INTRODUCTION FOR BOILER & STEAM SYSTEMS: CURRENT AND COMMON ENGINEERING PROBLEMS & THEIR SOLUTIONS IN INDUSTRY
A steam boiler is a device used to create steam by applying heat energy to water. Although the definitions are somewhat flexible, it can be said that older steam generators were commonly termed boilers and worked at low to medium pressure (1–300 psi or 6.895–2,068.427 kPa) but, at pressures above this, it is more usual to speak of a steam boiler.
A steam boiler is used wherever a source of steam is required. The form and size depend on the application: mobile steam engines such as steam locomotives, portable engines, and steam-powered road vehicles typically use a smaller boiler that forms an integral part of the vehicle; stationary steam engines, industrial installations, and power stations will usually have a larger separate steam generating facility connected to the point-of-use by piping. A notable exception is the steam-powered fireless locomotive, where separately-generated steam is transferred to a receiver (tank) on the locomotive.
This course is also designed to introduce the participants to the various terminologies frequently used, the various types of boilers used, various parts, and some basic design. The overall objective is to give the participants a functional knowledge of basic steam boiler theory.
Steam boilers have their fair share of engineering problems in the industry. The said problems could be classified into:
- Problems which could be identified and solved immediately, with little or no financial implications or loss in production and a drop in quality levels;
- Problems which could be identified and cannot be solved immediately, with little or no knowledge of its implications;
- Problems which recur frequently and cannot be solved permanently.
Some of the reasons for these are due to:
- Incompetent staff;
- A vast variety of equipment;
- Many moving (sliding, reciprocating, rotating) components.
This course is industry-designed to provide a broad understanding of the improvement methodology, concepts, and processes. The methodology is presented with case studies and examples drawn from service, business processes, and manufacturing applications. The integration of manufacturing and maintenance is also addressed. With a heavy practice orientation, as much as a third of your time will be spent working through interactive practical exercises and assessments. This course is designed as an introduction to concepts and methodology.
LEARNING OBJECTIVES
This training program is designed to provide an understanding of engineering-related problems related to industry globally and a clear sense of what is required to effectively structure, establish measurements, and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem-solving initiative within their organization.
LEARNING OUTCOMES
On successful completion of this course, the participant should be able to:
- Understand the benefits and implications of a boiler problem-solving program, and relate the concepts to the overall business mission and objectives.
- Think about his/her organization as a collection of processes, with inputs that determine the output.
- Use the concept of boiler engineering problem-solving to evaluate the capability of a process or organization.
- Recognize the engineering problem-solving model used to improve processes.
- Recognize the organizational factors that are necessary groundwork for a successful engineering problem-solving program.
- Integrate the boiler engineering problem-solving program effort with other process improvement initiatives.
TRAINING METHODOLOGY
- The latest educational methods and strategies will be utilized.
- The course is designed to maximize delegate participation.
- Questions and answers are encouraged throughout and at the daily wrap-up sessions. This gives participants the opportunity to discuss with others and the presenter their specific problems and appropriate solutions.
- The course shall be conducted through lectures, case studies, group discussions, and exercises to reinforce participants’ learning.
WHO SHOULD ATTEND
Manufacturing, process executives, managers, maintenance personnel, operational managers, etc.
COURSE FORMAT
The course consists of formal content presentation interspersed with content quiz sessions. The presenter’s style involves intensive participant participation.
MEASUREMENT TOOLS
Quiz, exercises, and a test at the end of the second day.
PAST PARTICIPANTS
Manufacturing, process executives, managers, maintenance personnel, operational managers, etc.
COURSE CONTENT
DAY 1
Introduction to Steam Boilers
- Need for steam
- Types of commercial boilers
- Fuel sources and combustion
- Properties of steam
Steam Boiler Operation & Maintenance
- Boiler operation basics
- Boiler maintenance
- Flue gas analysis
- Boiler and energy savings
- Boiler water treatment
Field Visit to a Boiler Room
- Identify components
- Operation methods
- Record keeping
- Flue gas measurement
- Steam distribution system
- Steam trap testing
- Insulation adequacy testing
Steam Distribution
- Steam distribution basics
- Distribution system components
- Steam traps
- Line insulation
- Efficient usage of steam
- Condensate return
- Condensate recovery
- Fuel pre-heating systems
- Air preheating systems
DAY 2
Classification of Steam Boilers
- Fire Tube type
- Water Tube type
- Advantages and disadvantages of Fire Tube Boilers
- Advantages and disadvantages of Water Tube Boilers
Energy Losses in Steam Boilers
- Stack Loss (flue gas loss)
- Blow Down Loss
- Radiation Loss
Saving Energy in Steam Systems
- Reduce heat escape
- Reduce heat load
- Reuse the heat
Determining Boiler Efficiency
- Heat input
- Useful heat output
- Overall boiler efficiency
Steam Boiler – Miscellaneous
- Boiler blowdown
- Insulation
- Condensate return
Q&A Session
End of Program
