Piping, Boilers-Pressure Vessel and Rotating Equipment: Design Calculations & Operation

Introduction:

This Steam Boilers training seminar will focus on the study of correct operation and regular routine maintenance to ensure that the boiler plant remains at peak efficiency, keeping running costs to a minimum. The training seminar provides participants with the best practices and procedures for boilers operation and maintenance
The goal of this training seminar is to ensure participants gain a comprehensive understanding of commercial, industrial, and utility boiler systems. This Steam Boilers training seminar covers the principle of operation of steam boilers, types, and the main components of steam boilers.  Boiler inspections, maintenance, operating controls testing, and troubleshooting will all be discussed. Also, the protection and burner management system will be discussed.
Overall, this Steam Boilers training seminar is designed to help maximize safety, dependability, and efficiency, thus extending boiler life, improving boiler efficiency, saving energy costs for the employer, and establishing a culture of safe work practices among the employees.
In addition, we will focus on Design, inspection, and testing methods of static Working principles.

Targeted Groups:

• Process, Mechanical, and Chemical Engineers.
• Operation and Maintenance Engineers.
• Project Engineers.
• Supervisors and Managers.
• Technical Personnel involved in the inspection.

Course Objectives:
At the end of this course the participants will be able to:

• Boiler Control Strategies: Safeguards, Interlocks, and Alarm Systems
• Explain PLC for boiler controls (practical)
• Burner Management System (BMS)
• Safe Start-Up and Shutdown Procedure
• Scale and Corrosion Control
• Chemical & Physical Treatment of Feed Water
• De-aeration of Feed Water: Removing of Oxygen and CO2

Targeted Competencies:

• Boiler Efficiency: Economic and Environmental Aspects.
• Boiler Feed Water Preheating Train.
• Air Economizers and Waste Heat Utilization.
• Boiler Performance and Specifications.
• Evaluating Boiler Efficiencies.
• Boiler Blow-Down Control Recovery.
• Steam Distribution System Losses.

Course Content:

Unit 1:  Boiler Inspection, Maintenance, and Repairs:

• Routine & Periodic Boiler Inspections: Risk Based Inspection (RBI)
• Common Boiler Problems in Operation
• Abnormal Operating Conditions and Operator Actions
• Maintenance Work Done Periodically
• Checklist for Maintenance of Fuel Supply System
• Maintenance of Condensate Recovery and treatment
• Using CMMS (computer managed maintenance systems)

Unit 2:  Boiler Troubleshooting and Accident Prevention:

• Boiler Failures and Accidents: Root Cause Analysis
• How to apply FMEA (Failure Mode Effective Analysis)
• Boiler Troubleshooting Guide
• Applying RBI (Risk-Based Inspection techniques)

Unit 3: Pressure Vessels, Tanks, and Piping Systems:

• Pressure Vessels and Steam Boilers
• Above Ground Storage Tanks: Operation & Safety
• Pipelines & Piping Systems: Operation & Safety
• Pressure Relief Valves: Selection & Sizing
• ASME BPV VIII & ASME B31.3 Standards and API Codes
• Storage Tanks: External & Internal Maintenance Techniques
• Cathodic Protection of Pipelines and Storage Tanks

Unit 4: Boilers and Valves: Design and Fundamentals of Operation:

• Design and Operation of Boilers
• Operation and Control Methods
• Types of Valves
• Inspection Techniques for Boilers and Valves

Unit 5: Inspection, Monitoring & Maintenance Engineering:

• Risk Management & Mitigation Technologies: ALARP Criteria
• Risk Based Inspection (RBI API 580) For Stationary Pressure Equipment (NDT)
• Pipeline Internal and External Corrosion Direct Assessment (ICDA & ECFA) Methods
• Repair Modern Technologies
• Review, Summary, and Conclusions

Unit 6: Design, Operation, and Monitoring Methods:

• Pump Types, Positive Displacement, and Dynamic
• Pump curves and Pump Selection
• Pumping system optimization
• Energy-saving opportunities for pumps

Unit 7:Steam Turbines, Design, Operation, and Monitoring Methods:

• Fundamentals of Steam
• Design and Operation of Steam Turbines
• Boiler Types and Characteristics
• Performance of Steam Turbines

Unit 8: NACE Corrosion

• Define corrosion and recognize the economic, environmental and safety impact of corrosion
• Recognize terms and definitions of basic electrochemistry, as well as define the processes and concepts of electrochemistry, oxidation and reduction reactions, thermodynamics, kinetics, and passivity
• Identify the characteristics of commonly-encountered corrosive environments such as atmospheric, water and other electrolytes, soil and high temperature environments
• Distinguish between engineering materials such as metals, non-metals, composites, concrete and ceramics and their relationship to corrosion control
• Discuss the various forms of corrosion, how to recognize each form, materials subject to each form, environments that promote each form and how to control each form
• Explain how corrosion can be controlled during the design process through construction, as well as process parameters, drainage, dissimilar metals, crevices, and corrosion allowance
• Give examples as to how and when to use the control corrosion methods of design, material selection, modification of environment, protective coatings, and cathodic and anodic protection
• Differentiate between inspection and monitoring and identify the common testing techniques for each

Unit 9: API 571 -Corrosion & Materials. 

• Scoring Area
• Exam Structure
• Important Damage Mechanisms,
• Check if You Qualified To Take The API 571 Exam,
• How to Register for API 571 Exam
• API 571 Certification, Recertification, Rescheduling and Cost and API 571 Exam tips

Unit 10: Expansion Effects and Compansating Methods

• Piping Systems Calculation
• Pipe Expansion
• Methods of Compensation
• Thermal Force Calculations
• Possible Equivilant Stresses Caused by Additional External Loads
• Expansion Devices
• Calculation of Anchor Force Using a Bellow
• Bellow Material and Life
• Use of Hinged Compensators