Boiler Water Testing

Details

1-day course

CPD Credit: 6 hours; Competence/s: 1

Course Delivery Options

Course Overview

This course will provide a comprehensive review of the principles of boiler water conditioning. The training is designed to give delegates a firm background in the objectives and control of water treatment of cooling systems and steam boilers. It explains how pre-treatment plants function and also considers the control of these systems.  The only way of knowing what’s going on inside your steam system is by testing your water and understanding what’s happening.  This training will help  delegates run an energy efficient system, prolong plant life and limit downtime. The following topics will be covered:

• The ASME and EPRI Boiler Chemistry Guidelines.  Oxygen control by means of de-aeration and chemical treatment will be reviewed. Boiler design principles will be developed, including heat transfer, circulation effects, and high-pressure requirements.

• The chemistry and control of phosphates, chelant, and sludge conditions will be reviewed in depth. Problems and solutions associated with steam purity and condensate corrosion will be covered in detail with several practical examples. Guidelines for chemical cleaning will be developed.

• The course reviews resin structure, function, and the gamut of water purification applications from softening to the preparation of ultra-quality water. The course has been modified to focus on monitoring performance and reacting to system upsets.

Course Programme

This is a one-day online training course. The course programme is structured as follows:

• Basic Water Chemistry.
• Base exchange softening and other methods of external treatment used to produce make-up water suitable for boiler systems.
• De-aeration of boiler feed-water.
• Review of internal treatment programmes for boiler water and control of blowdown.
• Methods available for treatment of condensate.
• Develop schemes to prevent scale, corrosion and fouling
• Understand chemical dosing requirements
• Know how to put in place a boiler water treatment strategy
• Understand the importance of water treatment guidelines

Part one:

• Introduction: Water Chemistry, Boiler Water Quality Requirements
• Oxygen Control: Mechanical De-aeration, Chemical Scavenging, Testing
• Boiler Calculations: Cycles of Operation, Blowdown Monitoring
• Principles of Internal Treatment: Boiler Design and Heat Flux, Circulation
• Deposition Control: Either Low Pressure—Phosphates, Chelants, Dispersants; or High Pressure—Iron Deposition, Dispersants. EPRI Guidelines

Part Two:

• Corrosion Control: Either Low Pressure—Corrosion Control in Cast Iron Boilers, Boiler System Testing or High Pressure—Coordinated Phosphate/pH, Congruent Control, AVT, Neutral Oxygen
• Flow and Load Considerations, Multiple Pressure System Chemistries
• Carry-Over Control: Carry-Over Mechanisms, Steam Purifications, Monitoring Carry-Over
• Chemical Cleaning of Boilers: Commissioning Cleaning, Deposit Monitoring, Deposit Removal

Part three:

• Condensate Corrosion: Corrosion Mechanisms, Amine Treatment, Testing
• Condensate Polishing: Mixed Beds, Powdered Resin Units, Magnetic Filtration
• Failure Analysis: Boiler Tube Failure Modes, Metallurgical Analysis, Metallurgical Workshop
• Boiler Tube Testing: Destructive Sampling and Non-Destructive Testing Methods, Visual Boiler Inspection

Part four:

• Introduction of Ion Exchange: Water Chemistry Units, Pre-treatment Requirements of Ion Exchange
• Ion Exchange Resins: Synthesis, Types, Water of Hydration, Commercial Equivalents
• Ion Exchange Softening: Equipment, Service and Regeneration Reactions, Troubleshooting
• Two-Bed Demineralization: Equipment, Service and Regeneration Reactions, Performance Expectations
• Two-Bed Demineralization: Equipment, Service and Regeneration Reactions, Performance Expectations
• Individual Conferences: Participants’ Water and Resin Analyses

Part five:

• Two-Bed Demineralization (continued): Exhaustion Profiles, Distributor Design, Regenerant Dilution Systems
• Troubleshooting Demineralizers: Short Run, Poor Water Quality, Resin Problems
• Mixed Beds: Makeup Mixed Beds, Performance Expectations, Regeneration Protocols, Three Component
• Systems, Uniform Particle Size Resins
• Resin Testing: Vessel Inspection, Sample Procurement, Interpretation of Resin Analysis, Decision to Clean or Replace
• Post-Test and Evaluation

Learning Outcomes

This course will give candidates an understanding of the common sources of water and wastewater and how water is used in different ways in commercial, industrial and process environments.

This course will also help candidates understand the basic chemistry of water and wastewater, common contaminants and the problems that can result from using water and wastewater containing these contaminants.

Candidates will gain a basic understanding of how to manage and control engineered systems in which water and wastewater is used to achieve optimum efficiency and cost effectiveness.

Additionally, candidates will develop an understanding of how to perform basic water analysis and testing, and how to interpret the results so as to monitor, control and manage the consequences of these parameter.

Who Should Attend?

This course has been developed for anyone involved in the day to day running of steam boilers and utility plants, including site technicians, boiler operators, supervisors, plant engineers and maintenance engineers. The training is designed for people who are not chemists and don't have any qualifications in boiler water treatment.

The job of managing boiler water treatment is often left to contractors to do on a once a month basis, which is not adequate. The water chemistry inside your boiler can change very quickly if something goes wrong therefore a minimum of daily testing is a must.

Trainer Profile

Trevor Montgomery is a Director & EHS Consultant working for Montgomery EHS Ltd with over 25 years specialising in Wastewater and Odour / VOC Treatment.  Trevor has completed third level courses in Dundalk IT, Sligo IT, UCC and UCD.   Trevor has developed a range of biological scrubbers for Odour and VOC’s from a variety of Industries from Animal Slaughtering, Seaweed extraction, Fish Processing, Dairy Industry, etc.  Trevor is employed by a number of companies as a retained consultancy for the design of wastewater treatment and odour management.  Trevor has worked with an extensive list of companies such as Thermo Fisher, Bio-Marine Ingredients, College Group, Mega Group, Carton Bros, Aurivo Ingredients, Glanbia, Silver Hill Duck, Arrabawn, Tipperary Cooperative, Hydro International, Leprino Foods to name a few. Based in Limerick, Trevor has served on policy committees for local government and lectured at various universities.  Trevor has delivered over 1000 training days on these topics (1 training day is when 1 person attends 1 course for 1 day).

Please contact the CPD Training Team for further information on scheduled course dates and In-Company options.