Boiler Failure Analysis & Prevention
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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 desecration 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.
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.
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.
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).
Upon successful completion of this course, the delegates will be able to:
- Have an understanding of 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.
- Have a strong understanding 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. The course also provides practical options to use when troubleshooting resin-based systems
- Water Chemistry, Boiler Water Quality Requirements
- Mechanical De-aeration, Chemical
- Scavenging, Testing
- Cycles of Operation, Blow-down Monitoring
Principles of Internal Treatment:
- Boiler Design and Heat Flux, Circulation
- Either Low Pressure—Phosphates, Chelants, Dispersants or High Pressure—Iron Deposition, Dispersants. EPRI
- Guidelines (Participants will Choose One)
- Either Low Pressure—Corrosion Control in Cast Iron Boilers, Boiler System Testing or High Pressure—Coordinated Phosphate/pH, Congruent Control, AVT, Neutral Oxygen
Heat Recovery Steam Generators:
- Flow and Load Considerations, Multiple Pressure System Chemistries
- Carry-Over Mechanisms, Steam Purifications, Monitoring
Chemical Cleaning of Boilers:
- Commissioning Cleaning, Deposit Monitoring, Deposit Condensate Corrosion: Corrosion Mechanisms, Amine Treatment, Testing
- Mixed Beds, Powdered Resin Units, Magnetic Filtration
- Boiler Tube Failure Modes, Metallurgical Analysis, Metallurgical
Boiler Tube Testing:
- Destructive Sampling and Non-Destructive Testing Methods, Visual Boiler Inspection
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
- Participants’ Water and Resin Analyses
- Exhaustion Profiles, Distributor Design, Regenerate Dilution Systems
- Equipment, Service and Regeneration Reactions, Performance Expectation
- Short Run, Poor Water Quality, Resin Problems
- Makeup Mixed Beds, Performance Expectations, Regeneration
- Protocols, Three Component Systems, Uniform Particle Size Resins
- Vessel Inspection, Sample Procurement, Interpretation of Resin
- Analysis, Decision to Clean or Replace
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
- Case Studies and Self Questionaires
- Group Work
Who should attend
This is course is intended to those new to the field take away a good multi-discipline understanding of the issues involved in their work. It helps them in becoming productive quickly and in building a knowledge framework that will help them identify, understand, classify and remember on the job learning and experiences.
Implementation Teams: This program can be used to train implementation teams? When a new project or initiative is being started in your organization; when a new strategic focus is being initiated; just prior to a consultant being hired to advise the organization