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

ICTD International Centre for Training and Development

How long?

  • 5 days
  • in person

ICTD International Centre for Training and Development


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Who should attend

This course is intended for utility superintendents, power house supervisors, and plant engineers should gain specific and practical knowledge from this course. 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. 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.

About the course

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.

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).

Course Objectives

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

  • 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
  • The course also provides practical options to use when troubleshooting resin-based 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

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Boiler & Steam System Management: Performance, Efficiency, Troubleshooting, Tune-up, Heat Recovery & Optimization at ICTD International Centre for Training and Development

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