Improving & Maximizing Boiler Efficiency & Performance
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COURSE DATES AND LOCATIONS
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INTRODUCTION
The key issue in the safe and efficient operation and maximizing investments The continuous performance monitoring of boiler, The yearly fuel cost can account to several multiples of the cost of boiler. Consequently, a difference of just a few percentage points in boiler efficiency can translate into substantial savings. So inthis course we will recognize to the key measures, which can be readily followed and implemented to improve efficiency,Also we will save money and limit environmental impacts.
This course also attempts to provide simple facts and energy efficiency opportunities in the areas of combustion management, makeup & feedwater management, blowdown system, waste heat recovery and steam distribution
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COURSE OBJECTIVES
At the end of this course you will be able to:
- Combustion analysis; Excess air control and Air-Fuel mix
- Automation using burner controls and oxygen trims
- ASME standards in boiler performance calculations
- Sources of errors in calculations
- Different definitions of boiler efficiency.
- Direct and indirect method for evaluating boiler efficiencies
- Establishing list of energy losses in a boiler system
- Heat recovery systems (economizers, preheater, flue gas condensing etc).
- Waterside and fireside problems.
- Monitoring performance indices leading to more efficient and safe operation.
- Blowdown optimization and waste heat recovery using flash tanks/ heat exchangers
- Energy efficiency in steam distribution
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COURSE AUDIENCE
This course is made for
- Rotating Equipment Engineer
- Automotive Engineer
- Naval Architect
- Pipeline Engineer
- Power Engineer
- Senior Mechanical Engineer
- Turbine Engineer
- Validation Engineer
- Boiler Engineer
- Ceramics Engineer
- High-Pressure Engineer
- Marine Engineer
- Mechanical Design Engineer
- Mechanical Engineer
- Equipment Engineer
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COURSE OUTLINE
Day One
- Introduction , objective and scope
- Boiler types and parts
- Boiler Auxiliaries
- Definitions of efficiency: Combustion efficiency, Steam to fuel efficiency and in service efficiency.
- Boiler heat balance
- Losses and Credits
- Key Factors in understanding efficiency calculations
- Efficiency calculations by input and output method
- Efficiency calculations by loss method.
- Comparison between the two methods.
- Errors in Boiler Efficiency.
- Typical Uncertainty and tolerances for Efficiency.
Day Two
- Combustion basics, flame temperature
- Types of Burners, oil fired , gas fired and combined burners
- Forced draft burner, Comparison between Natural & Forced Draft burners.
- Burner troubleshooting.
- Flue gas losses and air fuel ratio
- Dry flue gas loss
- Loss due to moisture from the combustion of hydrogen
- Combustion efficiency of the burner as a function of exhaust temperature
- Minimum exit flue gas temperature for different fuels
Day Three
- Combustion Management.
- Firing control. 1) Fuel gas/Fuel oil pressure 2) 2. Excess air 3) 3. Draft in the furnace
- Typical Excess Air Values for Liquid and gaseous fuel Firing
- Exhaust gas analyzers ( dry and wet analyzers)
- Effects of Air Properties on Oxygen Content
- Optimized Burner operation.
- Oxygen trim for optimizing air fuel ratio
- Compu-NOx technology for energy efficiency.
- Saving from Air fuel ratio control
- Saving from exit gas temperature
- Saving from replacing burners with new efficient burners
Day Four
- Water quality and requirements of boiler.
- ABMA standards.
- Outside and inside water treatment
- Energy Losses From Scale Deposits:
- Blowdown losses.
- The blowdown rate equation
- Blowdown charts and calculations.
- Blowdown Separators.
- Blowdown Control
- Blowdown heat recovery
- Energy recovery from blowdown
- Flash Steam.
- Estimating Savings with different cases.
- Casing losses and thermography monitoring.
- Casing losses estimation.
- Unaccounted losses
- More thermal losses sources; failed Valves, steam Leaks, etc
- Supply Lines and Condensate
- Thermal insulation.
Day Five
- Net efficiency and effect of Auxiliaries: Forced , Induced and Recirculating air fans, Soot blowers, Control devices, Fuel pumps and Auxiliary boilers
- Energy Recovery Components
- Preheating combustion air
- Thermal Insulation
- Energy conservation projects
- Typical Flash Recovery System
- Flue Gas Condensers
- General Recommendations
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