Interactive Workshop on

INCREASING BOILER AND STEAM SYSTEM EFFICIENCY

This course is designed to help the engineers and managers to improve the boiler and steam system efficiencies and reduce the system operating costs. The objective of this course is to provide practical information and techniques, which can be readily applied in the plant for improving boiler and steam system performance efficiencies.
Who will be benefited? This interactive workshop is targeted for people who manage, supervise, operate or maintain boilers and steam systems.

Programme overview: A comprehensive understanding of the boiler and its associated steam distribution systems is required in order to be able to identify opportunities for maximum utilization of energy in any plant. Discussions will focus on all aspects of boiler and steam system operation to provide you with information and easy to use techniques for achieving the lowest cost, most efficient operation. The end result in using these ideas and techniques will be reductions in: boiler fuel consumption, environmental impact, water and electricity usage plus chemical treatment costs. This adds up to reduce operating costs for the production and distribution of steam and an improved bottom line for your company.

Special Feature
This workshop will provide you with an opportunity to review current practices and compare them to your plant’s efficiencies in an effort to help you reduce operating costs. This assessment will help you target those areas in your plant where improvements can be made.

Date: 30^th & 31^st May 2005

Venue: Hotel Yuvraj, Near Central ST Bus depot, Station Road, Vadodara

Course Fees: Rs.3,000/- per participant 

                         (10.2% service tax will be charged additional)  

Course Content: 

Boiler & Steam system basics:

It is understood that all the delegates will have the engineering knowledge required to analyze the Boiler operation for economic optimization. However, before going into the discussion on that subject, we will have a brief recapitulation of the related engineering principals which would help to correlate each and every aspect fundamentally, which in turn gives way to better understanding. 

Analyzing Boiler Operation for Economic Optimization:

In order to achieve economic optimization in Boiler operation, it is required to ensure maximum extraction of heat from the fuel and transferring maximum extracted heat to water and steam without causing any accident. Analyzing each aspect of Boiler operation in this light will include discussion on

• Combustion process 

• The effects of variation in fuel composition.

• The requirements for complete combustion, in practice – Stoichiometric air.

• Air/fuel ratios & Combustion controls

• High and low excess air.

• How the quantity of excess air must be balanced between the effect on steam temperatures and control of losses.

• The significance of exit gas temperature and its control.

• The affect of air heaters and combustion air temperature on exit gas temperature.

• How combustion air temperature can be manipulated. How air in-leakage occurs and what it might do to excess air levels.

• Using draft pressures as an indication of gas path plugging.

• Furnace heat transfer, convection pass heat transfer, and air heater operation.

• Heat management in Water & Steam

• How final feed water temperature can change the required boiler heat input.

• Deaerating Heater Performance

• Variations in steam temperature as a function of load.

• Low Main Steam Pressure and (Throttle) Pressure

• Low Steam Temperature

• SH Temperature

• How attemperator problems affect steam temperature.

• The use of soot blowing to maintain steam temperatures and the natural water circulation.

• Boiler water treatment

• The problems of fireside deposits and waterside deposits.

• The significance of internal scaling of boiler tubes.

• The effect that silica content has on limiting operating pressure.

• Boiler Blow-down losses - Examples

• Blow-down heat recovery

• Maximizing Auxiliaries

• Proper Fan and Pump selection

• Improve Fan and Pumping System Efficiency

• Controlling Pumps and Fans with Variable Loads

• Optimizing motor drive system

• Replacing oversized and under loaded electric motor

• Reducing power factor

• Control valve performance

• Condenser Pressure (Vacuum)

• Condenser Sub-cooling

• Water and steam leakages

• Boiler efficiency calculations - Case studies

Analyzing Steam and Condensate System Operation for Economic Optimization:

Proper management of steam distribution system is a critical factor for optimum utilization of heat in steam. More complicated the distribution system; more difficult it becomes to manage the heat properly avoiding unnecessary losses through condensation and leakages. Proper condensate recovery will ensure preservation of expensive sensible heat in the feed water. This part of the workshop will be dealing with

• Thermal expansion effects

• Drainage issues

• Insulation losses

• Steam leak losses

• Wet steam effects

• Impacts of non-condensable gases

• Steam traps – losses, problems, sizing

• Flash steam losses and heat recovery options for flash steam - Examples

• Lifting of condensate

• Pumping of condensate

• System chemical protection

Target Outcomes is to:
learn new techniques for improving boiler and steam system efficiencies
Identify areas where losses are reducing plant efficiency
Develop confidence and increase your capability to recognize and determine boiler and steam system losses in efficiency
Calculate the cost of losses that are reducing efficiency
Enhance your understanding of boiler and steam system unique problems that affect their operation and efficiencies