Course Objectives The Participants will be able • To find and fix minor faults. • To carry out routine boiler maintenance. • To handle boiler operations confidently. • To carry our routine burner maintenance. • To pro-actively carry out the maintenance schedule and avoid breakdowns. • To initiate steps for reducing fuel bills by monitoring boiler efficiency. Course outline Ø Fundamentals of Boiler Design and Operation: • Fire tube and water tube boilers • Fuel and firing systems • Old and new boiler • Superheated steam • Induced draft – forced draft system Ø Optimizing Boiler Basics : • Efficiency parameters – Performance • Loss prevention Ø Energy Management Basics : • Heating value of fuels and B.T.U. • Input – output efficiency • Accounting for heat in steam and water • Principles of modern boiler design Ø Boiler Plant Efficiency : • Analyzing thermal performance and costs • Stack, blow down and surface losses • Tune-up and optimizing efficiency Ø Boiler Plant Operational Procedures and Problems : • High and low water levels • High and low superheat temperature and pressure • Boiler plant systems Ø Distribution System Losses : • Steam system losses • Traps and leaks Ø Efficiency Calculation Methods : • ASME computational methods • Comparing the input-output method and heat loss method • Use of formulas and calculations in computers Ø Combustion Analysis : • Chemistry of combustion • Flame characteristics/smoke testing and control • Flue gas heat loss an measurements • Use of analyzers and emissions monitoring Ø Flow Measurements : • Characteristics of various flow instrumentation Ø Boiler Plant Calculations : • Combustion losses and calculating efficiency • Economic analysis Ø Boiler Controls : • Steam pressure, combustion and water level control • Burner management and safety controls • Types of control and tuning for optimum performance Ø Boiler Tune-up : • Troubleshooting guide • Step by step tune-up procedure Ø Over 60 Ways to Improve Efficiency. Ø Waste Heat Recovery. Ø Boiler Water Treatment : • Prevention of scale and corrosion • Removing oxygen and CO2 from boiler water • Boiler water limits Ø Pollution Reduction.