Presents

National Level Training Workshop on

Increasing Reliability of Boiler

by Preventing Tube Failures

On

21^st, 22^nd and 23^rd September 2010

At

Hotel Park Palace

49/2, Gariahat Road,

Kolkata 

Co-organized by

India Boiler dot Com

Vadodara

Download Enrolment Form

Introduction:

Boiler tube failures are the leading cause of steam plant non-reliability.
A tube failure may cause a forced outage, usually at the most inappropriate time, resulting lost production and lost revenue. A reduction in the frequency of tube failures can be achieved by understanding the root cause of the failure and taking steps to eliminate the problem.

Boiler tube failures, unlike the common (mis)conception, may not result simply due to faulty operation and maintenance practices. The root of the failure could be traced to as far as Pre-design negotiations, Design, Manufacturing, Transportation, Storage, Erection and Commissioning.

This program provides a multi-discipline understanding of Boiler Tube Failures with basic understanding of Boiler tube metallurgy and their limitations, various tube failure mechanisms, their root causes and preventions with practical exposure through discussion of case studies. Program covers the issues of interest to both Technical and Managerial Staff with discussions by experienced faculties on Practical Techniques for eliminating the most frequent sources of failures in Boiler plant.

Objective:
Upon successful completion of this workshop the participant should be able to:

1. Understand the importance of natural circulation in sub critical boilers

2. Understand the undesirable conditions to which the Boiler tubes are exposed during normal and emergency operations

3. Understand the basic boiler metallurgy, their environment and limitations

4. Describe the most typical failure modes for boiler tubes

5. Given specific failure modes of a fossil-power plant boiler, describe the cause, how this failure might be prevented and routine repair procedures that might be applied

6. Describe the areas involved in a utility boiler inspection

7. Describe typical repair modes of failed boiler tubes

8. Understand the role of an Operation engineer, Maintenance Engineer, Testing & Inspection Engineer, Project Engineer and Senior Management in Prevention of Boiler Tube Failure

9. Step by step approach towards Failure Analysis

Special Feature:

One complete session would be allotted to discuss typical tube failure cases (particularly those with undefined root causes) from the participating industries. For this the participating industry has to send details of the specific failure case study to the programme coordinator after acceptance of nomination. Some of these case studies would be selected by our faculties for a brain storming session at the end of the programme.

Who Should Attend?

This programme would be useful to the Engineering and Managerial stuffs from Operation, Maintenance, Inspection and Project Department.

Topic Details:

I. INTRODUCTION TO BOILER TUBE FAILURES:

• Undesirability of BTFs & Myths about who can prevent them.

• Various adverse conditions in Boiler system leading to overheating, stress and corrosion

• Understanding the basics of Loadings, Stresses, Overload, Deformations, Creep, Fatigue, Corrosion and Erosion

II. BASIC METALLURGY OF STEELS USED IN BOILER TUBES:

o        Fundamentals of metallurgy to understand the behavior of steels in boiler environments

• Boiler tube materials and their ‘susceptibility’ for failures

• The reasons for extensively using Carbon Steels and Cr-Mo type Low Alloy Steels instead of Stainless Steel as boiler tube material.

• Limitations and degree of susceptibility of tube material’s for failure

• How to tackle these susceptibilities during actual operation of boilers?

• Standard Specifications of Boiler Tubes at various locations

III. DAMAGE MECHANISMS & ROOT CAUSES – Part one

o        Difference between Damage Mechanisms and Root Cause.

o        Long Time Overheating (Creep) and Short Time Overeating (Overheating) Failures.

IV. DAMAGE MECHANISMS & ROOT CAUSES – Part Two

1. Corrosion Failures:

o        Water Side

• Galvanic Corrosion process

• Low pH Corrosion

• Oxygen pitting

• Caustic Gouging / Acid Attack

• Various Water parameters and their significance

o        Fire Side

• Low temperature / cold end corrosion

• Harmful metals, Sulfur and Chlorine

• Corrosive characteristics of ash

• Slag deposits

2. Embrittlements:

• Hydrogen embrittlement

• Graphitisation

• Caustic embrittlement

3. Erosion Failures :

• Flue gas erosion

• Coal jet erosion

• Secondary air jet erosion

• Steam jet (secondary) erosion

• Wall blowers and LRSB steam jet erosion

• Falling slag erosion

• Air ingress associated erosion.

V. DAMAGE MECHANISMS & ROOT CAUSES – Part Three  

• Fatigue Failures:

• Mechanical Fatigue

• Thermal Fatigue

o        Weld related Failures:

• Tube weld joint failures

• Dissimilar weld joint failures

• Attachment weld joint failures

• Dissimilar attachment weld joint failures

• Plug weld failures.

VI. PREVENTION OF BOILER TUBE FAILURES – Part One

• Importance of Preventive Practices.

• Failure analysis of failed tubes (Importance & Limitations) and Identifying ‘Root Causes’ & necessary ‘Preventive Measures’.

• Timely Implementation of identified Preventive Measures

• Periodic Condition Assessment.

• RLA studies.

• Periodic Training Programmes / Interaction with experts

VII. PREVENTION OF BOILER TUBE FAILURES – Part Two

o        Role of Plant Persons in Prevention of BTFs

• Role of Maintenance Engineers.

• Role of Operation Engineers.

• Role of Testing/Inspection Persons

• Role of Senior Officers

VIII. CASE STUDY DISCUSSION AND CONCLUDING SESSION

• Discussion of cases referred by participants.

• Discussion of special & very uncommon BTFs

• Feedback

 Upon successful completion of the course, a certificate will be issued by POMC (Plant Operation & Maintenance Club) to each candidate.

Course Duration: 3 days

There would be 10 days follow-up interaction at the website between the participants and the faculties after the completion of the programme. This will increase the opportunities for more detail discussion on the large number of topic covered under the course module.

Date:  21^st, 22^nd and 23^rd September 2010

Time: 9.30 AM to 5.00 PM

Venue: Hotel Park Palace, 49/2, Gariahat Road, Behind Gariahat Pantaloon Shop, Kolkata

Programme Fees:

1. Rs. 7500/- per candidate + 10.30% service tax  (For Non-Residential participants)
2. Rs. 11500/- per candidate + 10.30% service tax  (For Residential participants)

(DD/ Cheque should be prepared in the name of India Boiler dot Com, payable at Vadodara)

The Workshop registration fees for non-residential participation include:

• 3-days workshop

• Course material

• Mid-session tea and coffee breaks

• Lunch on all 3 days

• Follow-up session at website

For Residential participants:

The fees also include accommodation and breakfast at the programme venue, Hotel Park Palace. The accommodation will be provided on twin sharing basis from 20^th September evening to 23^rd September evening.

Registration Procedure:

Candidate is required to send the duly filled registration form along with a demand draft on the course fees.

For Residential Participation:

Registration will be accepted till 1^st September 2010 only. Registration Form along with the DD has to be submitted before 1^st September 2010. We will be providing Residential facilities only to a limited number of participants on first come first serve basis. Nominating organizations are advised to verify the availability before preparing the DD.

Please contact the programme coordinator for further information by phone (0265) 2386658, 6541352 or email trg@indiaboiler.com / trg@pomc.info

CONTACT:

Programme Coordinator:

India Boiler dot Com

FF1 Keshav Complex

Samta Chaar Rasta, Near Puroshottam Park Society

Subhanpura, Vadodara – 390 023

Ph. 0265 – 2386658/ 6541352

Cell: 09824277793

e-mail: trg@indiaboiler.com / trg@pomc.info

website: www.indiaboiler.com / www.pomc.co.in