Video Training Series

Boiler Outage Mastery
Professional Training Course

A full video training series for outage managers, plant managers, boiler engineers, reliability leaders, inspectors, QA/QC professionals, and maintenance teams in WTE, biomass, RDF, CFBC, and high-fouling boiler service.

Available Now Chapter 1 — Introduction to Solid Fuel Boiler Systems

What you will learn in Chapter 1

Rafael E. Sanchez explains why a WTE boiler is not simply a steam generator. It is four systems operating simultaneously: a combustion machine, an ash-handling system, a gas-conditioning system, and a pressure-part reliability system.

This lesson introduces the operating logic behind solid-fuel boiler systems, the full gas path from the feed hopper to the stack, major damage-mechanism risk zones, ash-stream diagnostics, chlorine-loading risk, and the field logic required to build a better outage scope.

WTE boiler system architecture
Combustion, grate, air staging & bed-depth interaction
Bottom ash vs. fly ash as diagnostic evidence
Gas path from feed hopper to stack
Lower furnace active oxidation risk
Superheater creep and chloride/sulfate corrosion
Economizer erosion and FAC risk
Fuel chlorine loading by fuel type
Building scope around damage mechanisms
Field Rule: If you only look at where the damage is, not at what caused it, you will repair the symptom and repeat the failure at every outage cycle.
Full Course Outline

23 Chapters — Full Outage Lifecycle

Chapter 1 is available now. The full 23-chapter course is in development. Enter your email below to be notified at launch.

Ch. 1
Introduction to Solid Fuel Boiler Systems in WTE and High-Fouling Service
System architecture, gas path, damage risk zones, ash stream diagnostics, chlorine loading
Available
Ch. 2
Combustion Chemistry and Active Corrosion Mechanisms
Active oxidation cycle, chemical environment by zone, deposit stratification
Coming Soon
Ch. 3
Waterwall Inspection, Damage Patterns, and Fitness Assessment
Surface preparation, damage pattern recognition, repair decision logic, screening tools
Coming Soon
Ch. 4
Superheater and Platen Inspection — Creep, Corrosion, and Life Assessment
Creep mechanisms, inspection strategy, alloy selection, soot blower review
Coming Soon
Ch. 5
Economizer Inspection — Erosion, FAC, and Back-End Corrosion
Erosion mechanisms, flow-accelerated corrosion, acid dew-point, scope decision logic
Coming Soon
Ch. 6
Refractory Failure Modes, Material Selection, and QA Controls
Failure modes by service, dryout engineering, heat-up curves, QA release criteria
Coming Soon
Ch. 7
Welding QA/QC Workflow — ASME Section IX Framework
WPS/PQR/WPQ management, NCR workflow, heat-input control, field weld metrics
Coming Soon
Ch. 8
NDE Method Selection Framework
Method selection, PAUT, TOFD, guided-wave UT, replication, FFS and remaining-life logic
Coming Soon
Ch. 9
Hydrostatic Test Readiness, Execution, and Acceptance
Pre-hydro readiness, boundary control, safety protocols, acceptance criteria
Coming Soon
Ch. 10
Outage Critical Path and Gate Control
Technical gate framework, risk register, CPI/SPI recovery logic
Coming Soon
Ch. 11
Scaffold, Access, Lifting, and Fan/Damper Controls
Access engineering, technical consequences, fan and damper inspection thresholds
Coming Soon
Ch. 12
Material Traceability and QA Controls
Traceability requirements, MTRs, welding filler controls, contractor QA
Coming Soon
Ch. 13
Startup Stabilization and Post-Outage Watch Protocol
Startup surveillance, zone-by-zone watch logic, escalation triggers, readiness gate
Coming Soon
Ch. 14
Risk-Based Inspection Framework
Probability and consequence definitions, RBI risk bands, response requirements
Coming Soon
Ch. 15
Post-Outage FMEA and Failure Prevention
FMEA scoring and ownership, critical repair zones, watch actions
Coming Soon
Ch. 16
Between-Outage Reliability and Condition Monitoring
Zone-based monitoring intervals, interpreting results, recurring failure prevention
Coming Soon
Ch. 16A
Fan and Draft System Inspection
Fan inspection scope, screening thresholds, restart surveillance protocol
Coming Soon
Ch. 17
Outage Management Maturity Model
Three maturity levels across six performance dimensions
Coming Soon
Ch. 18
KPI Tracking and Management Feedback
KPI interpretation, pattern recognition, management response logic
Coming Soon
Ch. 19
Lifecycle Economics and the Repair-vs.-Replace Decision
Net Technical Value framework, lifecycle lens, documenting the decision basis
Coming Soon
Ch. 20
Outage Punch List and Turnover Classification
Class A/B/C classification, zone turnover status tracking
Coming Soon
Ch. 21
Damage Mechanism Summary and Quick-Identification Guide
Mechanism-to-evidence diagnostic table, visible evidence alignment
Coming Soon
Ch. 22–24
Bibliography, Code-Reference Index & Integrated Implementation Framework
Formal bibliography, code navigation matrix, edition-transition notes, governance model
Coming Soon

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Get the Field Manual Now

The full 120-page field engineering manual is available today. Individual license at $150. Site license for your entire plant team at $600. Instant PDF download.

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© 2026 Rafael E. Sanchez · Boiler Outage Academy · rafael@boileroutageacademy.com
This training series supplements but does not supersede ASME BPVC, NBIC, engineer-of-record authority, or jurisdictional requirements.