Introduction:
Steam is a crucial fluid in the oil, gas, and chemical industries’ process sectors. In addition to powering stream-turbine-driven generators, steam also influences chemical reactions in which water molecules at high temperatures are necessary for specific transformative reactions.
How does a commercial steam boiler function?
Boiling water for a long time produces steam, but producing steam for industrial purposes is more complicated and requires sophisticated constructed steam generation units with or without steam turbine engines (STGs).
Attendees will leave this training course with a thorough understanding of industrial steam boiler systems, operations, and maintenance.
Course Objectives
This comprehensive course will equip the participants to:
- Understand the concepts around Industrial Steam Boiler System, Operation and Maintenance.
- Comprehend the chemical and physical properties of steam, including its hazards.
- Learn about steam generation thermodynamic cycles e.g., Rankine Cycle
- Discover the advantages and disadvantages of steam
- Understand the layout of equipment in a steam generation plant
- Learn the operational procedures including safe shutdown, turnaround, and the start-up of a steam plant.
- Orient on safety preparation for the turnaround of a steam plant.
- Understand the inspection and maintenance aspects of a steam plant.
- Appreciate the importance of personnel protection equipment in steam plant
- Comprehend managing emergencies in the steam plant.
- Under legal, regulatory and insurance implications
Organizational Benefits
Companies who nominate their employees to participate in this ‘Industrial Steam Boiler System, Operation and Maintenance’ course can benefit in the following ways:
- Ensure a trouble-free operation, inspection and maintenance of steam Plants
- Appreciate hazards of steam and safety around it
- Confidently use steam to produce economically crucial power
- Improved financial performance due to a well-maintained steam plant
Personal Benefits
Individuals who participate in this ‘Industrial Steam Boiler System, Operation and Maintenance’ course can gain from it in the following ways:
- Confident to identify and implement in their professional careers the underlying success factors for safe, efficient and trouble-free operation and maintenance of steam Plants.
- Emerge as a skilled professional for Steam Plant e.g., production manager, inspection manager, maintenance manager and the associated technicians, operators and engineers.
- Prepare themselves to acquire boiler competence certification subsequently.
- The knowledge and skill provided in this course are useful for legal, insurance and regulation personnel as well to interface the steam plants as per their areas of responsibility
Who Should Attend?
This ‘Industrial Steam Boiler System, Operation and Maintenance’ course would be suitable for:
- Trainees/intern/fresh employees who want to take up Design, Operation, Inspection, Maintenance and HSE management of Industrial Steam Boiler System, as their career.
- All Steam Plant workers, supervisors and managers who want to promote productivity of operation, inspection, maintenance, health & safety in their steam plants.
- All employees/workers who have been on rotation from their existing departments to the Steam Plant (Planning, operation, Inspection, and maintenance).
Course Outline
Module 1: Basics/Concepts About Steam and Its GenerationÂ
- A short history of boiler design
- Why use steam? Where is steam used?
- How Boilers Work: A generic steam system
- Types of Boilers
- Key Components of Boilers
- Safety Issues
Module 2: Types of and Layout of Industrial Steam Boilers
- Coil steam generator (once through boiler)
- Water-tube boiler
- MTHS boilers (fire-tube or smoke-tube boilers)
- Basic overview of Steam Plant
Module 3: Basic Steam Distribution
- How steam moves (simple explanation)
- The motion of steam (detailed explanation)
- Strainers
- Steam traps
- Pipe expansion loops and drains
Module 4: Boiler Operation
- The boiler operator
- The manager
- The role and function of technology in the modern boiler house
- Boiler Feed Pumps
- Contamination of condensate
- Deaerators/Condenser
- Economizer
- Superheaters and Attemperators
- Condensate Shunt pump
- Boiler level controls
- Isolation and Control valves
- Safety valves/ Pressure reducing valves (PRV)
- Pressure and temperature gauges
- Non-return valves/check valves
- Total dissolved solids (TDS)
- Boiler Loading, Sequencing, Scheduling, and Control
Module 5: Boiler Management and Control
- Typical instrumentation for boiler management (Monitor Boiler Gauges)
- Optimized Air-to-Fuel Ratio: Boiler Combustion Efficiency
- Steam Boiler Efficiency (Indirect method and Direct or fuel-to-steam efficiency)
- Safety, Efficiency and Life of the Equipment
- Boiler Energy Best Practices
- Guarantee and Service
- Fuel System and Burners; Flame failure device
- Flare system and Regeneration
- Steam turbine and Power Generator
- Seasonal Operation
- Operating Multiple Boiler Plants
- Chillers/Cooling Towers
- Air Handling Systems
- Water treatment
- Feedwater pump arrangements
Module 6: Inspection of Steam Generation Plants
- Corrosion Issues: Cathodic Protection System
- Inspect and Repair Insulation: Thermography
- Thickness and crack monitoring of piping and vessels
- Metallography
- Inspection of drums: Visual and NDE (Non-Destructive Examination)
- Inspection of Headers, Piping, tubing
- Loaded Spring inspection
- Vibration monitoring
- PSV and PRV Testing
- Valid Permit to Work (PTW) for a confined space inspection
- Energy isolation during inspection: Lock and Tag
- Combustion analysers
- Trending Boiler Stack Temperature
Module 7: Maintenance of Steam Generation Plant Equipment
- Sample Maintenance Logs & Boiler Checklists
- PSV and PRV maintenance
- Maintenance of Air openings, Flue gas vent system, Pilot and main burner flames
- Maintenance of Fans, Blowers, Air Compressors and Pumps
- Maintenance of Electrical Systems and Motors
- Opportunity Identification
Module 8: Some Hazards of Steam
- Boiling liquid expanding vapor explosion (BLEVE)
- Column collapse water hammer
- Sub-cooled condensate induced water hammer
- Flash steam explosion
- Overpressure in the distribution system
- Overpressure (inside a pressure vessel)
- Plug flow water hammer
- Steam hammer
- Temperature
- Vacuum draw
- Waterlogging
- Other Safety Issues
- Safe & Functional Boiler Room | Requirements
Module 9: Â Other Miscellaneous Best Practices for Steam Plants
- Boiler Water-Use Best Practices
- Best Practices for Efficient Operation
- Boiler Rules of Thumb
- Best Practices for Inspection and Maintenance
Module 10: Case Studies, Incidents, Problem Resolutions, Q&A’s
- Case Studies
- Incidents
- Emergency Response
- References
- Other Resources
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Method of Instruction:
Online
Course Duration:
5 days
Type of Certificate Issued:
Certificate in Industrial Steam Boiler System, Operation and Maintenance
You can choose any of the three below:
- Digital Certificate(Downloadable PDF)
- Physical Certificate with security marking shipped to your location with a price
- Framed Certificate with security markings shipped to your location with a price.
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