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Home > Services > Swagelok Energy Advisors > Training Programs > Boiler Plant Operations Training > Level 1
Boiler Plant Operations Training
Utility Plant Operation Certification Level One Workshop Outline and Overview

Day 1

Registration

SEA Introduction

Understanding the Fundamentals
    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

Steam Generators - 10:30 to 12:00
    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

Fuels 1:00 to 2:00
    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

Steam Cost - 2:00 to 3:00
  • How to calculate
  • Load vs. unloaded
  • Establishing the steam cost for the system

Task: Calculate Steam Cost (Unloaded And Loaded)

Major Components - 3:00 to 4:30

    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
    2. 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

Flue Gas Analysis - 9:30 to 10:30
    1. Oxygen
    2. Carbon monoxide
    3. Carbon dioxide
    4. Other
    5. Devices for measurement
Task: Select Flue Gas Measurements

Efficiency Measurements - 10:30 to 11:30
    1. Combustion
    2. Thermal
    3. Fuel to steam
    4. Establishing fuel air ratio curves

Task: Document A Fuel/Air Ratio Curve

Boiler Plant Air Makeup Requirements - 11:30 to 12:00
    1. How to calculate
    2. Designs
    3. Location

Task: Calculate The Air Makeup Requirements

Correct startup and shut down procedures for steam generators - 1:00 to 2:00
    1. Time requirements
    2. Thermal stresses
    3. Refractory
Task: Write A Standard Operating Procedure

Heat Recovery - 2:00 to 3:00
    1. Economizer
      • Cost and payback
      • Applications
    2. Air heater
      • Cost and payback
      • Applications
    3. Full condensing technology
Task: Select Heat Recovery Devices

How to determine the correct steam pressure for the system - 3:00 to 4:30
    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 Types - 8:00 to 9:00
    1. Condensing / non-condensing
    2. Applications
      • Electrical generation
      • Pumping
      • Air compressors
      • 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
    5. Types
    6. Sizing
    7. Materials
    8. 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
Deaerator - 1:00 to 2:00
    1. Types
    2. Tray
    3. Spray
    4. Reboiler
    5. Operation and maintenance
Exam 2:00 to 4:30

Compressed Air System - 3:00 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
System Testing Equipment
    1. NDT
    2. Ultrasound
    3. Infra-Red
    4. Testing procedures

Day Four

Scheduling - 8:00 to 9:00
    1. Operational personnel, 24/7
    2. Maintenance
    3. Outage
Improving the boiler system’s operation, safety and efficiency - 9:00 to 10:00
    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.
Boiler room maintenance - 10:00 to 11:00
    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.
Meeting steam demands - 11:00 to 12:00
    1. Boiler load selection
    2. Standby units; “Summer load” boilers
    3. Meeting surges in the system
Managing the systems - 1:00 to 2:00
    1. Benchmarking the system
    2. Software and other tools to assist in profiling and management
    3. Programs to enhance the system
    4. Personnel training

Exam - 2:00 pm to 4:00 pm


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