Description
Identifying and benefiting from energy saving opportunities in high energy consuming industrial plants requires a comprehensive understanding of the boiler, combustion, feed water, condensate, controls as well as the associated steam distribution systems. This seminar is targeted for people who select, manage, supervise, operate or maintain boilers and steam systems. It will enable you to improve the boiler and steam system efficiencies and reduce the system energy costs. Discussions will focus on all aspects of boiler and steam system operation to provide you with information and easy to use best practices to achieve the most efficient operation at the lowest cost. The end result in using these techniques will be reductions in: boiler fuel consumption, environmental impact, water and electricity usage plus chemical treatment costs. This adds up to reduced operating costs for the production and distribution of steam and an improved bottom line for your company. Join us and benefit from this course.
Objective
To provide practical techniques for ready application in industrial plants to reduce energy and ownership costs by improving boiler and steam system performance.
Who Should Attend
Certified energy managers, boiler and steam operating staff, facility engineers/managers, process and project engineers, maintenance staff and engineers, supervisory personnel, consulting engineers, designers, and anyone involved with the administration, operation, or maintenance of boilers and steam systems in manufacturing and process plants as well as those who are planning on cogeneration for their facilities.
Industries That Will Specially Benefit
• Chemicals
• Pulp and paper
• Steel
• Power
• Food and beverage
• Pharmaceuticals
• Mining
• Oil and Gas
• Any industry that is heavy user of steam
Unique Features
This course includes 70% lectures to clarify your fundamentals and 30% ‘hands-on touch and feel the equipment’ in SPIRAX Steam Centre of Excellence and visit to a modern boiler plant. Through case studies of various industries, you review current best energy saving practices and compare them to your plant’s efficiencies. You leave with a repertoire of skills that enable you to prioritize and target those areas in your plant where immediate energy cost-savings can be made with the highest ROI.
Program Outline
DAY I
8:00 Registration and Coffee
8:30 Welcome and Introduction
8:40 Fundamentals of Steam Generation and Distribution
- Gord Fraser, TDS Enterprises
- Course objectives – to reduce energy and ownership costs
- Assessment measures
- Steam generation
- Heat transfer and its barriers
- Thermodynamic principles
- Steam tables
Break
10:10 System Scoping Tools
- Venkat Venkatesh, Spirax Sarco Canada Limited
- SSAT from US DOE and Cipec
- Boiler House
Break
11:00 Boiler Plant Components
- Gord Fraser
- Boiler types
- Boiler components
- High pressure tubes
- Fuel system
- Air system
- Feed water system
12:00 Lunch
1:00 Combustion System Design and Best Practices
- Gord Fraser
- Combustion process
- Air/fuel ratios
- Combustion calculations
- weight method
- mol method
- Combustion calculation questions
- Burner management
Break
2:40 Controls for Increasing Combustion Efficiency
- Gord Fraser, Sharam Pavri and Datta K. Kuvalekar, Forbes Marshall Inc.
- Combustion process losses
- Combustion controls
- Control set up
3:40 Case Study I – Boiler Plant in Brewery
4:30 Adjournment
Day II
8:30 Analyzing Boiler Efficiency I
Gord Fraser
- Boiler efficiency calculations
- direct method
- indirect method
- Boiler water treatment
9:30 Break
9:40 Analyzing Boiler Efficiency II
- Gord Fraser
- Boiler blow-down
- Blow-down heat recovery
10:40 Break
10:50 Boiler Economic Optimization
Gord Fraser
- Boiler and components and how they affect boiler efficiency
- How combustion controls affect boiler efficiency
12:00 Lunch
1:00 Case Study II: Boiler Plant in an Electric Power Plant
Paul Sehl, GE Water and Process Technologies
Discussion
2:30 Break
2:40 Boiler Controls
Gerardo Monge, Spirax Sarco Canada Limited
- Pressure and temperature controls – best practices
- Control products
- Sizing and selection
- System design
- Industry best practice
3:40 Open Forum on Boilers: Questions and Answers
Gord Fraser and Spirax Sarco Canada Limited
4:30 Adjournment
Day III
8:30 Laboratory Exercise
Gerardo Monge
- Review of pressure and temperature controls for boilers from Day II and
- lab exercise
Break
10:00 Analyzing Steam System Operation
- Venkat Venkatesh
- Thermal expansion effects
- Drainage issues
- Insulation losses
- Steam leak losses
- Wet steam effects
- Impacts of non-condensable gases
Break
11:00 Steam Utilization Equipment
- Shaibaal Roy
- Steam traps
- Thermostatic
- Mechanical
- Thermodynamic
- Heat Exchanger
12:00 Lunch
1:00 Case Study III– Boiler and Steam Distribution System in Food Processing Industry
Bert Jenkins, Innophos
Discussion
1:40 Increasing Steam System Efficiency
Venkat Venkatesh
- Steam trap losses
- Steam trap problems - steam locking, air binding, freezing etc
- Correct steam trapping
- Steam trap sizing
- Flash steam losses
3:00 Visit to Molson’s Brewery Steam Plant
Doug Dittburner and Ashau Kahol, Enbridge
4:30 Adjournment
Day IV
8:30 Analyzing Condensate Return System Efficiency
Shaukat Sangrar
- Lifting of condensate
- Pumping of condensate
- Piping lay-out
- System chemical protection
- Steam system opportunities
- Condensate system opportunities
- Heat recovery options for flash steam
- Pay-back analysis
10:00 Case Study V - Boiler and Steam Distribution System in Pulp and Paper Industry
Datta K. Kuvalekar
Discussion
Break
11:10 Laboratory Exercises
Spirax Sarco Canada Ltd.
- Lab exercise on pressure, temperature and flow controls for steam
- Design and selection of steam trap, heat exchanger, and steam system
12:00 Lunch
1:00 Advanced Steam Load Calculations
Shaibaal Roy
- Equipment hook-ups
- Energy balance and steam system assessment
2:35 SSAT worked example for a Manufacturing Plant
Venkat Venkatesh
Discussion
Break
3:00 Case Study VII – Boiler and Steam Distribution System in Petroleum Processing Industry
Andy Nokes, INEOS Canada Partnership - INEOS Oligomers
Discussion
4:00 Open Forum on Steam Distribution: Questions and Answers
Spirax Sarco Canada Ltd.
4:30 Concluding Remarks and Final Adjournment
2.5 CEUs/25 PDHs
After participating in this course, you will be able to:
Apply new techniques to improve boiler and steam system efficiencies
Identify areas where steam losses are reducing plant efficiency
Recognize boiler and steam system losses and calculate their cost to the plant
Use your newly acquired skills to identify boiler and steam system unique problems that affect their operation and efficiency
Itemize the steps that will increase your combustion system efficiency
Select and prioritize the acquisition of boiler and steam system components on the basis of their resultant saving in cost
Distinguish among the various condensate systems to determine the most suitable for your boiler system
Calculate boiler plant and steam efficiency for your plant
Evaluate for efficiency steam valves and steam traps and locate them for efficient service
Instructors:
Gordon Fraser, P.Eng., B.Sc. (Mech. Eng.) University of Toronto 1966,
Gordon is President of TDS Enterprises, specializing in the energy management field. He holds an Ontario 1st Class Stationary Engineer's license (1970) and has 35 years of power plant experience both in the utility and in the industrial sectors. He has hands on experience firing in coal, oil and natural gas, using various controls on boilers ranging from 55,000 lbs/hr at 150 psig. to 3,500,000 lbs/hr at 2700 psig.
Venkat Venkatesh is a licensed Professional Engineer in Ontario with over 23 years of experience in the field of power boiler manufacturing and steam system design. He has over 12 years of Canadian experience in the field of boilers and steam system design & marketing.
Venkat possesses 11+ years experience in Project management, Manufacture of power boiler drums, headers, pressure vessels and heat exchangers. He is well trained in functional aspects of power boilers, pressure vessels and heat exchangers and is conversant with welding processes GTAW, GMAW, SMAW, SAW.
Venkat is responsible for the design and marketing of Boiler house products. He has designed packages for boiler feed, condensate recovery, blowdown systems, blowdown heat recovery systems, level control systems, condensate contamination detection system and heat exchanger packages. He also conducts seminars on steam systems to consultants, steam users and undertakes site visits to conduct energy audit, evaluate steam system and troubleshoot installation problems.
Venkat is responsible for the design and marketing of Boiler house products. He has designed packages for boiler feed, condensate recovery, blowdown systems, blowdown heat recovery systems, level control systems, condensate contamination detection system and heat exchanger packages. He also conducts seminars on steam systems to consultants, steam users and undertakes site visits to conduct energy audit, evaluate steam system and troubleshoot installation problems.
Shaibaal Roy, B.E (Mechanical)
Bachelor of Engineering in Mechanical Engineering from the Maharaja Sayajirao University of Baroda. Shaibaal has worked with Batliboi and Company, a very large manufacturer of Machine Tools in India and worked on the shop floor in Production. At the site where he was located, the company manufactured Radial Drilling Machines, Horizontal and Vertical Milling Machines, CNC Milling Machines, etc. Sahibaal looked after the Heavy Engineering Division that was basically involved in machining the large components like the body, etc. In 1987, Shaibaal joined Spirax Marshall at the Western Regional Office in Baroda as a Junior Sales Engineer. By 1992 he was Product Manager for the SEG (Steam Engineering Group) that included Package Boilers and High Pressure Forged Valves in addition to the Spirax range of products. Shaibaal looked after two satellite offices too for the same activity and also service (mainly for boilers). In 1998 he moved to Canada and in October 1998 he joined Spirax Sarco Canada Limited and was located in Winnipeg. While in Winnipeg, he covered all of Manitoba, Saskatchewan and North West Ontario. In 1999, he moved to SW Ontario and started looking after the company's interests in the Niagara Peninsula.
Gerardo Monge is Product Manager Controls at Spirax Sarco Canada Ltd. He has more than 25 years of experience in the control valve and instrumentation industry which was gained mainly with Foxboro and Spirax. He worked in Peru for 8 years prior to coming to Canada. This gave him the exposure to the primary resources industries such as sugar cane refining, iron and copper concentrating plants, pulp and paper, and middle manufacturing industries such as chemicals, brewing, textile, etc. Gerardo is a P. Eng. and has an engineering degree in the controls field.
Shaukat Sangrar has over 30 years experience in Industrial Engineering covering design, installation and commissioning of plants. Expertise in Energy Conservation in Steam and energy intensive operations. He was employed by Spirax Sarco Group for the last 28 years as an Application Consultant. As of April 2007 he has partially retired and assists Spirax Sarco Canada Ltd in the design of Integrated Packages, with Energy Audits and Special Projects '
Sharam Pavri, Hon. B. Sc., MBA is Sales Manager with Forbes Marshall Canada. He has over 10 years in experience in management, and has grown up with the Spirax Sarco family – entering his first boiler plant at the age of 11. Now over-seeing marketing efforts of Forbes Marshall in Canada, he is working closely with the Spirax team to meet the broad needs of steam-users. Forbes Marshall has a global reputation for energy efficiency in steam processes, and they are now providing their expertise to Canadian industries.
Sharam takes great pleasure in meeting and listening to the needs of steam users, across various applications.
Paul Sehl, joined GE Water and Process Technologies in 1982 as a Chemical Technical Sales Representative. During that time he held progressively higher positions in Sales Management. In 1996 he transferred over to the Technical division where he had increasing roles leading up to the position of Manager for all product, technical, and research applications for boiler technology in Canada. In 2001 Paul transferred over to the equipment division where he currently consults in industrial applications for water pretreatment, re-use, and process applications. His extensive chemical, technical and equipment background allows a complete review of a plants operation. He is a member of NACE and CHES and has delivered papers on a wide breadth of subjects to many organizations and publications. Paul holds a BSc degree in general science from the University of Waterloo.
Datta K. Kuvalekar has a Master of Technology ( IIT Mumbai , India). He has over 16 years in heat transfer , fluid dynamics, heat exchangers , pressure vessels, energy management (Thermal). He has over 14 years experience in design of different kinds of Steam and Condensate systems and Automation systems for Paper machines and paper mills ranging from Tissue to Board. He has experience of over 200 such systems in India /Abroad and is the inventor of Thermocompressors in India (for FML) . He is a member of TAPPI (Technical Association of Pulp and Paper industry) Energy subcommittee, Confederation of Indian Industry –Technology Committee, Confederation of Indian Industry- IIT Panel member and the Industry-Institute interaction Panel for CII.
Currently he is General Manager (Research and development ) and leading its Paper
Business Segment at Forbes Marshall Limited , Pune India.
Doug Dittburner and Ashau Kahol, Enbridge
Bert Jenkins, Innophos
Spirax Sarco is a world leader in Steam System Design with operations in over 40 countries and 35 training centres. Our state of the art steam lab demonstrates steam as a modern energy efficient heating source. Training is the cornerstone of the philosophy of how Spirax goes to market. Our training mission is to set the standard in steam system design. This gives our customer the knowledge and skill they need to drive their business forward.
The fee for this course is $2,295 + GST. If you register after February 15, 2008 the fee increases to $2,495 + GST. A rebate of $200 will be available to participants from Union Gas/Enbridge.
Venue Information
Day I and II
EPIC Learning Centre
5759 Coopers Avenue
Mississauga, ON L4Z 1R9
Tel: 1-888-374-2338
Click here to open the map
Day III and IV
Spirax Sarco Canada Limited
383 Applewood Crescent
Concord, Ontario L4K 4J3
Phone: (905) 660-5510
