TM

STEAM GENERATORS, WASTE HEAT BOILERS, HEAT TRANSFER & WATER CHEMISTRY.
THEORY & APPLICATION OF WATER CHEMISTRY FOR HIGH PRESSURE BOILERS

Mumbai
20th/ 21st/ 22nd Feb 2012
INTRODUCTION:

Chennai
23rd/24th/ 25th Feb 2012
st nd

Delhi
1 /2 / 3 March 2012
rd

Kolkata
5th/ 6th/ 7th March 2012

This Workshop, of three day duration, is aimed at Engineers and Management Personnel of Power and Process Plants, Cogeneration Plants, Refineries and Steam Plants who are involved with performance, Design/Engineering and Operation of Oil/Gas fired Steam Generators, Waste Heat Boilers and HRSGs . It highlights Thermal Process and Heat Transfer aspects, Boiler Design features & Recent Trends in Packaged Boiler Design. It also highlights what to look for in a good design & identifies a poor design, evaluate Operating Parameters and critical issues such as Boiler or Superheater tube wall temperatures, efficiency, Steam temperatures, Heat Flux, Circulation, deviations from design operating point and Economizer Steaming to mention a few. Review of Boiler/HRSG operating costs and proper technical evaluation of options before purchasing the units will also be discussed. Typical field problems or issues from process viewpoint such as Fouling, Corrosion, Variations between design and operating data, efficiency improvement and modifying existing equipment for better performance will also be discussed. The discussions are more process and Thermal Design Oriented. The author feels that lot of plants buy Steam Generation Equipment without understanding the Thermal Design or process aspects and then spend lot of money and time fixing the equipment later to meet plant performance needs & parameter changes. [This course is NOT on mechanical design of boilers or their components but on thermal and process design aspects]. Boiler performance related problems will also be discussed in this workshop. Basically it is a course dealing with process issues which can help Plant/Design & operating engineers to understand & improve their equipment performance to ensure that a good design is being purchased. It is an Education in Thermal Process Behind these Boilers/Heat Transfer equipment, which will give an Overall understanding of various design and operating issues. This workshop will deal with the problems of poor Boiler & feed WATER CHEMISTRY on Boiler Fouling, Tube Failures and Steam Purity, Carry Over, Superheater Failures, Steam Temperature variations etc. Similarly if the waste heat boiler is operating at Off-Design Conditions, is it meeting the original design expectations or performing poorly? If the plant requires steam at multiples pressures, how to optimize the HRSG configuration? Are we getting the best package boiler or waste heat transfer for our plant? Can its performance be better? It is easier to make changes to your boiler before you buy it.

Participants are expected to have some background in boiler or heat recovery equipment design/performance aspects and some process, heat transfer knowledge.

CONTENTS:
The contents for this workshop are given below: Thermal Design and Off-Design performance, Heat Transfer issues, Optimization, Field Problems, Demonstration of software for Boiler calculations and HRSG simulation. The course material will be in the form of power point presentations. Also several articles published by the Faculty are included as Course Material.

Tel: +91-22-40510100 Fax: +91-22-40510102

info@marcepinc.com www.marcepinc.com

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STEAM GENERATORS, WASTE HEAT BOILERS, HEAT TRANSFER & WATER CHEMISTRY.
THEORY & APPLICATION OF WATER CHEMISTRY FOR HIGH PRESSURE BOILERS

WASTE HEAT BOILERS:

Classification- Fire Tube and Water Tube Boilers, Boilers in Hydrogen Plants(reformed Gas Boiler, Flue Gas Boiler) Sulphur Plants(Claus Plants, Sulphuric Acid Plants)-Incineration Systems and Engine/Gas Turbine HRSGs- Design features of different applications-performance-importance of flue gas analysis-low and high temperature fouling and corrosion issues and minimizing the problems-Insulation selection-hot and cold casing designs-acid dew point calculations-unfired, supplementary fired and furnace fired HRSGs-burner calculations- why fired Gas Turbine HRSGs are more efficient than unfired units-Savings in fuel consumption-fresh air firing -HRSG efficiency calculations-economizer steaming-what happens, why it occurs and how to avoid it. Performance variation with load-Effect of ambient temperature on HRSG performance, how to combine operation of steam generators and HRSGs to minimize overall fuel consumption-natural vs forced circulation HRSG designs-fouling inside and outside tubes and how to minimize the concerns-effect of emission regulations on boiler design and performance-relating field data with design and evaluation of potential problems-drum sizing, drum internals, steam purity concerns-comparison between Fire Tube and Water Tube Boilers-Use of fins or bare tubes-noise and vibration analysismaterial selection. Importance of Gas Pressure, Drop-Drum Internals, Water Chemistry issues & how to develop Boiler specifications from process view point.

OIL/GAS FIRED GENERATORS:

STEAM

APPLIED HEAT TRANSFER:

Heat Transfer Basics - Heat Transfer inside and outside bare and finned tubes-advantages of finned tubes. comparison with bare tube boilers-effect of tube size on heat transfer and tube wall temperature-importance of fin configuration on heat transfer and surface areas-optimization through proper fin geometry-how surface areas can be misleading especially with finned tubes. Solid and serrated fins-inline vs staggered arrangement of tubeseffect of fin configuration on tube and fin tip temperatures-scale formation and impact on tube wall temperatures-tube bundle vibration-predicting performance of furnaces, evaporators, superheaters, air heaters and economizers, off design calculations. Evaluating field data. Use of NTU method to predict boiler performance-effect of steam demand on steam pressure, drum level. Calculation of convective, non-luminous radiation coefficients. Simplified performance predicting methods for boiler components. Tube wall temperature, tube life estimation. Why comparison of surface areas can be misleading.

Boiler Basics- Boiler ClassificationPackage Boilers- A,D,O types-custom Designing & Recent Trends. Advantages of completely water cooled furnaces-membrane wall vs tangent tube designs. Why economizer is preferred to an air heater for heat recovery-boiler performance aspects-oil vs gas firingvariation of Steam temperature, efficiency etc with Boiler load-minimizing operating costs-furnace design-performance-effect of fuels on furnace duty-heat flux-boiling process, Understanding heat flux-heat release ratesBoiler circulation-super heaters-radiant vs convective designs and problemsMaterials for Boilers-Steam Temperature control methods. Why refractory is avoided in recent designs- Boiler surface area comparison-effect of Steam pressure on operation-heat losses in a Boiler and efficiency calculations-short method-field data analysis-efficiency on HHV ,LHV basis-relating excess air with oxygen in flue gases-effect of emission regulations on design and performance-what to look for while buying/selecting future Boilers- Drum level fluctuations with load-effect of fuel on Boiler performance-low and high temperature corrosion problemsrequirements for quick startup. Operating and life cycle costs- How to evaluate Boilers before buying themimportance of surface areas. Impact of future emission regulations on Boiler design. Recent trends in Boiler design.

HRSG SIMULATION (GAS TURBINE-HRSGs)

What is simulation-understanding pinch and approach points-how to predict temperature profiles and performance of a given HRSG and check if it is operating-well-how to predict performance of HRSGs under different gas inlet temperatures-steam pressures, feed water temperatures, load conditions, unfired or fired conditions using the simulation program-planning future HRSG projects using simulation-how to optimize heat recovery-single or multiple pressure units, fresh air firing and fuel consumption-oxygen depletion and exhaust gas firing. Illustration with practical examples-optimizing HRSG configuration using simulation. Single or multi pressure HRSG for your plant?

CONTENTS. Introduction: Steam generators Waste Heat Boilers Superheaters Evaporators Economizers Air Heaters HRSG Simulation Applied Heat Transfer Quiz Water Treatment External Water Treatment Internal
info@marcepinc.com www.marcepinc.com

Tel: +91-22-40510100 Fax: +91-22-40510102

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STEAM GENERATORS, WASTE HEAT BOILERS, HEAT TRANSFER & WATER CHEMISTRY.
THEORY & APPLICATION OF WATER CHEMISTRY FOR HIGH PRESSURE BOILERS

Mumbai
20 / 21 / 22 Feb 2012
th st nd

Chennai
23 /24 / 25 Feb 2012
rd th th

Delhi
1 /2 / 3 March 2012
st nd rd

Kolkata
5 / 6 / 7th March 2012
th th

COURSE FACULTY: Mr.

V. GANAPATHY

&

Mr. S.MAHADEVAN
M.Sc(Chemistry) - was working with Bharat Heavy Electricals Ltd., Trichy for last 15 years looking after the Water Treatment Internal and External, required for high pressure boilers. Adviser on water regime to be maintained in Feed Water, Boiler Water and Steam to have trouble free operation of Boilers. Failure Analysis, Remedial Measures etc.

Education: B.Tech from IIT, Madras 1969 in Mech. engg. & Msc (engg) in Boiler Technology in 1972 from Madras University. Professional Experience: BHEL, Trichy:1972-1982: Served in various positions in Research and Engineering, Boiler design and proposals and responsible for basic engineering of a coal based combined cycle research plant. 1982-1984:Engineer at Struthers Thermo Flood in Winfield, Kansas, involved in engineering of once through steam flood boilers for oil field applications. 1984-2003: Boiler Specialist at ABCO Boilers in Abilene, Texas, involved in design of steam generators and waste heat boilers for a variety of applications in process and power plants. Designed over 200 oil/gas fired packaged boilers, over 350 water tube and fire tube waste heat boilers and HRSGs for FCC units, incineration (solid, liquid and fume ) systems, hydrogen and sulfur plants, gas turbine plants and custom designed systems for various process applications. Developed software for design of steam generators and waste heat boilers and programs for steam plant engineers including HRSG simulation, a program that predicts design as well as off-design performance of complex, multiple pressure, unfired and fired HRSGs. 2003-present: Boiler Consultant, based at Chennai, India. Consulting for several overseas Boiler and Incinerator suppliers and helping Boiler plants to solve their performance problems and improve their Boiler/HRSG efficiency. Other: Authored over 250 articles on Boiler Design, Heat Recovery, Boiler Heat Transfer and Calculations, which have been published in numerous professional journals such as Chemical Engineering, Hydrocarbon processing, Power, Power Engineering, Plant Engineering, Chemical Engineering Progress and in UK and India. Authored 5 text books, the latest being, Industrial Boilers and HRSGs, published by Marcel Dekker, New York. .Contributed several chapters to Handbook of Mechanical Engineering Calculations and Encyclopedia of Chemical process and Design, published by Marcel Dekker. Conducted courses on Boilers and Heat Recovery in India and in Venezuela for PDVSA Refineries, RIPI and Farab consulting in Tehran, Iran, Reliance, IPCL, L&T in Baroda and for various consulting organizations at Mumbai.

LIST OF USEFUL ARTICLES:

(COURSE MATERIAL TO BE DISTRIBUTED)

1.Superheaters: Design and Performance 2. Understand the basics of Steam Generators 3. Simplify HRSG Evaluation 4. Simulation aids Cogeneration 5. Specify Packaged Steam Generators Properly 6. HRSGs-understand the basics 7. Cold end Corrosion Causes and Cures 8. Understand Steam Generator performance 9. Evaluate extended surfaces carefully 10.How important is surface area? 11.Boiler Circulation Calculations 12.Fouling the silent heat transfer thief 13.Avoid heat transfer equipment vibration problems

Tel: +91-22-40510100 Fax: +91-22-40510102

info@marcepinc.com www.marcepinc.com

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STEAM GENERATORS, WASTE HEAT BOILERS, HEAT TRANSFER & WATER CHEMISTRY.
THEORY & APPLICATION OF WATER CHEMISTRY FOR HIGH PRESSURE BOILERS

Schedule : DAY 1 Introduction Importance of Thermal Design Boiler Types Recent Trends in Boiler Design-Custom Design Superheaters. Sizing and Performance Aspects. Checking Performance of new and existing Boilers. Efficiency Improvement. Boiler Circulation. Specifying and Evaluating Designs. How Emission Regulations can affect Boiler Design. DAY 2 Types of Waste Heat. Fouling, Corrosion and Impact on Boiler Design and Performance. Thermal Design and Performance Aspects. Gas Turbine HRSGS. Pinch and Approach Points, HRSG Simulation. Checking Performance of new and existing HRSGS and Optimizing Temperature Profiles. Heat Transfer IssuesProcess wise Specifying Boilers and HRSGS. Discussion of Specific Problems if any. DAY 3 WATER CHEMISTRY THEORY AND APPLICATION OF WATER CHEMISTRY FOR HIGH PRESSURE BOILERS: 1. WATER TREATMENT a. Classifier and its Filtration . b. D.M.Plant 2. WATER TREATMENT a. Caustic PO4 Treatment b. Co-ordinated Phosphate c. Congruent Control d. Caustic Treatment e. All Volatile Treatment f. Chemical Control of feed Water and Steam g. Failure Analysis h. Internal Corrosion Purity.

Tel: +91-22-40510100 Fax: +91-22-40510102

info@marcepinc.com www.marcepinc.com

TM

STEAM GENERATORS, WASTE HEAT BOILERS, HEAT TRANSFER & WATER CHEMISTRY.
THEORY & APPLICATION OF WATER CHEMISTRY FOR HIGH PRESSURE BOILERS

Mumbai
20 / 21 / 22 Feb 2012
th st nd

Chennai
23 /24 / 25 Feb 2012
rd th th

Delhi
1 /2 / 3 March 2012
st nd rd

Kolkata
5 / 6 / 7th March 2012
th th

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