Stationary Engineer Course

Lesson 1 • Overview of Plant Systems

Surveys boilers, HVAC, refrigeration, electrical, and auxiliary systems found in industrial plants. Provides a systems-level map students reference throughout the course.

Lesson 2 • Engineering Mathematics and Units

Reviews arithmetic, algebra, and unit conversions essential for pressure, temperature, and flow calculations. Prepares students for quantitative work in later chapters.

Lesson 3 • Workplace Safety and Regulatory Compliance

Covers hazard identification, personal protective equipment, and compliance with occupational safety standards. Safety principles underpin every operational chapter.

Lesson 1 • Properties of Steam and Water

Examines steam tables, saturation curves, and quality calculations critical to boiler operation. Students interpret steam properties to optimise system performance.

Lesson 2 • Laws of Thermodynamics

Explains the first and second laws of thermodynamics and their direct application to boilers and engines. Provides the theoretical basis for energy efficiency analysis.

Lesson 3 • Combustion Theory and Efficiency

Analyses fuel chemistry, stoichiometric air requirements, and flue gas composition. Students calculate combustion efficiency and identify losses for improvement.

Lesson 4 • Energy Balances and System Efficiency

Applies energy balance equations to boilers, turbines, and heat exchangers. Students quantify losses and propose efficiency improvements.

Lesson 1 • Boiler Codes and Inspection Standards

Introduces pressure vessel construction codes, inspection intervals, and documentation requirements. Compliance with these standards is mandatory for licensed operation.

Lesson 2 • Boiler Components and Construction

Identifies drums, headers, tubes, furnace walls, and refractory materials. Understanding construction enables accurate inspection and maintenance planning.

Lesson 3 • Boiler Classification Systems

Categorises boilers by tube arrangement, pressure rating, and fuel type. Classification knowledge guides equipment selection and regulatory compliance.

Lesson 1 • Boiler Monitoring and Routine Adjustments

Trains students to read instrumentation, adjust combustion controls, and log operational data. Continuous monitoring ensures safe and efficient boiler performance.

Lesson 2 • Boiler Startup and Shutdown Procedures

Details pre-startup checks, light-off sequences, load ramping, and controlled shutdown steps. Proper sequencing prevents thermal shock and equipment damage.

Lesson 3 • Boiler Water Chemistry Fundamentals

Explains pH, hardness, dissolved oxygen, and conductivity parameters that govern water quality. Water chemistry directly affects boiler longevity and steam purity.

Lesson 4 • Boiler Abnormal Conditions and Response

Identifies low water, high pressure, flameout, and carryover events and prescribes corrective actions. Rapid, correct response prevents catastrophic failures.

Lesson 1 • Heat Exchangers and Process Heating

Covers shell-and-tube, plate, and coil heat exchangers used for process and space heating. Students calculate duty, identify fouling, and perform cleaning procedures.

Lesson 2 • Pressure-Reducing and Control Valves

Explains pressure-reducing stations, control valve types, and positioner calibration. Proper valve operation delivers steam at correct pressure to end users.

Lesson 3 • Steam Piping Systems and Components

Covers pipe materials, fittings, expansion joints, and insulation used in steam distribution. Proper piping design prevents water hammer and heat loss.

Lesson 4 • Steam Traps and Condensate Management

Explains trap types, selection criteria, and testing methods for condensate removal. Effective trap management recovers heat and reduces makeup water consumption.

Lesson 1 • HVAC System Operation

Covers air handling units, ductwork, dampers, and terminal units used in comfort and process HVAC. Students balance airflow and maintain indoor air quality standards.

Lesson 2 • Refrigeration and HVAC Troubleshooting

Applies systematic fault-finding to common refrigeration and HVAC failures using gauges and diagnostics. Students develop structured diagnostic habits transferable to all plant systems.

Lesson 3 • Cooling Towers and Condenser Water Systems

Explains cooling tower operation, water treatment, and Legionella prevention in open recirculating systems. Proper management protects equipment and public health.

Lesson 4 • Refrigeration System Components

Identifies compressors, condensers, expansion devices, and evaporators and explains their functions. Component knowledge supports accurate troubleshooting and maintenance.

Lesson 1 • Electrical Maintenance and Testing

Trains students to use multimeters, megohmmeters, and thermal imaging for electrical maintenance. Preventive testing reduces unplanned outages and extends equipment life.

Lesson 2 • Electrical Fundamentals Review

Reviews voltage, current, resistance, power, and Ohm's law as applied to plant electrical systems. Provides the quantitative base for motor and control circuit analysis.

Lesson 3 • Electrical Distribution and Switchgear

Covers transformers, switchboards, breakers, and bus systems that distribute power throughout the plant. Students perform safe switching operations and interpret single-line diagrams.

Lesson 4 • Instrumentation and Control Systems

Covers sensors, transmitters, controllers, and control loops used in boiler and HVAC automation. Students calibrate instruments and interpret control system responses.

Lesson 1 • Predictive Maintenance Techniques

Introduces vibration analysis, oil analysis, thermography, and ultrasonic testing as condition-monitoring tools. Predictive methods detect faults before failure occurs.

Lesson 2 • Root Cause Analysis and Failure Investigation

Applies fault tree analysis, fishbone diagrams, and the five-whys method to equipment failures. Systematic root cause analysis prevents recurrence and improves plant reliability.

Lesson 3 • Energy Management and Sustainability

Applies energy auditing, key performance indicators, and conservation measures to reduce plant operating costs. Students identify and quantify energy-saving opportunities across all systems.

Lesson 4 • Work Order and Maintenance Management Systems

Covers computerised maintenance management system use for work orders, parts inventory, and history tracking. Accurate records support compliance audits and reliability analysis.