Safe Operation, Inspection and Maintenance of Six Essential Boiler Fittings

Training Information	Details
Date	16-17 October 2026
Time	9:00 a.m.-5:00 p.m.
Training Fee	RM2,100 per participant, inclusive of SST
Day 1 Venue	GoldenBay Hotel, Bintulu
Day 2 Venue	Mahagamy Training Center, Bintulu
Steam Engineer CEP Points	10 CEP Points
Trainer	Ts. Dr. Bede Simon
HRD Corp	HRD Corp Claimable Course, subject to terms and conditions

Course Introduction

Steam boilers operate under pressure and contain significant stored thermal energy. Failure of an essential boiler fitting may result in overpressure, low-water conditions, overheating, steam release, pressure-part damage, fire, explosion or serious injury.

This two-day programme provides participants with the knowledge and practical skills required to understand, inspect, test and safely operate six essential boiler fittings:

1. Pressure safety valve

2. Steam pressure gauge

3. Water gauge glass

4. Low-water alarm and fuel cut-off

5. Boiler blowdown valve

6. Boiler manufacturer’s nameplate

The programme also covers statutory requirements, routine inspections, maintenance, emergency response, recordkeeping and preparation for Certificate of Fitness inspections.

The course is conducted with reference to the Occupational Safety and Health Plant Requiring Certificate of Fitness Regulations 2024, P.U. (A) 99/2024.

Learning Objectives

Upon completing this programme, participants should be able to:

• Explain the hazards associated with steam-boiler operations.

• Identify the six essential boiler fittings and their locations.

• Explain the purpose and operating principle of each fitting.

• Relate each fitting to boiler protection and safe operation.

• Inspect boiler fittings for leakage, blockage, damage, calibration and correct installation.

• Explain or carry out the required functional tests.

• Perform an approved water-gauge-glass blow-through procedure.

• Explain the safe operation of boiler blowdown valves.

• Respond correctly to low-water, overpressure and instrument-failure situations.

• Interpret the information on a boiler manufacturer’s nameplate.

• Recognise defects requiring shutdown, isolation or maintenance.

• Complete boiler logbooks, inspection checklists and maintenance records.

• Explain regulatory responsibilities relating to boiler inspections and Certificate of Fitness requirements.

Training Outcomes

By the end of the programme, participants should be able to:

• Conduct routine checks on the six essential boiler fittings.

• Identify unsafe or defective conditions.

• Carry out or support approved functional-test procedures.

• Respond appropriately to overpressure and low-water conditions.

• Support boiler maintenance and statutory inspections.

• Prepare for Certificate of Fitness inspections.

• Maintain complete operating, inspection and maintenance records.

• Demonstrate improved boiler-safety awareness and procedural compliance.

Training Methodology

The programme will be delivered through:

• Instructor-led presentations

• Facilitated group discussions

• Technical demonstrations

• Practical exercises

• Case studies and emergency scenarios

• Written assessment

• Practical competency assessment

Course Outline

Day 1: Boiler Safety, Regulatory Requirements and Pressure/Level Fittings

Module 1: Boiler Safety Fundamentals
Boiler hazards, stored energy, overpressure, low water, thermal damage and accident prevention.

Module 2: Regulatory Requirements
P.U. (A) 99/2024, Certificate of Fitness requirements, competent persons, statutory inspections and maintenance responsibilities.

Module 3: Pressure Safety Valve
Construction, operation, set pressure, blowdown, inspection, testing and failure response.

Module 4: Steam Pressure Gauge
Bourdon-tube operation, siphon, pressure range, calibration, defects and operational checks.

Module 5: Water Gauge Glass
Water-level indication, gauge-glass components, false water levels, blow-through procedures and emergency response.

Module 6: Day 1 Integrated Practical
Inspection of the pressure safety valve, steam pressure gauge and water gauge glass.

Day 2: Low-Water Protection, Blowdown, Nameplate and Assessment

Module 7: Low-Water Alarm and Fuel Cut-Off
Low-water hazards, detection methods, alarms, trips, burner cut-off and emergency response.

Module 8: Boiler Blowdown Valve
Bottom blowdown, surface blowdown, valve arrangements, safe operating sequences and associated hazards.

Module 9: Boiler-Water and Blowdown Control
Total dissolved solids, conductivity, sludge, scale, carryover and effective blowdown control.

Module 10: Boiler Manufacturer’s Nameplate
Design pressure, safe working pressure, capacity, serial number and boiler traceability.

Module 11: Inspection, Maintenance and Records
Routine inspections, defect reporting, boiler logbooks and maintenance records.

Module 12: Boiler Emergency Scenarios
Response to overpressure, low water, broken gauge glass, valve leakage and instrument failure.

The programme concludes with a practical competency assessment and written post-assessment.

Trainer Profile

Ts. Dr. Bede Simon

Ts. Dr. Bede Simon is an Industrial Management doctorate holder with approximately 20 years of multidisciplinary experience in power-plant operations, utilities and manufacturing.

His professional experience covers the full lifecycle of industrial assets, including pre-commissioning, commissioning, performance testing, safe plant operation and long-term maintenance. He currently leads safe combined-cycle gas-turbine plant operations at Petroleum Sarawak Berhad.

He specialises in steam-boiler systems, plant maintenance, operational safety, asset performance and DOSH/OSHA compliance. He is also experienced in developing competency programmes that strengthen the technical knowledge and practical capabilities of plant operations personnel.

Ts. Dr. Bede Simon is registered with DOSH as a trainer for Boiler and Steam Engineer programmes.