Thermal Power Plant Maintenance Training

Lesson 1 • Turbine and Generator Overview

Introduces steam turbine stages, rotor assemblies, and generator coupling. Provides context for turbine maintenance tasks covered in later chapters.

Lesson 2 • Plant Layout and Major Systems

Maps the physical arrangement of boiler, turbine, condenser, and auxiliary systems. Enables technicians to navigate plant areas and understand system interdependencies.

Lesson 3 • Boiler System Components

Identifies boiler drums, headers, superheaters, reheaters, and economisers. Connects component function to steam quality and plant output.

Lesson 4 • Auxiliary and Balance-of-Plant Systems

Surveys pumps, fans, compressors, and control systems that support primary equipment. Establishes awareness of auxiliary failures that affect overall plant reliability.

Lesson 1 • Environmental and Chemical Safety

Addresses safe handling of boiler chemicals, fuel oils, and ash residues in compliance with environmental standards. Prepares technicians to manage spills and chemical exposures safely.

Lesson 2 • Lockout/Tagout Procedures

Details energy isolation steps for electrical, pneumatic, hydraulic, and thermal energy sources. Ensures technicians can safely de-energise equipment before any maintenance activity.

Lesson 3 • Hazard Identification and Risk Assessment

Teaches systematic identification of thermal, electrical, chemical, and mechanical hazards. Directly supports safe execution of all maintenance tasks in subsequent chapters.

Lesson 4 • Permit-to-Work Systems

Explains hot work, confined space, and high-voltage permit types and their authorisation chains. Connects permit compliance to accident prevention across all maintenance disciplines.

Lesson 1 • Boiler Inspection Techniques

Covers visual, dimensional, and non-destructive inspection methods for pressure parts. Provides the diagnostic foundation for all boiler maintenance decisions.

Lesson 2 • Boiler Pressure Testing and Recommissioning

Details hydrostatic testing, leak detection, and step-by-step boiler startup after maintenance. Validates repair quality and ensures safe return to service.

Lesson 3 • Tube Failure Analysis and Repair

Identifies common tube failure modes including corrosion, erosion, and overheating. Connects failure root causes to appropriate repair and prevention strategies.

Lesson 4 • Soot Blower and Ash Handling Maintenance

Covers soot blower lance inspection, packing replacement, and drive mechanism servicing. Ensures heat transfer surfaces remain clean for efficient boiler operation.

Lesson 1 • Blade and Nozzle Repair

Addresses blade erosion, cracking, and fouling assessment along with approved repair methods. Directly impacts turbine efficiency and mechanical integrity.

Lesson 2 • Turbine Disassembly and Inspection

Covers safe turbine isolation, casing removal, and systematic internal inspection procedures. Establishes the correct sequence for all turbine overhaul work.

Lesson 3 • Rotor Balancing and Alignment

Teaches rotor runout measurement, dynamic balancing, and shaft alignment to coupling. Prevents vibration-induced failures after turbine reassembly.

Lesson 4 • Turbine Reassembly and Startup

Details casing reassembly, bolt torquing sequences, and controlled turbine startup procedures. Validates overhaul quality through performance trending during initial operation.

Lesson 1 • Pump Disassembly and Component Inspection

Covers systematic pump teardown, impeller wear measurement, and casing inspection. Provides the procedural basis for pump repair and parts replacement.

Lesson 2 • Mechanical Seal and Packing Maintenance

Addresses mechanical seal face inspection, spring setting, and packing gland adjustment. Prevents leakage failures that cause pump downtime and environmental incidents.

Lesson 3 • Centrifugal Pump Fundamentals

Reviews pump curves, cavitation, and NPSH requirements as the basis for maintenance decisions. Connects hydraulic performance to mechanical condition assessment.

Lesson 4 • Shaft Alignment and Coupling Maintenance

Teaches dial indicator and laser alignment methods for pump-motor and fan-motor trains. Misalignment is a leading cause of bearing and seal failures in rotating equipment.

Lesson 1 • Transformer Inspection and Maintenance

Covers oil sampling, cooling system checks, and tap changer maintenance for power transformers. Transformer health is critical to plant output and grid connection reliability.

Lesson 2 • Instrumentation Calibration and Maintenance

Teaches calibration of pressure, temperature, flow, and level transmitters used in plant control loops. Accurate instrumentation is essential for safe and efficient plant operation.

Lesson 3 • Switchgear and Circuit Breaker Maintenance

Addresses contact inspection, mechanism lubrication, and trip testing for medium-voltage switchgear. Ensures reliable fault protection for all plant electrical systems.

Lesson 4 • Motor Maintenance and Testing

Covers winding insulation testing, bearing replacement, and cooling system inspection for plant motors. Motor reliability directly supports all rotating equipment covered in prior chapters.

Lesson 1 • Vibration Analysis Fundamentals

Introduces vibration measurement, frequency spectra, and fault signatures for rotating machinery. Provides the analytical foundation for predictive maintenance decisions.

Lesson 2 • Ultrasonic and Acoustic Monitoring

Covers ultrasonic detection of steam leaks, bearing defects, and electrical discharge. Complements vibration and thermography data for comprehensive equipment assessment.

Lesson 3 • Thermographic Inspection Techniques

Covers infrared camera operation, emissivity settings, and thermal anomaly interpretation for electrical and mechanical equipment. Enables non-contact detection of overheating faults.

Lesson 4 • Oil and Lubricant Analysis

Teaches sampling procedures, viscosity testing, and wear particle analysis for turbine and bearing oils. Oil condition data guides lubrication system maintenance and component life decisions.

Lesson 1 • Outage Scheduling and Critical Path

Teaches network scheduling, critical path identification, and resource levelling for outage planning. Scheduling accuracy directly determines outage duration and return-to-service dates.

Lesson 2 • Outage Scope Development

Covers work scope identification from condition data, inspection findings, and regulatory requirements. A well-defined scope prevents scope creep and unplanned outage extensions.

Lesson 3 • Post-Outage Review and Lessons Learned

Teaches outage performance analysis, cost variance review, and formal lessons-learned documentation. Continuous improvement of outage processes reduces future outage duration and cost.

Lesson 4 • Spare Parts and Materials Management

Addresses critical spare identification, inventory control, and pre-outage kitting procedures. Parts availability is a primary driver of outage duration and cost.