LEARNING PLAN

COURSE: MECHANICAL PLANT LEVEL: MODULE V (LEVEL 6)

TECHNOLOGY
UNIT OF INSTALL STEAM UNIT CODE: 0715 551 21A
COMPETENCY: SYSTEM
DEPARTMENT: MECHANICAL AND NAME OF
AUTOMOTIVE TRAINER:
EMAIL OF THE PHONE NUMBER
TRAINER: OF THE TRAINER:
DATE OF DATE OF
PREPARATION: REVISION:
NUMBER OF CLASS:
TRAINEES:
TOTAL UNIT 200 HOURS NUMBER OF 48 SESSIONS OF 1.5
HOURS: SESSIONS: HRS (24 SESSIONS OF
3 HRS)

Skill or Job Task:

This unit of learning covers the learning outcomes, content, assessment methods, methods of
delivery and resources required to train steam system installation. The learning outcomes shall
enable the learner to prepare for installation of steam system, assemble steam system
equipment, fit steam distribution system and accessories, and test and commission steam
system.
Benchmark or Criteria to be used
Prepare for installation of Steam system
Safety procedures are adhered to according to OSH Act, 2007.
Site conditions and installation requirements are assessed according to manufacturer's
specification.
Steam system components specifications are verified according to design requirements.
Tools, equipment and materials needed for installation are selected and assembled according to
site conditions and site installation requirements.
Housekeeping is carried out according to workplace procedure.
Assemble Steam System Equipment
Safety procedures are adhered to according to OSH Act, 2007.
Boiler is mounted as per manufacturer's specifications.
Boiler components are fitted as per manufacturer's specifications.
Feed water system is fitted as per manufacturer's specifications.
Fuel system is fitted as per manufacturer's specifications.
Flue gas system is fitted as per manufacturer's specifications.
Auxiliary components are fitted as per manufacturer's specifications.
Housekeeping is carried out according to workplace procedure.
Fit Steam Distribution System and Accessories
Safety procedures are adhered to according to OSH Act, 2007.
Piping of steam distribution system is done as per job specifications.
Steam distribution accessories are fitted in place as per manufacturer's specification.
Lagging and cladding is carried out as per manufacturer's specification.
Housekeeping is carried out according to workplace procedure.
Test and Commission Steam System
Safety procedures are adhered to according to OSH Act, 2007.
Assembly layout is checked according to installation manual.
Steam system is run and checks are made for any abnormalities according to job specifications.
Steam system troubleshooting is carried out according to manufacturer's specifications.
Training steam system end user is carried out according to manufacturer's specifications.
Documentation and handing over is carried out according to manufacturer's specifications.
Housekeeping is carried out according to workplace procedure.
 SESSION PLAN

WE SESS SESSIO LEARNIN

EK ION N TITLE LEARNIN G
TRAINER TRAINEE REFLEC
NO. G RESOURCES & CHECKS
ACTIVITI ACTIVITIE TION &
OUTCOM REFS /
ES S DATE
E ASSESS
MENTS
1 1&2 Prepare 1. Define Present Observe REFs: Oral
(3 for steam physical and OS/Curriculum questioni
HRS) Installati systems steam identify Learning Guide, ng on
on of and system steam Trainer's Notes compone
Steam explain compone system Industrial Boilers nt
System their nts and componen and Heat identificat
industrial labelled ts from Recovery Steam ion
applicatio diagrams physical Generators by V. Written
ns. for visual samples Ganapathy compone
2. Identify identificat and Training Aids: nt-
the major ion. labelled Physical steam matching
types of Explain diagrams. system quiz
steam and Match components Observati
systems compare each (boiler, steam on of
(fire-tube, types of componen traps, safety trainee
water- steam t to its valves, pressure participati
tube, systems function gauges) on in
electric (fire-tube using a Manufacturer's diagram
boiler). vs. water- provided manuals and tracing
3. tube) worksheet. datasheets Portfolio
Describe using Read a Labelled system of
the key manufact steam schematic evidence:
compone urer system diagrams complete
nts and manuals schematic Component d
their and and trace identification identificat
functions: charts. the flow worksheet ion
boiler, Describe path from Multimedia workshee
steam each boiler to projector and t
header, compone end use. whiteboard
steam nt's Record
receiver, function nameplate
steam with data
pipes, reference (pressure
 steam to a rating,
traps, system capacity,
safety schematic model
valves, drawing. number)
and stack Demonstr for
pipe. ate how displayed
4. to locate componen
Distinguis and read ts.
h compone Participate
between nt in group
high- nameplat discussion
pressure es and on
and low- data tags. industrial
pressure Facilitate steam
steam a guided system
systems. Q&A application
5. State discussion s and
the on steam complete
importanc system a short
e of applicatio identificati
proper ns in on quiz.
installatio industry.
n for
system
efficiency
and
safety.
1 3&4 Prepare 1. Identify Explain Wear full REFs: Oral
(3 for site why site PPE and Occupational questioni
HRS) Installati conditions assessme apply OSH Standards, ng on
on of required nt is Act 2007 Learning Guides, OSH Act
Steam for safe critical for safety Trainer's Notes 2007 site
System steam safe and procedure Industrial Boilers safety
system efficient s and Heat requirem
installatio steam throughou Recovery Steam ents
n. system t the Generators by V. Written
2. Assess installatio session. Ganapathy assessme
foundatio n. Interpret Training Aids: nt on site
n Demonstr the Manufacturer's condition
strength, ate how manufactu installation s and
clearance to read rer's manual, Site installatio
, manufact installation Assessment n
ventilatio urer's manual to Checklist requirem
n, installatio identify Tools: Tape ents
drainage, n site measure, spirit Observati
and utility manuals preparatio level, plumb line, on of
availabilit to n thermometer, correct
y. determine requireme anemometer PPE use
3. site nts. PPE: Helmets, and safe
Interpret requireme In groups, gloves, safety site
manufact nts. inspect boots, goggles, inspectio
urer's Guide the reflective vest n
installatio trainees simulated practices
n through a installation Portfolio
requireme structure site: of
nts and d site measure evidence:
design inspection floor complete
specificati , checking flatness, d Site
ons. foundatio check Assessme
4. Apply n level, clearance nt
OSH Act clearance distances Checklist
2007 , (minimum with
safety ventilatio 1 m), findings
procedure n, verify and
s relevant drainage, ventilation corrective
to steam and utility adequacy, actions
system access. and
installatio Enforce confirm
n. PPE use utility
5. and locations.
Complete review Complete
a site OSH Act the Site
assessme 2007 Assessme
nt provisions nt
checklist relevant Checklist,
based on to the site recording
given assessme findings
installatio nt phase. and noting
n Provide any non-
requireme trainees complianc
nts. with a es.
 Site Report site
Assessme assessmen
nt t findings
Checklist to the
and group and
supervise suggest
its corrective
completio actions
n. where
required.
Perform
housekeep
ing.
2 5&6 Prepare 1. Verify Explain Collect REFs: Oral
(3 for steam why design OS/Curriculum questioni
HRS) Installati system compone requireme Learning Guide, ng on
on of compone nt nt sheets, Trainer's Notes how to
Steam nt specificati manufactu Training Aids: interpret
System specificati on rer Boiler, steam nameplat
ons verificatio datasheets traps, pressure e data
against n is , and gauges, safety and
design critical physical valves with datasheet
requireme before componen visible s
nts. installatio ts or labels nameplates Written
2. Read n for Manufacturer's assessme
and commenc inspection. datasheets and nt
interpret es. Read design identifyin
compone Demonstr nameplate requirement g
nt ate how data on documents specificati
nameplat to read each System layout on
es, nameplat componen and P&ID mismatch
manufact e data t and drawings es from a
urer and cross- record: Component sample
datasheet reference pressure Specification datasheet
s, and against rating, Verification Observati
design design temperatu Checklist on of
drawings. drawings re rating, PPE: Gloves, correct
3. and flow goggles, safety data
Compare manufact capacity, boots comparis
actual urer material, on
compone datasheet and procedur
nt s. connection e
specificati Guide sizes. Portfolio
ons trainees Compare of
(pressure through recorded evidence:
rating, comparis data complete
capacity, on of a against d
material, boiler and the design Specificat
connectio steam requireme ion
ns) with trap nt sheet Verificatio
design specificati and mark n
requireme ons compliant/ Checklist
nts. against non-
4. Identify provided compliant
discrepan design items.
cies requireme Identify
between nt sheets. and
supplied Highlight document
compone conseque at least
nts and nces of two
design installing discrepanc
specificati non- ies (e.g.,
ons. compliant wrong
5. compone pressure
Complete nts rating,
a (safety incorrect
compone risks, connection
nt warranty size) using
verificatio loss, the
n system verificatio
checklist failure). n
and Supervise checklist.
recomme trainees Present
nd as they checklist
corrective complete findings
actions. the and
verificatio recommen
n d
checklist corrective
and measures.
present Perform
 findings. housekeep
ing.
2 7&8 Prepare 1. Identify Present Identify REFs: Oral
(3 for all tools, and and name OS/Curriculum questioni
HRS) Installati equipmen identify each tool Learning Guide, ng on tool
on of t, and all and its Trainer's Notes identificat
Steam materials installatio specific Training Aids: ion and
System required n tools: installation Pipe wrenches, correct
for steam pipe application assorted applicatio
system wrenches, from the spanners, chain n
installatio chain displayed block, lifting Written
n. blocks, set. trolley, hoist, tool
2. Select forklifts, Inspect spirit level, tape inspectio
correct assorted assigned measure, gas n
hand spanners, tools for welding kit, assessme
tools, spirit defects, flaring and nt
power level, recording swaging tools identifyin
tools, and tape any unsafe Manufacturer's g
lifting measure, or installation defective
equipmen gas unservicea manual tools from
t for welding ble items Tool Inspection a
specific kit, flaring on an Checklist checklist
installatio and inspection PPE: Helmets, Observati
n tasks. swaging sheet. gloves, safety on of
3. Inspect tools. Select the boots, goggles, correct
tools and Demonstr correct ear protection manual
equipmen ate tools and handling
t for correct materials and lifting
safety inspection for a given technique
and of each installation s
serviceabi tool for task Portfolio
lity before condition scenario of
use. and (e.g., evidence:
4. serviceabi mounting complete
Organise lity boiler on d Tool
tools and (checking foundation Inspectio
materials for ). n
systemati cracks, Practice Checklist
cally worn safe
according threads, handling
to the missing and
installatio guards). transport
n plan. Show of a heavy
5. Apply correct pipe
correct manual section
manual handling using a
handling technique lifting
and lifting s for trolley and
technique heavy chain
s for compone block
heavy nts (boiler under
steam sections, supervisio
system pipe n.
compone sections) Organise
nts. and safe tools and
use of materials
lifting into a
equipmen labelled
t. layout
Demonstr matching
ate the
systemati installation
c layout sequence.
and Perform
labelling housekeep
of tools ing.
and
materials
prior to
starting
installatio
n.
Supervise
trainees
in tool
selection
exercise
and
provide
corrective
feedback.
3 9& Assembl 1. Prepare Demonstr Wear full REFs: Oral
10 (3 e Steam the ate PPE and OS/Curriculum questioni
HRS) System installatio foundatio apply Learning Guide, ng on
Equipme n area for n LOTO Trainer's Notes boiler
nt – boiler preparati procedure Industrial Boilers mounting
Boiler mounting, on: s before and Heat sequence
Mountin including checking commenci Recovery Steam and
g foundatio flatness ng any Generators by V. torque
n checks (±2 mm mounting Ganapathy specificati
and tolerance) activity. Training Aids: ons
clearance , marking Inspect Boiler unit Written
verificatio centreline and (training/demons assessme
n. s, and prepare tration model), nt on OSH
2. Select verifying the manufacturer's Act 2007
and load- foundation installation LOTO and
assemble bearing : measure manual and safe
tools, capacity. and mark drawings lifting
lifting Show centrelines Tools: Tape requirem
gear, and correct , check measure, spirit ents
materials selection flatness level, torque Observati
required and with a wrench, chain on of
for boiler rigging of spirit level, block, hoist (1 correct
mounting. lifting and ton), slings, mounting
3. Mount equipmen confirm anchor bolts, technique
the boiler t (chain clearances shims, grout, ,
on the block, . vibration levelling,
prepared hoist, Assist in isolators and
foundatio slings) for lifting and PPE: Helmets, torque
n safe positioning gloves, safety applicatio
according boiler the boiler boots, goggles, n
to placemen using ear protection Portfolio
manufact t. chain Installation of
urer's Demonstr block and logbook and evidence:
specificati ate step- slings mounting complete
ons. by-step under checklist d
4. Level, boiler trainer mounting
align, and mounting: supervisio checklist
secure position n. with
the boiler base Insert recorded
using frame, anchor torque
anchor drill bolts, values
bolts anchor shim, and
tightened holes, level the
to insert boiler;
specified vibration tighten
torque isolators, anchor
values. place bolts in
5. Apply boiler the correct
OSH Act using sequence
2007 lifting to
safety gear, manufactu
procedure insert rer-
s anchor specified
througho bolts torque
ut the loosely, using a
mounting level with torque
process. spirit wrench.
level, Recheck
shim as level and
required, alignment
tighten after
anchor tightening;
bolts to record
manufact mounting
urer parameter
torque s in the
specificati installation
on. logbook.
Enforce Perform
OSH Act housekeep
2007 ing.
safety
procedure
s: PPE
use,
LOTO,
and safe
lifting
protocols
througho
ut.
Inspect
 trainee
work at
each step
and
provide
corrective
feedback.
3 11 & Assembl 1. Identify Identify Identify REFs: Oral
12 (3 e Steam and and each boiler OS/Curriculum questioni
HRS) System describe explain componen Learning Guide, ng on the
Equipme the the t from Trainer's Notes function
nt – function function physical Training Aids: and
Fitting of each of each samples Boiler training correct
Boiler boiler boiler and unit, physical location
Compon compone compone drawings, boiler of each
ents nt: nt using stating its components boiler
pressure physical function (pressure compone
gauges, samples and gauges, sight nt
sight and the correct glass, safety Written
glasses, manufact mounting valves, blow- assessme
safety urer's location. down valve, nt
valves, drawing. Fit water level identifyin
blow- Demonstr pressure sensors, burner) g correct
down ate gauges, Manufacturer's and
valve, correct sight component incorrect
water fitting glasses, fitting manual compone
level sequence: blow-down and drawings nt
sensors, pressure valve, and Tools: Spanners, placemen
and gauge at water level torque wrench, ts from a
burner. designate sensors at pipe wrenches, diagram
2. Fit d tapping designated screwdrivers, Observati
boiler point, tapping sealing on of
compone sight points, compound, PTFE correct
nts in the glass at applying tape, gaskets sealing
correct correct correct PPE: Helmets, technique
location height, sealing gloves, safety and
according safety materials. boots, goggles torque
to valve at Install the Installation applicatio
manufact discharge safety logbook and n
urer's port, valve in component Portfolio
specificati blow- the correct fitting checklist of
ons and down orientation evidence:
drawings. valve at (vertical, complete
3. Apply bottom of discharge d
correct boiler, unobstruct compone
torque water ed) and nt fitting
and level tighten to checklist
sealing sensors at specified with
technique prescribe torque inspectio
s d using n findings
(gaskets, positions, calibrated
PTFE burner at torque
tape) to furnace wrench.
all port. Fit the
fittings. Show burner
4. Inspect correct assembly
fitted applicatio at the
compone n of furnace
nts for gaskets port
correct and PTFE following
orientatio tape to manufactu
n, sealing, prevent rer's fitting
and leaks; instruction
accessibili demonstr s.
ty. ate Inspect all
5. Apply tightening fitted
OSH Act to componen
2007 specified ts against
safety torque. the
procedure Demonstr manufactu
s during ate how rer's
compone to verify drawing
nt fitting. compone for correct
nt orientation
orientatio , sealing,
n and and
confirm accessibilit
accessibili y; record
ty for findings in
future the
maintena installation
 nce. logbook.
Supervise Perform
trainee housekeep
fitting ing.
practice
and
provide
corrective
feedback
at each
stage.
4 13 & Assembl 1. Identify Explain Identify REFs: Oral
14 (3 e Steam compone the feed and OS/Curriculum questioni
HRS) System nts of the water describe Learning Guide, ng on the
Equipme feed system's each feed Trainer's Notes function
nt – water role in water Training Aids: and
Feed system: boiler system Feed water sequence
Water feed operation: componen pump, service of feed
System water supplying t from water tank, feed water
Fitting pump, pre- physical water system
service treated samples conditioning compone
water water at and P&ID unit, filters, nts
tank, feed the drawings. connecting pipes Written
water correct Mount the and fittings assessme
conditioni pressure feed water Manufacturer's nt on
ng unit, to pump on installation feed
filters, maintain its base, manual and water
and safe checking P&ID drawings system
connectin water for level Tools: Pipe pipe
g levels. and wrenches, routing
pipework. Identify correct spanners, torque and
2. and orientation wrench, spirit connectio
Describe demonstr of level, tape n
the role of ate fitting inlet/outlet measure, PTFE requirem
the feed of each ports. tape, gaskets, ents
water feed Connect pipe supports Observati
system in water the service PPE: Helmets, on of
boiler compone water tank gloves, safety correct
efficiency nt: pump and boots, goggles compone
and position filtration Installation nt
safety. and base unit to the logbook and feed mounting
3. Fit feed mounting, pump, water system , sealing,
water service applying fitting checklist and pipe
system water correct support
compone tank seals and installatio
nts in the connectio tightening n
correct ns, filter to Portfolio
location installatio specified of
and n torque. evidence:
sequence upstream Install pipe complete
as per of pump, supports d feed
manufact and feed and water
urer's water hangers at system
specificati conditioni required fitting
ons. ng unit. intervals checklist
4. Demonstr and with
Connect ate connect inspectio
feed correct the feed n results
water pipe water
pipes and connectio conditionin
verify n g unit in
pressure technique the correct
and s for feed flow
temperat water direction.
ure lines: Cross-
ratings of correct check
all reducer completed
connectio orientatio layout
ns. n, pipe against
5. Inspect supports manufactu
the at rer's
complete required drawing,
d feed intervals, verifying
water and use all
system of connection
layout appropria ratings;
against te record
the gaskets inspection
manufact and seals. findings in
urer's Show how the
drawing. to verify installation
 pressure logbook.
and Perform
temperat housekeep
ure ing.
ratings of
pipes and
fittings
against
manufact
urer's
specificati
ons.
Supervise
trainees
during
hands-on
fitting and
provide
corrective
feedback.
4 15 & Assembl 1. Identify Identify Wear REFs: Oral
16 (3 e Steam fuel fuel appropriat OS/Curriculum questioni
HRS) System system system e PPE and Learning Guide, ng on
Equipme compone compone apply OSH Trainer's Notes OSH Act
nt – Fuel nts: fuel nts and Act 2007 Training Aids: 2007 fuel
System lines, explain safe Fuel supply pipe handling
and Flue burner, their working sections, shut-off safety
Gas control functions: procedure valve, regulator, procedur
System valves, fuel s for fuel burner control es
Fitting regulators supply handling valve, flue pipe Written
, and line, shut- throughou sections, assessme
safety off valve, t. chimney stack nt
shut-off regulator, Identify section, clamps, identifyin
valves. burner and flanges g correct
2. Fit the control prepare Manufacturer's and
fuel valve, fuel installation incorrect
system and system manual and fuel line
according safety componen combustion connectio
to interlock. ts; connect system drawings ns from
manufact Demonstr fuel supply Tools: Pipe diagrams
urer's ate safe line using wrenches, Observati
specificati fuel line correct spanners, torque on of leak
ons, connectio fitting wrench, leak testing
ensuring n: technique detection spray procedur
leak-free pressure and apply (soapy solution), e and
connectio rating leak test spirit level, correct
ns. verificatio with soapy clamps flue pipe
3. Identify n, correct solution. PPE: Helmets, gradient
flue gas flare or Fit the flame-resistant Portfolio
system compressi burner gloves, safety of
compone on fitting control boots, goggles, evidence:
nts: technique valve and fire extinguisher complete
chimney, , and leak safety nearby d fuel and
flue testing shut-off Installation flue
pipes, with valve in logbook and system
and soapy the correct fuel/flue fitting fitting
dampers. solution flow checklist checklist
4. Fit the after direction
flue gas fitting. and verify
exhaust Enforce connection
system OSH Act torque
ensuring 2007 values.
correct safety Install flue
routing, procedure gas pipes
ventilatio s for fuel from boiler
n handling: exhaust
complianc PPE, no port to
e, and naked chimney
emissions flames, stack with
standards ventilatio correct
. n, LOTO gradient,
5. Apply on fuel secure
OSH Act supply. clamping
2007 Demonstr at required
safety ate flue intervals,
measures gas and
for system confirm
working fitting: chimney
with fuel correct clearances
and high- flue pipe .
temperat routing Inspect
 ure flue (minimum completed
systems. gradient), fuel and
secure flue
clamping, systems
and against
chimney manufactu
stack rer's
connectio drawings;
n with record
appropria findings
te and any
clearance corrective
s. actions in
Supervise the
trainee installation
fitting of logbook.
both Perform
systems, housekeep
checking ing.
for
correct
orientatio
n and
leak-free
completio
n.
4 17 (1.5 CONTINOUS ASSESMENT TEST CAT 1
HRS)
5 18 & Assembl 1. Identify Identify Identify all REFs: Oral
19 (3 e Steam auxiliary each auxiliary OS/Curriculum questioni
HRS) System compone auxiliary componen Learning Guide, ng on the
Equipme nts: compone ts from Trainer's Notes function
nt – economiz nt with physical Industrial Boilers of each
Auxiliary er, air physical samples and Heat auxiliary
Compon pre- samples and Recovery Steam compone
ents heater, and drawings, Generators by V. nt and its
Fitting forced describe stating the Ganapathy location
draught its function Training Aids: in the
fan, function: and Economizer unit, steam
induced economiz installation air pre-heater, system
draught er (pre- location of FD and ID fan Written
fan, heats each. models, steam assessme
steam feed Mount the header section, nt on
header, water economize condensate auxiliary
and using flue r on its recovery tank, system
condensa gas), air support connecting pipe fitting
te pre- frame in sections, duct sequence
recovery heater the flue sections, and
system. (pre-heats gas duct flanges, gaskets connectio
2. combusti and Manufacturer's n
Describe on air), connect to auxiliary requirem
the FD and ID the feed systems ents
function fans water line installation Observati
of each (control using manual and on of
auxiliary combusti correct drawings correct
compone on air and pipe Tools: Spanners, compone
nt in flue gas fittings torque wrench, nt
improving flow), and screwdrivers, mounting
boiler steam gaskets. spirit level, tape , flange
efficiency. header Install FD measure, alignment
3. Fit (distribute and ID multimeter (for , and
auxiliary s steam), fans on electrical electrical
compone condensa prepared connections) connectio
nts in the te bases, PPE: Helmets, n safety
correct recovery connect gloves, safety Portfolio
location system inlet and boots, goggles, of
and (returns outlet ear protection evidence:
sequence condensa ducts, and Installation complete
as per te to make logbook and d
manufact boiler). electrical auxiliary auxiliary
urer's Demonstr connection component compone
specificati ate s to the fitting checklist nt fitting
ons. correct control checklist
4. Make mounting panel with
correct of the under inspectio
mechanic economiz trainer n findings
al and er in the supervisio
electrical flue gas n.
connectio path and Fit the
ns to connectio steam
auxiliary n to the header
compone feed with
nts. water mounting
5. line. brackets,
Perform Show FD connect
post- and ID fan steam
fitting installatio supply
inspection n: base flanges,
of mounting, and install
auxiliary duct the drain
systems connectio valve at
against n, and the lowest
installatio electrical point.
n wiring to Inspect
drawings. control completed
panel. auxiliary
Demonstr systems
ate steam against
header the
installatio manufactu
n: rer's
mounting installation
brackets, drawing;
pipe record
connectio inspection
n flanges, findings in
and drain the
valve installation
fitting. logbook.
Supervise Perform
trainee housekeep
fitting ing.
exercises
and
inspect
complete
d work
against
manufact
urer's
drawings.
5 20 & Fit 1. Identify Identify Identify REFs: Oral
21 (3 Steam types of steam and select OS/Curriculum questioni
HRS) Distribut steam distributio the correct Learning Guide, ng on
ion distributio n piping pipe Trainer's Notes pipe
System – n piping materials material Training Aids: material
Piping materials: and for the Carbon steel selection
carbon explain given pipe sections, criteria
steel, selection steam flanges, gaskets, and
stainless criteria distributio pipe fittings connectio
steel, and based on n service (elbows, tees, n
copper. pressure, (temperat reducers), pipe methods
2. temperat ure, supports and Written
Interpret ure, and pressure). hangers assessme
steam fluid Interpret Manufacturer's nt on
distributio compatibi the piping piping interpreti
n piping lity. layout installation ng P&ID
layout Demonstr drawing to manual, piping drawings
drawings ate how identify layout drawings, and
and P&ID to the pipe and P&ID identifyin
diagrams. interpret route, Tools: Pipe g pipe
3. Cut, a piping support cutter, threading support
prepare, layout locations, machine, requirem
and join drawing: and welding kit ents
steam identifyin connection (arc/gas), pipe Observati
distributio g pipe points wrenches, on of
n pipes routes, before spanners, torque correct
using support commenci wrench, spirit cutting,
correct locations, ng work. level, tape joining,
technique valve Cut pipes measure and
s positions, to required PPE: Welding torque
(welding, and lengths helmet, flame- tightenin
threading, connectio using a resistant gloves, g
flanged n points. pipe cutter safety boots, technique
connectio Show safe or saw, goggles, ear s
ns). pipe deburr cut protection Portfolio
4. Install cutting, ends, and Installation of
pipe deburring prepare logbook and evidence:
supports , and for joining piping inspection complete
and preparati using the checklist d piping
hangers on correct inspectio
at technique technique n
manufact s; (threading checklist
urer- demonstr machine, with
specified ate welding, or alignment
intervals. threaded, flanged and
5. Inspect flanged, fitting). support
complete and Join pipe findings
d piping welded sections
for connectio using the
correct n correct
alignment methods. method;
, support Demonstr tighten
spacing, ate flanged
and leak- correct connection
free installatio s to
connectio n of pipe manufactu
ns. supports rer-
and specified
hangers torque in
at the correct
required star-
intervals pattern
to sequence.
prevent Install pipe
sag and supports
stress on and
equipmen hangers at
t specified
connectio intervals;
ns. inspect
Supervise completed
trainee piping
piping against
installatio the layout
n and drawing
inspect for
for alignment
alignment and
, support support
placemen adequacy.
t, and Perform
connectio housekeep
 n quality. ing.

6 22 & 23 Fit Steam • 1. • Present • Identify • REFs: • Oral

(3 HRS) Distributi Identify and each OS/Curriculum questionin
on steam describe accessory Learning Guide, g on
System – distributi each from Trainer's Notes; accessory
Steam on steam physical Industrial function
Distributi accessori distributi samples Boilers and and correct
on es: steam on and P&ID Heat Recovery installation
Accessori traps, accessor drawings; Steam location
es check y using state the Generators by • Written
valves, physical function, V. Ganapathy assessmen
pressure- samples flow • Training Aids: t
reducing and direction, Float-and- identifying
valves P&ID and thermostatic correct and
(PRVs), drawings installatio steam trap, incorrect
strainers, ; explain n location thermodynamic accessory
and function, of each. steam trap, placement
condensa correct • Fit float- strainer, check s from a
te orientati and- valve, PRV, diagram
pumps. on, and thermost condensate • Observatio
• 2. location. atic pump n of correct
Describe • Demonst steam • Manufacturer's fitting
the rate traps at fitting manuals technique,
function correct designate and P&ID sealing,
and fitting of d trap drawings and torque
correct a float- pockets: • Tools: Pipe application
location and- apply wrenches, • Portfolio of
of each thermost joint spanners, evidence:
accessory atic compoun torque wrench, completed
in the steam d, check spirit level, PTFE accessory
steam trap: vertical tape, joint fitting
distributi isolate, orientatio compound checklist
on position n, tighten • PPE: Helmets, with
system. correctly to torque gloves, safety inspection
• 3. Fit (trap specificat boots, goggles; findings
steam pocket, ion with Installation
distributi vertical calibrate logbook and
on orientati d torque accessory fitting
accessori on), wrench. checklist
 es in the apply • Install
correct joint strainers
sequence compou in correct
per nd, flow
manufact tighten direction
urer's to upstream
specificat torque. of control
ion. • Demonst valves;
• 4. Apply rate install
correct fitting a check
sealing, strainer valves at
torque, upstrea condensa
and m of te return
orientatio control points
n for all valves with
fitted and a correct
accessori check orientatio
es. valve in n.
• 5. Inspect the • Fit a PRV
complete condens in the
d ate correct
accessory return flow
installatio line. direction;
n against • Show connect
the P&ID correct downstre
drawing. installati am
on of a pressure
PRV: gauge
verify and
pressure verify
rating, pressure
inlet/outl rating
et against
direction design
, sheet.
downstr • Inspect
eam all fitted
gauge accessori
connecti es
on. against
• Supervis the P&ID
 e trainee drawing
fitting for
exercise correct
s at each location,
accessor orientatio
y n, and
station; sealing;
provide record
correctiv findings
e in the
feedbac installatio
k on n
orientati logbook.
on, Perform
sealing, housekee
and ping.
torque.
6 24 & 25 Fit Steam • 1. State • Explain • Identify • REFs: • Oral
(3 HRS) Distributi the the lagging OS/Curriculum questionin
on purpose purpose and Learning Guide, g on
System – of lagging of cladding Trainer's Notes insulation
Lagging and lagging materials • Training Aids: material
and cladding and from Mineral wool selection
Cladding in steam cladding physical sections, criteria and
distributi : energy samples; calcium silicate purpose of
on efficienc state pipe sections, cladding
systems y, selection aluminium • Written
(heat loss surface criteria cladding sheets, assessmen
preventio tempera based on cladding bands, t on
n, ture temperat rivets, vapour insulation
personnel reductio ure rating barrier tape thickness
protectio n, and and pipe • Manufacturer's selection
n). personn diameter. insulation for given
• 2. el • Measure specification pipe sizes
Identify safety; and cut sheets and and
lagging referenc mineral lagging temperatur
and e wool or installation es
cladding manufac calcium manual • Observatio
materials turer's silicate • Tools: Tape n of correct
: mineral specifica lagging measure, utility lagging
tion for
 wool, insulatio sections knife, tin snips, cutting,
calcium n to correct rivet gun, spirit fitting, and
silicate, thicknes length for level joint taping
fibreglass s. assigned • PPE: Helmets, technique
, • Present pipe gloves (cut- • Portfolio of
aluminiu lagging sections; resistant), evidence:
m and fit snugly safety boots, completed
cladding, cladding and tape goggles, dust lagging
stainless material all joints. mask; and
steel s with • Apply Installation cladding
cladding. physical aluminiu logbook and inspection
• 3. Select samples; m lagging checklist
appropria demonst cladding inspection
te rate over checklist
insulation correct lagging:
thickness selection measure,
and based on cut, form
material pipe to shape,
for given diameter overlap
pipe , joints
diameter tempera correctly,
and ture and
operating rating, secure
temperat and with
ure. environ bands or
• 4. Apply mental rivets.
lagging exposur • Inspect
sections e. complete
correctly • Demonst d lagging
to steam rate and
distributi step-by- cladding
on step for gaps,
pipework lagging loose
per installati sections,
manufact on on a or
urer's pipe exposed
specificat section: pipe; re-
ion. measure apply
• 5. Apply , cut where
and insulatio necessar
secure n y and
cladding section, record
over fit findings
lagging around in the
and pipe, installatio
inspect tape n
for joints, logbook.
airtight and • Perform
coverage. check housekee
for gaps. ping:
• Demonst dispose
rate of offcuts,
cladding store
applicati unused
on: cut materials
aluminiu , and
m sheet, clean the
form work
around area.
insulatio
n,
overlap
joints,
secure
with
rivets or
bands,
and
check
for
airtight
seal.
• Supervis
e trainee
lagging
and
cladding
practice;
inspect
for
correct
joint
 overlaps
, secure
fixings,
and gap-
free
coverag
e.
7 26 & 27 Fit Steam • 1. • Explain • Identify • REFs: • Oral
(3 HRS) Distributi Describe the role condensa OS/Curriculum questionin
on the of the te return Learning Guide, g on the
System – function condens compone Trainer's Notes; function of
Condensa of the ate nts from Industrial condensat
te Return condensa return physical Boilers and e return
System te return system: samples Heat Recovery component
system recoveri and P&ID; Steam s and their
and its ng hot state the Generators by installation
importan condens function V. Ganapathy requireme
ce to ate and • Training Aids: nts
boiler reduces connectio Condensate • Written
efficiency energy n point of receiver, assessmen
and consump each condensate t on
water tion and compone pump, flash condensat
conservat preserve nt. vessel, return e return
ion. s treated • Install pipe sections, pipework
• 2. feed condensa flanges, gradient
Identify water; te return gaskets, pipe and
condensa referenc pipework supports support
te return e the with • Manufacturer's spacing
system P&ID for correct condensate • Observatio
compone system gradient system n of correct
nts: overview (minimu installation pump
condensa . m 1:100), manual and connection
te • Identify secure P&ID drawings and flow
receiver, condens pipe • Tools: Pipe direction
condensa ate supports wrenches, verification
te pump, return at spanners, • Portfolio of
flash compon specified torque wrench, evidence:
vessel, ents intervals, spirit level, tape completed
and with and measure, PTFE condensat
return physical connect tape, gaskets e return
 pipework. samples: to • PPE: Helmets, system
• 3. Install condens condensa gloves, safety checklist
condensa ate te boots, goggles; with P&ID
te return receiver, receiver. Installation compariso
pipework pump, • Connect logbook and n findings
with flash the flash condensate
correct vessel, vessel to return checklist
gradient, and the
pipe return condensa
supports, lines; te
and explain receiver
connectio each with
n to the compon correct
hot well. ent's orientatio
• 4. function. n and
Connect • Demonst vent
the rate connectio
condensa correct n to the
te pump installati atmosphe
and flash on of re or
vessel condens steam
per ate header.
manufact return • Mount
urer's pipework and
specificat : connect
ions. gradient the
• 5. Inspect direction condensa
the (minimu te pump:
complete m 1:100 inlet from
d fall back receiver,
condensa to outlet to
te return receiver) feed
layout , pipe water
against support tank;
the P&ID spacing, verify
drawing and low- connectio
for point n torque
correct trap and flow
flow connecti direction
direction ons. arrows.
and • Demonst • Inspect
connectio rate complete
n. connecti d
on of the condensa
condens te return
ate system
pump to against
the P&ID;
receiver record all
and connectio
return n details
line, and any
including correctiv
inlet and e actions
outlet in the
valve installatio
positions n
and logbook.
electrical Perform
connecti housekee
on. ping.
• Supervis
e trainee
installati
on of
condens
ate
return
pipework
and
pump;
inspect
against
P&ID
drawing
and
provide
correctiv
e
feedbac
k.
7 28 & 29 Test and • 1. State • Explain • Don full • REFs: • Oral
(3 HRS) Commissi the the PPE OS/Curriculum questionin
on Steam purpose purpose appropria Learning Guide, g on OSH
System – and of pre- te for Trainer's Notes Act 2007
Pre- importan commiss steam • Training Aids: steam
commissi ce of pre- ioning: commissi Fully assembled commissio
oning commissi verify oning and steam system ning safety
Checks oning correct recite the (training requireme
checks installati LOTO model), nts
before on procedur installation • Written
running before e for the manual, as-built assessmen
the introduci boiler drawings, P&ID t
steam ng fuel and • Pre- identifying
system. steam electrical commissioning missing or
• 2. Apply pressure systems. checklist incorrectly
OSH Act ; • Conduct (formatted installed
2007 referenc a full form) component
safety e OSH assembly • Tools: Torque s from a
procedur Act 2007 layout wrench, commissio
es for requirem check: spanners, ning
steam ents for trace the flashlight for diagram
system steam steam visual • Observatio
commissi system flow path inspection n of correct
oning: commiss from • PPE: Helmets, PPE
PPE, ioning. boiler to insulated selection
LOTO, • Demonst distributi gloves, face and LOTO
and high- rate on shield, fire- application
pressure correct header, resistant before
steam PPE verifying clothing, safety commenci
precautio selection pipe boots, goggles; ng checks
ns. for routing, Installation • Portfolio of
• 3. Verify steam valve logbook evidence:
the commiss positions, completed
assembly ioning and and signed
layout (insulate accessory pre-
against d gloves, locations commissio
the face against ning
installatio shield, the checklist
n manual fire- installatio
and as- resistant n
built clothing) drawing.
 drawings. and • Verify all
• 4. review flanged
Complete LOTO connectio
a pre- procedur ns are
commissi e for tightened
oning isolating to
checklist electrical specified
covering and fuel torque;
all systems. confirm
mechanic • Lead all steam
al, trainees traps and
electrical, through safety
and a valves
safety structure are
compone d correctly
nts. assembl installed
• 5. y layout and
Identify check: accessibl
and compare e.
record installed • Complete
discrepan pipework the pre-
cies routing, commissi
between valve oning
the positions checklist,
installed , recording
system accessor the
and the y status of
installatio locations each item
n manual , and (complian
prior to insulatio t/non-
start-up. n compliant
coverag ) and the
e correctiv
against e action
the taken for
installati any
on deficienci
manual. es.
• Demonst • Submit
rate complete
completi d pre-
 on of the commissi
pre- oning
commiss checklist
ioning to trainer
checklist for
: verify review
all and sign-
flanged off.
joints Perform
are housekee
tightene ping.
d, all
valves
are in
correct
position
(open/cl
osed),
and all
safety
valves
and
interlock
s are
fitted
and
accessibl
e.
• Supervis
e trainee
layout
verificati
on
exercise;
correct
any
deficienc
ies
found
and
record
 them on
the pre-
commiss
ioning
form.
8 30 & 31 Test and • 1. Explain • Explain • Don • REFs: • Oral
(3 HRS) Commissi the the appropria OS/Curriculum questionin
on Steam purpose purpose, te PPE Learning Guide, g on
System – of test and Trainer's Notes; hydraulic
Cold and hydraulic pressure enforce Industrial test
Hydraulic (cold) specifica the Boilers and pressure
Pressure pressure tion exclusion Heat Recovery specificatio
Testing testing (typicall zone Steam n and
prior to y 1.5× around Generators by safety
steam design the V. Ganapathy requireme
start-up. pressure pressuris • Training Aids: nts
• 2. Apply ), and ed Steam system • Written
OSH Act safety system (training assessmen
2007 requirem per OSH model), t on the
safety ents for Act 2007 hydraulic test hydraulic
procedur hydrauli requirem pump, pressure
es for c ents. calibrated testing
hydraulic pressure • Prepare pressure gauge, procedure
pressure testing the blanking from a
testing: per OSH steam flanges, filling given flow
exclusion Act system hose diagram
zones, 2007; for • Manufacturer's • Observatio
pressure enforce hydraulic pressure testing n of correct
relief, exclusio testing: procedure and pressurisat
and PPE. n zone isolate hydraulic test ion
• 3. and PPE branches, certificate sequence
Prepare use. install • Tools: and leak
the • Demonst blanking Spanners, detection
steam rate flanges torque wrench, technique
system preparat on open leak detection • Portfolio of
for ion of ends, and spray (soapy evidence:
hydraulic the connect solution), completed
pressure steam the bucket and hydraulic
testing: system hydraulic draining hose test
isolate for test • PPE: Helmets, certificate
 sections, hydrauli pump to face shield, with
fill with c the insulated identified
water, testing: system gloves, safety leaks and
and isolate fill point. boots, goggles; corrective
connect all open- • Slowly fill Installation actions
test ended the logbook and
pump. branche system hydraulic test
• 4. s, close with certificate
Conduct steam water,
hydraulic outlet bleeding
pressure valves, air at
test to remove high
the or blank points;
specified safety pressuris
test valve e in
pressure outlets, stages to
(typically and 1.5×
1.5× connect design
design hydrauli pressure
pressure) c test while
and pump. monitorin
monitor • Demonst g the
for leaks. rate pressure
• 5. Record filling gauge.
test the • Inspect
results system all joints,
and with fittings,
identify water, and
any leaks bleeding connectio
or air from ns for
pressure high leaks
drop for points, using
correctiv and visual
e action. pressuris inspectio
ing n and
slowly to soapy
test water;
pressure mark all
in stages leaks
while found
monitori and
 ng for record
leaks. their
• Show locations
correct on the
use of a test
calibrate certificat
d e.
pressure • Depressu
gauge to rise and
monitor drain the
pressure system
stability; safely;
demonst complete
rate leak the
detectio hydraulic
n test
techniqu certificat
e (visual e with all
inspectio findings
n, soapy and
water on correctiv
joints). e actions.
• Supervis Perform
e trainee housekee
hydrauli ping.
c
pressure
testing;
guide
recordin
g of
results
on the
test
certificat
e and
identific
ation of
leaks for
rectificat
ion.
8 32 & 33 Test and • 1. State • Brief • Don live • REFs: • Oral
(3 HRS) Commissi the trainees steam OS/Curriculum questionin
on Steam purpose on live PPE (face Learning Guide, g on cold-
System – of a steam shield, Trainer's Notes; start check
Initial controlle hazards insulated Industrial requireme
Steam d warm- (scalds, gloves, Boilers and nts and
Start-up up thermal fire- Heat Recovery live steam
and procedur shock, resistant Steam safety
Warm-up e before water clothing) Generators by precaution
Procedure full steam hammer and V. Ganapathy s
commissi ) and confirm • Training Aids: • Written
oning. enforce exclusion Fully assembled assessmen
• 2. Apply OSH Act zone is in boiler training t on the
OSH Act 2007 place unit, fuel correct
2007 PPE before supply, boiler
safety requirem start-up. instrumentation start-up
procedur ents and • Carry out panel (pressure sequence
es for live exclusio cold-start gauge, from a
steam n zones checks: thermometer, provided
operation for all verify water level procedure
: PPE for personn water gauge) sheet
hot el not level in • Manufacturer's • Observatio
surfaces, directly gauge start-up and n of correct
personnel involved. glass commissioning warm-up
exclusion • Demonst (between manual procedure,
zones, rate normal • Tools: drain valve
and cold- working Spanners, drain operation,
emergen start limits), valve keys, and
cy checks: confirm inspection torch parameter
shutdown verify all valves • PPE: Helmets, recording
. water in correct face shield, • Portfolio of
• 3. Follow level in start-up insulated evidence:
the gauge position, gloves, fire- completed
correct glass, and resistant commissio
boiler confirm inspect clothing, safety ning log
start-up all fuel filter boots; with
sequence valves in and Commissioning recorded
: cold- correct burner logbook start-up
start position, nozzle. parameters
checks, check • Follow
fuel fuel the start-
 system supply, up
priming, and sequence
and inspect under
burner burner trainer
ignition. nozzles supervisi
• 4. Carry and fuel on: purge
out a filter. firebox,
controlle • Demonst prime
d warm- rate the fuel,
up: boiler ignite
gradually start-up burner,
raise sequenc and
steam e: purge monitor
pressure the pressure
while firebox, gauge as
monitorin prime steam
g water the fuel pressure
level, system, rises.
pressure ignite • Open the
gauges, the boiler
and burner, main stop
safety and valve
valve monitor slowly;
operation the drain
. initial condensa
• 5. pressure te from
Monitor rise. distributi
and • Demonst on
record rate the pipework
steam controlle low-point
system d warm- drain
paramete up valves
rs during procedur before
warm-up: e: open opening
pressure, the main
temperat boiler distributi
ure, stop on valve
water valve to
level, and slowly to prevent
any introduc water
abnormal e steam hammer.
 ities to the • Record
observed. distributi steam
on pressure,
system; water
drain level, flue
condens temperat
ate from ure, and
low- any
point observed
drain abnormal
valves ities on
before the
opening commissi
steam to oning log
pipework at 5-
. minute
• Supervis intervals
e trainee during
warm-up warm-up.
procedur Perform
e housekee
executio ping.
n;
monitor
readings
together
and
demonst
rate
recordin
g on the
commiss
ioning
log.
8 34 (1.5 CONTINOUS ASSESMENT TEST CAT 1
HRS)
9 35 & 36 Test and • 1. • Present • Under • REFs: • Oral
(3 HRS) Commissi Identify the trainer OS/Curriculum questionin
on Steam the key steam supervisi Learning Guide, g on key
System – operation system on, carry Trainer's Notes; steam
Running al running out a full Industrial system
Checks paramete check running Boilers and parameters
and rs to schedule check of Heat Recovery and their
Abnormali monitor : list the Steam normal
ty during paramet steam Generators by operating
Detection steam ers to system: V. Ganapathy ranges
system monitor record • Training Aids: • Written
running: (pressur pressure, Running boiler assessmen
pressure, e, temperat training system, t
temperat tempera ure, instrumentation identifying
ure, ture, water panel, low abnormaliti
water water level, and water level es from a
level, flue level, flue alarm, pressure provided
gas flue temperat gauge, commissio
temperat tempera ure at thermometer ning log
ure, and ture, each • Manufacturer's extract
steam steam monitorin operating • Observatio
quality. quality) g point. manual with n of correct
• 2. Carry and • Identify normal systematic
out accepta at least parameter inspection
systemati ble two ranges technique
c running ranges simulated • Tools: and
checks from the abnormal Inspection parameter
on all manufac ities torch, notebook recording
steam turer's introduce for field • Portfolio of
system manual. d by the recording evidence:
compone • Demonst trainer • PPE: Helmets, completed
nts as per rate how (e.g., low insulated running
job to water gloves, face check log
specificat conduct level shield, safety with
ions. a alarm, boots, goggles; detected
• 3. Detect systema abnormal Commissioning abnormaliti
and tic pressure logbook and es and
describe running reading, running check actions
common inspectio steam schedule taken
operation n: walk leak) and
al the state the
abnormal system correct
ities: from immediat
steam boiler to e action.
leaks, low end use, • Record
 water inspect all
level, each abnormal
pressure compon ities
fluctuatio ent while detected
ns, and the on the
burner system commissi
lockouts. is oning log:
• 4. Apply running location,
correct under descriptio
procedur steam. n,
es for • Simulate paramete
recording common r reading,
abnormal abnorma time, and
ities on lities action
the (low taken.
commissi water • Demonstr
oning log. level ate the
• 5. Take alarm, correct
appropria pressure immediat
te drop, e
immediat steam response
e actions leak at a to a low
in joint) water
response and level
to demonst alarm:
detected rate the initiate
abnormal correct manual
ities identific feed
(isolate, ation water
drain, re- and pump
set) in immedia operation
accordan te and
ce with response check
the procedur make-up
manufact e. water
urer's • Demonst valve
operating rate position.
manual. correct • Demonstr
techniqu ate
e for response
recordin to a
 g steam
abnorma leak:
lities on identify
the the leak
commiss location,
ioning close the
log: isolation
descripti valve on
on, the
location, affected
paramet branch,
er and
reading, record on
time, the
and commissi
action oning log.
taken. Perform
• Supervis housekee
e trainee ping.
running
check
exercise;
introduc
e
simulate
d faults
for
trainees
to
identify
and
respond
to.
9 37 & 38 Test and • 1. Apply • Introduc • Apply the • REFs: • Oral
(3 HRS) Commissi a e the systemati OS/Curriculum questionin
on Steam systemati systema c Learning Guide, g on
System – c tic troublesh Trainer's Notes; systematic
Steam troublesh troubles ooting Industrial troublesho
System ooting hooting methodol Boilers and oting
Troublesh methodol methodo ogy to a Heat Recovery methodolo
ooting ogy to logy: simulated Steam gy and its
(Part 1) steam sympto burner Generators by application
system m lockout: V. Ganapathy to steam
faults per identific check • Training Aids: systems
manufact ation → fuel Running boiler • Written
urer's isolation supply training system, assessmen
specificat and pressure, simulated faults t
ions. inspectio inspect (blocked diagnosing
• 2. n → root fuel filter, strainer, failed faults from
Diagnose cause verify steam trap, a set of
boiler- diagnosi thermost thermostat given
side s→ at fault) symptoms
faults: correctiv setting, • Manufacturer's and
burner e action and troubleshooting parameter
failure, → diagnose guide and fault readings
low water verificati root codes • Observatio
level, on; cause. • Tools: Contact n of correct
pressure referenc • Diagnose thermometer, diagnostic
relief e the a pressure gauge tool use
valve manufac simulated set, spanners, and fault
operation turer's low water inspection torch isolation
, and troubles level • PPE: Helmets, technique
thermost hooting fault: insulated • Portfolio of
at guide. check gloves, face evidence:
malfuncti • Demonst make-up shield, safety completed
on. rate water boots; Fault fault
• 3. diagnosi valve diagnosis forms diagnosis
Identify s of a position, forms for
and burner inspect all
diagnose lockout float simulated
common fault: switch faults
steam check operation
distributi fuel , and
on faults: pressure verify
steam , verify feed
leaks at fuel filter water
joints, conditio pump
waterlog n, check operation
ged thermost .
steam at • Diagnose
traps, setting, a
 and and waterlog
blocked identify ged
strainers. the fault steam
• 4. Use cause trap on
manufact from the the
urer's boiler distributi
troublesh fault on
ooting indicator system:
charts . use a
and • Simulate contact
diagnosti and thermom
c tools demonst eter at
(pressure rate inlet and
gauge, diagnosi outlet;
thermom s of a compare
eter) to waterlog temperat
identify ged ures to
root steam determin
causes. trap: e if trap
• 5. check has failed
Propose inlet and open or
and outlet closed.
impleme tempera • Diagnose
nt tures a blocked
correctiv with a strainer:
e actions contact measure
for thermo upstream
diagnose meter and
d boiler- and downstre
side and confirm am
distributi trap has pressure
on-side failed at the
faults. open. strainer;
• Demonst calculate
rate pressure
blocked differenti
strainer al and
diagnosi confirm
s: blockage.
compare • Complete
inlet and a fault
 outlet diagnosis
pressure form for
using each fault
pressure diagnose
gauges; d:
confirm symptom
blockage ,
by inspectio
pressure n
differenti findings,
al. root
• Supervis cause,
e correctiv
trainees e action,
in and
troubles verificatio
hooting n.
exercise Perform
s on the housekee
boiler ping.
and
distributi
on
system;
require
completi
on of
fault
diagnosi
s forms.
10 39 & 40 Test and • 1. • Demonst • Diagnose • REFs: • Oral
(3 HRS) Commissi Diagnose rate a OS/Curriculum questionin
on Steam feed diagnosi simulated Learning Guide, g on feed
System – water s of feed feed Trainer's Notes; water and
Steam system water water Industrial flue gas
System faults: pump pump Boilers and system
Troublesh pump failure: fault: Heat Recovery fault
ooting failure, check check Steam diagnosis
(Part 2) feed electrical motor Generators by procedures
water supply electrical V. Ganapathy • Written
 conditioni to supply • Training Aids: assessmen
ng unit motor, with a Running boiler t on
malfuncti inspect multimet training system, identifying
on, and impeller er, simulated faults faults from
blocked for inspect (pump fault, a table of
filter. blockage suction blocked filter, abnormal
• 2. , and strainer damper fault, parameter
Diagnose verify for economizer readings
flue gas suction blockage, fouling) • Observatio
system strainer and clear • Manufacturer's n of correct
faults: conditio the fault. troubleshooting multimeter
blocked n. • Diagnose guide, flue gas use for
chimney, • Demonst a blocked analyser electrical
damper rate feed • Tools: fault
malfuncti diagnosi water Multimeter, diagnosis
on, and s of a filter: contact and
inadequa blocked measure thermometer, pressure
te feed inlet and pressure gauge measurem
draught. water outlet set, spanners, ent
• 3. filter: pressure filter element technique
Diagnose compare differenti replacement set • Portfolio of
auxiliary inlet and al; • PPE: Helmets, evidence:
compone outlet replace insulated completed
nt faults: pressure the filter gloves, face fault
economiz ; confirm element shield, safety diagnosis
er fouling blockage and boots, goggles; and
and ID/FD and verify Fault diagnosis corrective
fan demonst restored forms action
failure. rate flow. forms for
• 4. filter • Diagnose all faults
Impleme element a flue gas
nt replace draught
correctiv ment fault:
e actions procedur inspect
for all e. chimney
diagnose • Simulate and
d faults a flue damper
per gas position;
manufact draught correct
urer's problem the
specificat (partially damper
 ions. blocked setting
• 5. Verify damper) and
the : verify
steam demonst improved
system rate use combusti
returns to of flue on from
correct gas flue gas
operation analyser temperat
after readings ure
correctiv to reading.
e action identify • Diagnose
and incomple economiz
record te er
the combust fouling:
outcome. ion compare
caused flue gas
by temperat
draught ures at
deficienc inlet and
y. outlet
• Demonst using a
rate contact
diagnosi thermom
s of eter;
economi report
zer fouling
fouling: and state
compare the
flue gas correctiv
tempera e
ture procedur
before e (soot
and after blowing).
economi • After all
zer; correctiv
increase e actions,
d monitor
tempera system
ture paramete
indicates rs to
fouling verify
 reducing return to
heat normal
recovery operation
. ; record
• Supervis all
e findings,
trainees actions,
in and
completi verificatio
ng the n results
full on fault
troubles diagnosis
hooting forms.
cycle for Perform
all housekee
assigned ping.
faults;
verify
system
returns
to
normal
operatio
n after
each
correctiv
e action.
10 41 & 42 Test and • 1. Plan • Model • Plan a • REFs: • Oral
(3 HRS) Commissi and best 10- OS/Curriculum questionin
on Steam structure practice minute Learning Guide, g on
System – an end for end end user Trainer's Notes; content
End User user user training Industrial and
Training training training session: Boilers and structure
session delivery: prepare a Heat Recovery of an end
for steam clear session Steam user
system structure outline Generators by training
operation (start- covering V. Ganapathy session
per up, start-up, • Training Aids: • Observatio
manufact operatio monitorin Boiler training n of
urer's n, g, and unit, trainee-
 specificat monitori one instrumentation delivered
ions. ng, emergen panel, training
• 2. Explain shutdow cy operator's session for
and n, response manual, accuracy,
demonstr emergen procedur maintenance safety
ate cy e. schedule emphasis,
correct response • Deliver template, daily and clarity
start-up, ), use of the start- check sheet • Written
monitorin visual up • Manufacturer's assessmen
g, and aids and procedur operator t: trainee
shutdown physical e training prepares a
procedur demonst explanati guidelines and written
es to ration. on to emergency summary
system • Demonst peers procedures of the
operators rate using the • Tools: start-up
. delivery manufact Blowdown valve and
• 3. Train of a urer's key, logbook shutdown
end users start-up manual • PPE: Helmets, procedure
to procedur and the insulated • Portfolio of
identify e actual gloves, safety evidence:
early explanat boiler boots; End user completed
warning ion to training training pack end user
signs of the unit; template training
system group; confirm pack
faults and emphasi understa (manual,
the se safety nding check
correct checks, through sheet,
immediat water Q&A. maintenan
e level • Demonstr ce
response. verificati ate and schedule,
• 4. on, and explain emergency
Demonstr pressure the daily card)
ate monitori blowdow
routine ng. n
operator • Demonst procedur
maintena rate e: open
nce delivery boiler
tasks: of blowdow
checking routine n valve
water operator for the
level, mainten specified
 blowing ance: duration,
down the daily confirm
boiler, boiler water
and blowdow level
checking n after
steam procedur blowdow
traps. e, water n, and
• 5. level record on
Provide gauge the log
end users glass sheet.
with the blowdow • Walk a
operating n, and peer
manual, visual through
maintena check of the
nce steam emergen
schedule, traps. cy
and • Role- shutdown
emergen play an procedur
cy emergen e:
procedur cy identify
e scenario the high-
reference (high- pressure
. pressure alarm,
alarm) close
and main
demonst steam
rate how valve,
to coach shut
an down
operator burner,
through and
the record
correct the
emergen event.
cy • Prepare
response and hand
procedur over a
e. training
• Supervis pack:
e include
trainees operator'
 in s manual,
deliverin daily
g their check
own sheet,
short maintena
training nce
sessions schedule,
(10 and
minutes emergen
each) to cy
peers; procedur
provide e card.
structure Perform
d housekee
feedbac ping.
k on
clarity,
safety
emphasi
s, and
accuracy
.
11 43 & 44 Test and • 1. • Present • Assemble • REFs: • Oral
(3 HRS) Commissi Identify the full all OS/Curriculum questionin
on Steam all set of complete Learning Guide, g on
System – documen docume d Trainer's Notes handover
Document tation nts checklists • Training Aids: documenta
ation and required required , test Fully assembled tion
Handover for steam for certificat and requireme
system steam es, and commissioned nts and
handover system running boiler training their
per handove logs into system, original purpose
manufact r: a installation • Written
urer's commiss structure drawings assessmen
specificat ioning d • Commissioning t: list all
ions. report, commissi report template, documents
• 2. hydrauli oning as-built drawing required
Compile c test report template, for steam
a certificat with a handover system
commissi e, as- cover checklist handover
built page,
 oning drawings table of • All previously and state
report: , contents, completed the
pre- warranty and checklists and purpose of
commissi certificat summary test certificates each
oning e, section. from sessions • Observatio
checks, operator • Prepare 27–40 n of
hydraulic manual, an as- • PPE: Helmets, handover
test mainten built safety boots; walkthroug
certificat ance drawing: Documentation h for
e, schedule mark folder clarity,
running , and deviation completen
check training s from ess, and
log, fault records. the professiona
diagnosis • Demonst original l conduct
records, rate installatio • Portfolio of
and end compilat n drawing evidence:
user ion of on a complete
training the clean commissio
records. commiss copy and ning
• 3. ioning annotate report, as-
Prepare report: with built
as-built assembl revision drawing,
drawings e all notes. and signed
and previousl • Complete handover
annotate y the checklist
any complet formal
deviation ed handover
s from checklist checklist:
the s, test confirm
original certificat all
design es, and systems
drawing logs into are
made a operation
during structure al, all
installatio d report documen
n. format. tation is
• 4. • Show complete,
Complete how to and all
a formal prepare defects
handover as-built are
checklist drawings rectified.
 and : mark • Conduct
obtain up the a peer
client/sup original handover
ervisor installati walkthrou
sign-off. on gh (10
• 5. drawing minutes):
Conduct with any present
a deviatio the
handover ns made operating
walkthrou during steam
gh with installati system,
the on explain
client, (change key
demonstr in pipe features
ating the routing, and
operating addition safety
system al interlocks
and support, , and
presentin etc.). hand
g all • Demonst over the
documen rate a documen
tation. formal tation
handove package.
r • Obtain
walkthro peer
ugh: sign-off
introduc on the
e the handover
client to checklist.
the Perform
system, housekee
explain ping and
key tidy the
operatio installatio
nal and n area.
safety
features,
and
hand
over the
docume
 ntation
package.
• Supervis
e
trainees
in
compilin
g their
commiss
ioning
reports
and
preparin
g
handove
r
docume
ntation;
review
for
complet
eness
and
accuracy
.
11 45 & 46 Integrate • 1. Apply • Brief • Conduct • REFs: • Continuous
(3 HRS) d all trainees a site OS/Curriculum trainer
Practical – preparati on the assessme Learning Guide, observatio
Full on simulatio nt using Trainer's Notes; n using the
Steam compete n the Industrial simulation
System ncies: scenario: provided Boilers and assessmen
Installatio site complet checklist; Heat Recovery t checklist
n assessme ea verify Steam (safety,
Simulatio nt, steam compone Generators by sequence,
n (Part 1: compone system nt V. Ganapathy technique,
Preparati nt installati specificat • Training Aids: and
on to verificatio on from ions Full boiler quality)
Distributi n, and site against training unit, all • Team
on) tool/mate preparat the steam system leader oral
rial ion design components, report at
 selection through requirem distribution end of
for a to ent sheet pipework, session:
complete distributi and accessories, describe
simulated on select lagging and what was
installatio system tools and cladding completed
n. completi materials materials and any
• 2. Mount on using . • Simulation issues
the boiler all • Mount installation encountere
and fit all previousl the boiler pack: drawings, d
boiler y on the P&ID, • Peer
compone learned prepared checklists, review of
nts skills. foundatio manufacturer's installation
(pressure • Assign n, level manuals quality at
gauges, roles and • Tools: Full key
safety within secure installation tool completion
valves, trainee with set (pipe points
sight teams anchor wrenches, • Portfolio of
glass, (team bolts torque wrench, evidence:
blow- leader, tightened spirit level, simulation
down boiler to the chain block, installation
valve, fitter, specified tape measure, log (stages
burner) distributi torque, welding kit, completed,
as per on fitter, and fit all threading times,
manufact docume boiler machine) observatio
urer's ntation compone • PPE: Full PPE ns)
specificat officer) nts set; Installation
ions. and (pressure logbook and
• 3. Fit the issue the gauges, simulation
feed simulatio safety assessment
water n valve, checklist
system, installati sight
fuel on pack glass,
system, (drawing blow-
and flue s, down
gas checklist valve,
system in s, burner).
the manuals • Fit the
correct ). feed
sequence • Circulate water
. between system,
• 4. Fit teams to fuel
 auxiliary observe supply
compone work lines with
nts quality; leak test,
(economi provide and flue
zer, ID/FD guidanc gas
fans, e and exhaust
steam correctiv pipework
header) e in the
and feedbac correct
steam k at key sequence
distributi stages ; record
on (boiler completio
pipework. mountin n of each
• 5. Fit all g, safety stage on
steam valve the
distributi fitting, installatio
on pipe n log.
accessori alignme • Fit
es and nt). auxiliary
apply • Monitor compone
lagging safe nts
and working (economi
cladding practices zer, ID/FD
to the througho fans,
distributi ut: steam
on enforce header);
pipework. OSH Act install
2007 steam
PPE distributi
complian on
ce, LOTO pipework
applicati with
on, and correct
correct pipe
use of supports
lifting at
equipme specified
nt. intervals.
• At the • Fit all
end of steam
the distributi
 session, on
lead a accessori
team es (steam
debrief: traps,
identify PRV,
strength strainers,
s and check
areas for valves);
improve apply
ment; lagging
relate and
findings cladding
to the to all
assessm distributi
ent on
criteria. pipework.
Perform
housekee
ping.
12 47 & 48 Integrate • 1. • Issue the • Complete • REFs: • Summative
(3 HRS) d Complete simulatio the pre- OS/Curriculum practical
Practical – all pre- n commissi Learning Guide, assessmen
Full commissi commiss oning Trainer's Notes; t using the
Steam oning ioning checklist Industrial simulation
System checks scenario: on the Boilers and commissio
Installatio on the trainees simulatio Heat Recovery ning
n simulatio are to n- Steam assessmen
Simulatio n- commiss installed Generators by t checklist
n (Part 2: installed ion the system; V. Ganapathy (pre-
Testing steam steam correct • Training Aids: commissio
and system. system any Fully installed ning,
Commissi • 2. they deficienci boiler training hydraulic
oning) Conduct installed es found system from test, start-
a in the and simulation Part up, running
hydraulic previous obtain 1, hydraulic test checks,
pressure session trainer pump, troublesho
test and as an sign-off calibrated oting)
record integrate before pressure gauge • Oral
results on d, proceedin • Commissioning questionin
the test assessed g. log, pre- g during
practical
 certificat exercise. • Conduct commissioning and after
e. • Observe the checklist, the
• 3. Carry and hydraulic hydraulic test commissio
out the assess pressure certificate, fault ning
boiler pre- test: diagnosis forms exercise on
start-up commiss prepare • Tools: Full tool safety,
sequence ioning the set, contact procedure,
and checks system, thermometer, and fault
controlle and pressuris pressure gauge diagnosis
d warm- hydrauli e to test set, multimeter, • Completed
up c pressure leak detection commissio
procedur pressure in stages, spray ning log
e. test monitor • PPE: Full live reviewed
• 4. executio for leaks, steam PPE; for
Perform a n record all Complete accuracy
full set of without findings commissioning and
running intervent on the documentation completen
checks, ion test pack ess
identifyin unless a certificat • Portfolio of
g and safety e. evidence:
recording issue • Execute complete
any arises. the boiler commissio
abnormal • Introduc start-up ning
ities. e two sequence documenta
• 5. pre- and tion set
Conduct planned controlle (pre-
troublesh simulate d warm- commissio
ooting on d faults up ning
at least during procedur checklist,
two the e; record hydraulic
simulated running all test
faults and phase paramete certificate,
verify (e.g., rs commissio
return to low (pressure ning log,
normal water , fault
operation level temperat diagnosis
. alarm, ure, forms,
blocked water commissio
strainer) level) on ning
for the report)
trainees commissi
 to detect oning log
and at 5-
diagnose minute
. intervals.
• Assess • Carry out
trainee a full
response running
to faults: check of
evaluate the
diagnost commissi
ic oned
approac system;
h, tool detect
use, and and
applicati record all
on of the simulated
manufac abnormal
turer's ities
troubles introduce
hooting d by the
guide. trainer.
• Lead a • Diagnose
structure both
d debrief simulated
at the faults
end of using the
the systemati
session: c
review troublesh
commiss ooting
ioning methodol
logs, ogy;
discuss impleme
fault nt
response correctiv
s, and e actions
identify and
any verify
areas return to
requiring normal
further operation
 consolid .
ation Complete
before the
summati commissi
ve oning
assessm report.
ent. Perform
housekee
ping.
12 49 & 50 Unit • 1. Review • Lead a • Participat • REFs: • Mock oral
(3 HRS) Review, all structure e in the OS/Curriculum assessmen
Portfolio learning d unit unit Learning Guide, t responses
Finalisati outcomes review: review: Trainer's Notes; reviewed
on, and covered use state the Occupational against
Summativ in the 12- visual key tasks Standard (Unit performanc
e week unit summar and Code 0715 551 e criteria
Preparati of y charts performa 25A) – for depth
on learning: of the nce Performance and
preparati four criteria Criteria accuracy
on, learning for each • Training Aids: • Portfolio of
assembly outcome of the Visual summary evidence
, areas four charts of unit reviewed
distributi (prepara learning content, unit by trainer
on, and tion, outcome performance for
testing assembl areas criteria checklist completen
and y, (preparati • All completed ess against
commissi distributi on, checklists, test all unit
oning. on, assembly certificates, competenc
• 2. testing , logs, and ies
Identify and distributi commissioning • Completed
and commiss on, reports from the self-
address ioning) testing full 12-week assessmen
any and and unit t form
knowledg invite commissi • Mock oral returned to
e or skill trainees oning). assessment trainer
gaps to recall • Complete question bank • Portfolio of
identified key the gap- (prepared by evidence:
during tasks identifica trainer) fully
the and tion • Self-assessment compiled,
integrate procedur exercise: form; Portfolio organised,
 d es. compare folder with and
simulatio • Facilitate personal dividers labelled
n. a gap- portfolio portfolio
• 3. identific against covering all
Compile ation the unit 4 learning
and exercise: performa outcomes
organise trainees nce of the unit
a compare criteria
complete their list;
portfolio complet highlight
of ed any
evidence checklist missing
covering s and documen
all unit logs ts or
compete against incomplet
ncies. the full e
• 4. list of records.
Demonstr unit • Organise
ate perform portfolio
compete ance of
nce in criteria evidence
respondin to into the
g to a identify required
range of areas sequence
oral needing : place all
assessme further complete
nt consolid d
questions ation. checklists
covering • Guide , test
the full trainees certificat
unit. in es, logs,
• 5. organisi and
Confirm ng their reports
readiness portfolio into a
for of labelled
summativ evidence portfolio
e : ensure folder.
assessme all • Respond
nt by required to mock
completin docume oral
g a self- nts are assessme
assessme present nt
nt (site questions
against assessm on
all unit ent compone
performa checklist nt
nce , identifica
criteria. compon tion,
ent installatio
verificati n
on procedur
checklist es, OSH
, Act 2007
mountin requirem
g ents,
checklist troublesh
, fitting ooting
checklist methodol
s, ogy, and
hydrauli commissi
c test oning
certificat procedur
e, es.
commiss • Complete
ioning the self-
log, assessme
handove nt form:
r pack). rate
• Conduct personal
a mock compete
oral nce
assessm against
ent each
round: performa
pose nce
question criterion
s and
covering identify
all four up to
learning three
outcome areas for
areas; final
 provide revision
feedbac before
k on the
depth, summativ
accuracy e
, and assessme
confiden nt.
ce of
response
s.
• Administ
er the
self-
assessm
ent
form;
review
complet
ed forms
with
individua
l
trainees
and
confirm
readines
s or
recomm
end
specific
revision
activities
before
the
summati
ve
assessm
ent.

Prepared By (Trainer) Verified By Approved By

Name: Name: Name:
______________________________ ______________________________ ______________________________
Signature: Signature: Signature:
__________________________ __________________________ __________________________
Date: Date: Date:
_______________________________ _______________________________ _______________________________