1.3 Rubber Hose Pipes
2 4
1.4 Welding Torch
1.5 Spark Lighter
1.6 Welding Goggle
1.7 Welding Pliers
2. Gas Welding Blind Weld Flat
2.1 Preparation of Job
2.2 Marking 6
2,3 Center Punching
2.4 Gas Welding
3. Double Flanged Butt Weld
3.1 Mark and Cut the Pieces
3.2 Marking 6
3.3 Centre Punching
3.4 Gas Welding
4. Welding Joint
4.1 Square Butt Joint
4.2 Single Vee Butt Joint
4.3 Edge Joint
6
4.4 Bevel Joint
4.5 Tee Joint
4.6 Flange Joint
4.7 Lap Joint
5. Square Butt Joint (FL)
5.1 Preparation
5.2 Tacking 4
5.3 Weld the Pieces with Left Ward Technique
Page 25 of 43
6. Fillet Weld
6.1 Preparation
6.2 Tacking
4
6.3 Practice
6.4 Safety
7. Single V Butt Weld on Pipe

7.1 Preparation
7.2 Rolling Position
5
7.3 Penetration
7.4 Practice
8. Welding Technique
8.1 Left Ward Welding 6
8.2 Right Ward Welding
9. Welding Defects
9.1 Gas Pocket
9.2 Poor Penetration
4
9.3 Under Cuts
9.4 Improper Speed
9.5 Crack
ARC WELDING
No.
1. Introduction of ARC Welding
1.1 Welding Screen/ Helmet
1.2 Leather Apron
1.3 Leather Gloves
1.4 Chipping Hammer
1 5
1.5 Goggles
1.6 Sleeves
1.7 Tong
1.8 Wire Brush
Page 26 of 43
2. Blind Weld Flat

2.1 Preparation
5
2.2 Selection of Current / Striking
2.3 Angle of Electrode
3. Electricity Circuit
2 5
3.1 Volt, Ampere & Resistance
4. Single V Butt Joint
4.1 Preparation
4.2 Tacking
4
4.3 Penetration
4.4 Distortion Control
5. Fillet Weld Flat
5.1 Preparation
5.2 Equal Layers 4
5.3 Multi Layers
5.4 Under Cut Control
6. Transformer 4
6.1 Primary Welding
6.2 Secondary Welding
7. Arc Welding Positions
7.1 Flat, Vertical, Overhead,
4
7.2 Horizontal
7.3 Safety Rules
8. Square Butt Weld Flat
8.1 Preparation
8.2 Speed Control 3 4
8.4 Proper Fusion
8.5 Convex Contour
9. Welding Power Source
9.1 Welding Machine
4
9.2 Transformer
9.3 Rectifier
Page 27 of 43
10 Single V Butt Weld V Up

10.1 Preparation Movement of Root Pass
4
10.2 Movement of Filling Pass
10.3 Movement of Capping Pass
11 Single V Butt Weld (H)
11.1 Preparation
4
10.2 Movement of Electrode
12 Tube on Plate(H)
12.1 Preparation
12.2 Position of Electrode 2 4
12.3 Thin Pipe with Thick Plate
12.4 Control Under Cut
13 Welding Positions
13.1 Welding Position 4
13.2 Flat / Vertical / Horizontal / Over head
Total 10 100
Workshop-III
Detail of Topics
No. Hours Hours
1. Hand Operation Technique 2 25
1.1 Riveting
1.2 Process of Riveting
1.3 Effect of Up-Setting
1.4 Force Acting on Rivet Joints
1.5 Forging
1.6 Alignment of Parts
2. Pipe Fitting 3 25
2.1 Pipe Threading
2.2 Types of Pipes
2.3 Types of Pipe Fitting
2.4 Cutting of Pipe
2.5 Bending of Pipe and Tube
2.6 Flange Coupling Joints
Page 28 of 43
3 Temporary Fastening Method 2 25

3.1 Joining of Parts with Nut and Bolt
3.2 Types of Nut and Bolt
3.3 Motion and Forces at Threads
3.4 Representation of Forces on Threads by
Means of Drawing
4 Lathe Machine Operations 3 25
4.1 Introduction of Centre Lathe
4.2 Types of Lathe Machine
4.3 Turning Operations
4.4 Turning Tools
4.5 Threading Operation (Internal, External)
4.6 Boring Operation
4.7 Knurling Operation
4.8 Taper Turning (Compound Slide + Tail Stock)
Total 10 100
Technical Mathematics-III
No.
1. 1.1 Transposition of Formula 20
1.2 Equation
1.3 Pythagorean Proposition
1.4 Application of Pythagorean Theorem
1.5 Surface Area of Composed Figures
Total 20
Technical Drawing-III
No.
1. 1.1 Identifying the First Angle and Third Angle 20
Projection
1.2 Cavileir Projection
1.3 Types of Projections (Isometric, Diametric,
Oblique)
1.4 Drawing of Riveted Joints
1.5 Welding Symbols
1.6 Drawing of Different Models
1.7 Introduction of CAD (2D/3D Concept) (Basic
Commands)
Total 20
Page 29 of 43
th
4 Semester
Page 30 of 43
4th Semester
Steam Generation-IV
Sr. Theory
No.
1. Boiler Inspection / Cleaning 10
2. Dryness of Friction 4
3. Boiler Material 4
4. Boiler Chimneys 4
5. Boiler Fuels /Combustion /Smoke 4
6. Water Walls 4
7. Boiler Operation 5
8. Safety Appliances 5
Total 40
1 Steam Reducing Valve Working / Setting 25

Dead Weight Tester For Pressure Gauge
2 25
Testing
3 Change The Mechanical Seal Of Pump 25
4 Draught Gauge Reading / Working 20
5 Calorimeters Working / Reading 20
6 Boiler Cleaning / Inspection Method 30
7 Change The Diapharm Of Valves 30
8 Boiler Opening / Closing 30
Total 205
Page 31 of 43
Water Treatment-II
No.
1. 1.1 Corrosion / Pitting 40 155
1.1.1 General Corrosion
1.1.2 Localized Corrosion
1.1.3 Galvanic Corrosion
1.1.4 Stress Corrosion
1.1.5 Inter-granular
1.1.6 Corrosion Fatigue
1.1.7 Oxygen Corrosion
1.1.8 Hide out Corrosion
1.2 Chemical Used For Boiler Water Treatment
1.2.1 Feed Water Test
1.2.2 PH Test
1.2.3 TDS Test
1.2.4 Phosphate Test
1.2.5 Hardness Test
1.2.6 Culphate Test
1.2.7 Alkalinity Test
1.2.8 Chloride Test
Total 40 155
Page 32 of 43
Industrial Boiler Automation

No.
1. 1.1 Programmer 30 145
1.2 High And Low Water Cut Off System
1.3 Feed Water Pump Auto System
1.4 Steam Pressure Switch System
1.5 Gas Pressure Switch System
1.6 Air Pressure Switch System
1.7 Damper Closed Switch System
1.8 Door Limit Switch System
1.9 Purching Define / Timing
1.10 Ignition / Pilot / Main Burner System
1.11 Relays Function / Working
1.12 Relays Function Working
1.13 Sensors / Detectors
Total 30 145
Page 33 of 43
Workshop Practice- IV
Detail of Topics
No. Hours Hours
1. Measuring 1 20
1.1 Introduction of Micrometer (Outside, Inside,
Depth)
1.2 Care and Use of Micrometer
1.3 Thread Gauges
1.4 Snap and Plug Gauges
1.5 Gauge Blocks
1.6 Dial Indicators
1.7 Reading of Micrometer
1.8 Profile Gauge
2. Sheet Metal Work 2 30
2.1 Introduction of Sheet Metal Tools and
Machines
2.2 Sheet Metal Processes
2.3 Sheet Metal Joints
2.4 Soldering (Hard, Soft)
2.5 Sheet Metal Jobs
3. Assembling 2 20
3.1 Introduction of Assembling
3.2 Assembling Tools
3.3 Assembling Processes
4. Machine Work (Surface/ Cylindrical Grinder) 2 30
4.1 Introduction of Grinding
4.2 Types of Grinding
4.3 Grinding Machine
4.4 Cylindrical Grinding
4.5 Grinding Processes
4.6 Bonding Material
4.7 Safety on Grinding
4.8 Grinding Wheel’s Abrasives
5. Off Hand Grinding 1 15
5.1 Introduction to Pedestal Tool Grinder
5.2 Kinds of Grinding Wheel and Use
5.3 Testing and Mounting of Wheel
5.4 Setting of Tool Rest
5.5 Care and Maintenance of Grinding Machine
5.6 Introduction and Use of Drill Grinding
Attachment
Page 34 of 43
6. ISO Fits and Tolerance 2 20

6.1 Necessity of Fits
6.2 Basic Definitions
6.3 Types of Fits
6.4 Tolerance Zone (Grade and Position)
6.5 Fit Systems
(Basic Hole / Basic Shaft)
6.6 Tolerance
Total 10 135
Technical Mathematics-IV
No.
1. Technical Mathematics
1.1 Volume and Their Units 10

1.2 Volume of Parallel Engineering Solids
1.3 Volume of Frustum of Cone
1.4 Volume of Pyramid
1.5 Quantity of Liquids
1.6 Weights of Engineering Solids
1.7 Estimation
1.8 Calculating Area of Composed Figures
Total 10
Technical Drawing-IV
No.
1. 1.1 Sectioning 10
1.2 Full Section
1.3 Half Section
1.4 Threads (Outside, Inside)
1.5 Parts on to be Sectioned
1.6 Symbols (Welding / Surface)
1.7 Application of CAD (Computer Aided Design)
Total 10
Page 35 of 43
1. How to Operate a Boiler 01
2. Ignition Rod Settings 01
3 Regulation Valve Setting 04
4 Steam Reducing Valve Setting 04
5 Safety Valve Setting 04
6 Lead Plug Cleaning & Filling 03
7 Tube Welding 02
8 Tube Expanding 02
9 Tube Bedding 02
10 Tube Bell Mouthing 02
11 Tube Seal Welding 02
12 Boiler Cleaning Method 06
13 Feed Check Valve Fitting 02
14 Change of Mechanical Seal of Pump 04
15 Steam Cock, Water Cock Setting 05
16 Gauge Glass Fitting 04
17 Pressure Gauge Working /Reading 02
18 Dead Weight Tester for Pressure Gauge 02
19 Mobbrey Float & Prob Rod Setting 02
20 Siphon Tube 01
21 Anti Collapse Ring 02
22 Backing Ring Changing / Fitting 02
23 Reinforcing Ring Fitting 02
24 Admison Ring Fitting 02
Page 36 of 43
25 Washout Plug Fitting 01
26 Change the Diapharam of Valves 04
27 Pump Fittings 05
28 Gauge Glass Sleeve &Washers Fitting 04
29 Safety Valve Setting 04
30 Boiler Opening & Closing 04
31 Inspection & Cleaning 04
Page 37 of 43
LIST OF TOOLS AND EQUIPMENT

FOR CLASS OF 25
Name of Trade Boiler Operator

Duration of Course 2 - Years
Sr. No. Tools / Equipments Quantity

1. Model of Boilers – Different Models One Each Type
2. Feed Check Valve 2
3 Pressure Gauges ( PSI, Bar, KPa, Kg / Cm2) 5 Each Type
4 Stop Valve 1
5 Temperature Gauges (Co, Fo, K) 5 Each Type
6 Gauge Glass Tester 01
7 Lead Plug 02
8 Stays – Different Types One Each Type
9 Dry Pipe 01
10 Antipriming Pipe 01
11 Dead Weight Tester 01
12 Butterfly Valve 01
13 Steam Globe Valve 03
14 Gate Valve 03
15 Ball Valve 03
16 Keys Set 02
17 Alkey Set 02
18 Spanner Set 02
19 Ignition Rods 01
20 Boiler Tubes – Different Types One Each Type
21 Hammer Set 01
22 Gas Regulating Valve 01
23 Slow Opening Valve 02
24 Solaniod Valve 02
25 Oil Pumps 01
Page 38 of 43
26 Isolating Valve 01
27 Water Conditioner 01
28 Non Return valve 02
29 Water Injector 01
30 Anticollaps Ring 01
31 Backing Ring 01
32 Reinforcing Ring 01
33 Blow Down Valve – Different Types One Each Type
34 Safety Values – Different Types One Each Type
35 Oil Heaters 01 Set
36 Feed Water Pumps – Different Types One Each Type
37 Steam Traps – Different Types One Each Type
38 Hydraulic Pump 01
39 Siphon Tube 02
40 Pressure Trouel Switch 01
41 Air Pressure Switch 01
42 Gas Pressure Switch 01
43 U – V Cell / Photocell 01
44 Programmer 01
45 Relays 03
46 Gas Filter 01
47 Water Filter 01
Page 39 of 43
List of Special Auxiliaries For Boiler
S.No Special Auxiliaries For Boiler Quantity

1 Super Heater 01
2 Economizer 01
3 De Super heater 01
4 Air Pre Heater 01
5 Attemperator 01
6 Deaeraheater 01
7 Water Tank 01
8 Oil tank 01
9 Blow Down Tank 01
Page 40 of 43
MINIMUM QUALIFICATION OF INSTRUCTOR
 B. Tech (Pass) with First Class Boiler Engineer.
OR
 DAE (Mechanical) with First Class Boiler Engineer having five years
minimum operational / maintenance experience of boiler.
Page 41 of 43
REFERENCE BOOKS
1- Heating Boiler Operator’s Manual (Maintenance, Operation,

and Repair)
 By: Mohammad A Malek

 Date: December 12, 2006
 Format: Hardback, 352 pages
 ISBN: 0071475222 / 9780071475228
 Publisher: McGraw-Hill, USA
2- Boiler Operator\'s Handbook

 By: Kenneth E. Heselton (Oct 19, 2004)
 ISBN-10: 0824742907
 ISBN-13: 978-0824742904
 Publisher: Fairmont Press (October 19, 2004)
3- Boiler Operator's Guide 4th Edition
 By: Anthony Lawrence Kohan (Oct 1, 1997)

 ISBN: 007036574L
 Publisher: McGraw-Hill, USA
Page 42 of 43
EMPLOYABILITY OF THE PASSOUTS
1. Power Generation Sector

2. Sugar Mills
3. Textile Industry
4. Paper Industry
5. Pharmaceutical Industry
6. Feed Industry
7. Power Press Industry
8. Chilling System
9. Dairies Industry
10. Ghee Industry
11. Leather Industry
12. Rice Sheller
13. Food Industry Like K&Ns, Wall’s
14. Chemical Plants
15. Hospitals (C.S.S.D Plants & Laundry)
Page 43 of 43

Learn Boiler Operation Skills in 2-Years

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Boiler Operator (2-Years) 1

Entry Level Matric with Science having 2nd Division

Duration of course 2 – Years

Total Training Hours 3200

Training Hours Per Day 7 Hours Per Day

Training Hours Per Week 40 Hours

Training Methodology Practical 80%

Medium of Instruction: English / Urdu

SKILL PROFICIENCY DETAILS: -

After completion of course the trainees will be able to:

 Recognize the different electrical components used in electricity.

KNOWLEDGE PROFICIENCY DETAILS

After completion of course the trainees will be able to:

 Understand the whole process of steam generation-I at an ordinary stage.

Curriculum Delivery Structure

3. Technical Drawing and Drafting– I 20 - 20

4. Electrical – I 20 200 220

5 Workshop Practice – I 40 200 240

Total 160 640 800

2 Technical Drawing and Drafting-II 20 - 20

4 Workshop Practice – II 40 200 240

5 Welding-I 20 200 220

Total 160 640 800

2 Water Treatment-II 40 155 195

3 Industrial Boiler Automation 30 145 175

4 Workshop Practice – IV 10 135 145

6 Technical Drawing & Drafting-IV 10 - 10

Total 160 640 800

DETAIL OF COURSE CONTENTS

Sr. Theory Practical

3. Decimal System of Measuring

Technical Drawing and Drafting-I

1.2 Kinds of Lines 01

1.3 Drawing Instruments 01

1.5 Views (introduction and Types) 02

1.6 Representation in Three Views 02

1.7 Assembling Bodies 02

1.8 Completion of Views Visible Edges 02

1.9 Work Pieces with Cover Edges 02

1.11 Draw True Scale 02

1.12 Drawing of Circle and Radius 02

2.2.3 DC Three Wire

2. Calculating Area of Composed Figures 4

3.7 Burning Process

5. Electric Arc Welding

Welding ARC &GAS

Sr. Theory Practical

Sr. Theory Practical

4. Double Lap Joint 2 20

3. Destructive & Nondestructive Test 4

5. Feed Water Injector 3

8. Oil Heaters /Strainer /Filters 3

Sr. No. Practicals Hours

Plumbing & Pipe Fitting

7. Single V Butt Weld on Pipe

2. Blind Weld Flat

10 Single V Butt Weld V Up

3 Temporary Fastening Method 2 25

5. Boiler Fuels /Combustion /Smoke 4

Sr. No. Practicals Hours

1 Steam Reducing Valve Working / Setting 25

3 Change The Mechanical Seal Of Pump 25