Day 1

Registration

SEA Introduction

1. Steam “the vapor”
2. Energy (types)
3. Pressure and temperature relationships
4. Steam Tables
5. Thermodynamics

Task: Steam Tables

Flash Steam

1. Calculations
2. Understanding
3. Recovery of flash
4. Sizing a flash tank

Task: Calculate flash steam

Task: Size a flash tank

1. Types

• Firetube,
• Watertube
• Coil and tubeless

2. Refractory considerations

• Field erected vs. package
• Types
• Temperature limits

3. Internal components

• Skimmer piping
• Steam separators
• Etc.

Task: Select a boiler design

1. Types

• Natural gas
• Fuel oil
• Coal
• Liquor
• Others

2. Cost comparisons

• How to evaluate
• What are the market trends
• Cost of burning one fuel vs. another fuel type

3. Selection

• Factors

Task: Select a main fuel and a back up fuel

• How to calculate
• Load vs. unloaded
• Establishing the steam cost for the system

Task: Calculate steam cost (unloaded and loaded)

1. Burner

• Function
• Air requirements
• Throat design
• Diffuser designs
• Design
• Low excess air
• Low NOx
• Rotary
• Multiple burner configuration
• Non standard burners (liquor , etc.)
• Fuel types
• Coal
• Gas
• Fuel oil
• Liquor

1. Fuel delivery

• Fuel trains
• Pre-heating systems

Day 2

Boiler Control - 8:00 to 9:30

1. Burner management control

• Codes
• Devices
• Low water
• High water
• Etc.
• Prints

2. Combustion control

• Single point positioning
• Parallel positioning
• Metering
• Steam flow/air flow

Task: Select a burner management system

Task: Select a boiler control system

1. Oxygen
2. Carbon monoxide
3. Carbon dioxide
4. Other
5. Devices for measurement

Task: Select flue gas measurements

1. Combustion
2. Thermal
3. Fuel to steam
4. Establishing fuel air ratio curves

Task: Document a fuel/air ratio curve

1. How to calculate
2. Designs
3. Location

Task: Calculate the air makeup requirements

1. Time requirements
2. Thermal stresses
3. Refractory

Task: Write a Standard Operating Procedure

1. Economizer

• Cost and payback
• Applications

2. Air heater

• Cost and payback
• Applications

3. Full condensing technology

Task: Select heat recovery devices

1. How to calculate
2. Cost factor for higher then necessary steam pressure

Task: Select a steam pressure for the plant.

Day Three

 Steam Turbine - 8:00 to 9:00

1. Types

• Condensing / non-condensing
• Applications

1. Electrical generation
2. Pumping
3. Air compressors
4. How to apply in the system

Task: Select a steam turbine

Steam system piping - 9:00 to 10:30

1. Codes
2. Materials
3. Sizing
4. Condensate recovery

• Types
• Sizing

1. Materials
2. Proper startup & shut down procedures

Utility plant accessories - 10:30 to 12:00

1. Pretreatment equipment
2. Filters
3. Softeners
4. Dealkalyzers
5. Blowdown systems
6. Chemical feed
7. Sample coolers

1. Types

• Tray
• Spray
• Reboiler

1. Operation and maintenance

Exam 2:00 to 4:30

1. Compressed air system fundamentals
2. Air Compressors
3. Types
4. Selection
5. Cost per cfm
6. Aftercoolers
7. Air dryers
8. Air quality
9. Compressed air distribution
10. System layout
11. Storage
12. Filters
13. Regulators
14. Management

1. NDT
2. Ultrasound
3. Infra-Red
4. Testing procedures

1. Operational personnel, 24/7
2. Maintenance
3. Outage

1. The affects of scale on the heating surfaces
2. TDS and blowdown control
3. Flue gas analysis; what, how, and why
4. O2 trim
5. Increasing burner turndown. Is it an economical option?
6. VSD for combustion air and feed water control
7. Predictive versus demand maintenance.

1. Daily, weekly, monthly, bi-Annual, annual
2. National Board Incident reports from 1992-2002
3. Visual consequences……
4. The importance of the boiler room log.

1. Boiler load selection
2. Standby units; “Summer load” boilers
3. Meeting surges in the system

1. Benchmarking the system
2. Software and other tools to assist in profiling and management
3. Programs to enhance the system
4. Personnel training