Boiler & Steam System Management Performance, Efficiency, Troubleshooting, Tune-up, Heat Recovery & Optimization

The chemistry and control of phosphates, chelant, and sludge conditions were be reviewed in depth. Problems and solutions associated with steam purity and condensate corrosion will be covered in detail with several practical examples. Guidelines for chemical cleaning will be developed.  This course will provide a comprehensive review of the principles of boiler water conditioning. The ASME and EPRI Boiler Chemistry Guidelines will be developed. Oxygen control by means of de-aeration and chemical treatment will be reviewed. Boiler design principles will be developed, including heat transfer, circulation effects, and high-pressure requirements. The special requirements of HRSGs will be reviewed in depth.

Ion exchange is a critical unit process in purifying water for steam generation, semiconductor manufacture, and pharmaceutical applications. The course reviews resin structure, function, and the gamut of water purification applications from softening to the preparation of ultra-quality water. The course has been modified to focus on monitoring performance and reacting to system upsets (troubleshooting). The discussion of the metallurgical analysis of failed boiler tubes includes a workshop. The course concludes with destructive and non-destructive options for boiler tube inspection.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

• The course also provides practical options to use when troubleshooting resin-based systems
• Understand the chemistry of boiler water treatment for scale, corrosion, and carryover control, treatment options for the gamut of industrial boiler system pressures, the options and precautions associated with boiler chemical cleaning, and metallurgical analysis of failed boiler specimens
• Obtain knowledge of the chemistry of ion exchange resins and the operation of systems using ion exchange resins for water purification, including system and vessel design parameters

Who Should Attend?

Foremen/women and shift supervisors should gain job enrichment by understanding the importance of water treatment equipment, early detection of problems, and operator training techniques. Those in a design capacity at architect-engineering firms should find merit in the review of the technology. At the corporate level, this course provides a comprehensive update for company water consultants or engineering review committee members. This course is intended for utility superintendents, power house supervisors, and plant engineers should gain specific and practical knowledge from this course. The course should be especially valuable for engineers working on plant expansions, since technology trends are reviewed. Special emphasis has been added on cogeneration and combined cycle systems.

Course Outline

Day 1
Water Chemistry, Boiler Water Quality Requirements
Oxygen Control

• Mechanical De-aeration, Chemical Scavenging, Testing

Boiler Calculations
Cycles of Operation, Blowdown Monitoring
Principles of Internal Treatment:
Boiler Design and Heat Flux, Circulation

Day 2
Deposition Control

• Either Low Pressure—Phosphates, Chelants, Dispersants
• High Pressure—Iron Deposition, Dispersants, EPRI
• Guidelines (Participants will Choose One)

Corrosion Control:

• Either Low Pressure—Corrosion Control in Cast Iron Boilers, Boiler System Testing or High Pressure—Coordinated Phosphate/pH, Congruent Control, AVT, Neutral Oxygen

Day 3
Heat Recovery Steam Generators
Flow and Load Considerations, Multiple Pressure System Chemistries
Carry-Over Control
Carry-Over Mechanisms, Steam Purifications, Monitoring Carry-Over
Chemical Cleaning of Boilers
Commissioning Cleaning, Deposit Monitoring, Deposit Removal

• Condensate Corrosion

Corrosion Mechanisms, Amine Treatment, Testing
Condensate Polishing
Mixed Beds, Powdered Resin Units, Magnetic Filtration
Failure Analysis

• Boiler Tube Failure Modes, Metallurgical Analysis, Metallurgical Workshop

Boiler Tube Testing

• Destructive Sampling and Non-Destructive Testing Methods, Visual Boiler Inspection

Day 4
Introduction of Ion Exchange
Water Chemistry Units, Pretreatment Requirements of Ion Exchange
Ion Exchange Resins:
Synthesis, Types, Water of Hydration, Commercial Equivalents
Ion Exchange Softening:
Equipment, Service and Regeneration Reactions, Troubleshooting
Two-Bed Demineralization:

• Equipment, Service and Regeneration Reactions, Performance Expectations

Day 5
Individual Conferences
Participants’ Water and Resin Analyses
Two-Bed Demineralization (continued)
Exhaustion Profiles, Distributor Design, Regenerate Dilution Systems
Troubleshooting Demineralizers

• Short Run, Poor Water Quality, Resin Problems

Mixed Beds

• Makeup Mixed Beds, Performance Expectations, Regeneration Protocols, Three Component Systems, Uniform Particle Size Resins

Resin Testing

• Vessel Inspection, Sample Procurement, Interpretation of Resin Analysis, Decision to Clean or Replace

Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation

Course Fees

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings

Daily Course Timings
08:00 - 08:20 Morning Coffee / Tea
08:20 - 10:00 First Session
10:00 - 10:20 Coffee / Tea / Snacks
10:20 - 12:20 Second Session
12:20 - 13:30 Lunch Break & Prayer Break
13:30 - 15:00 Last Session