course | Improving & Maximizing Boiler Efficiency & Performance

Module 1:
 

• Introduction, objective, and scope
• Boiler types and parts
• Boiler Auxiliaries
   

Module 2:
 

• 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 the input and output method
• Efficiency calculations by the loss method.
• Comparison between the two methods.
• Errors in Boiler Efficiency.
• Typical Uncertainty and tolerances for Efficiency. 

Module 3
 

• 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 

Module 4
 

• Combustion Management.
• Firing control: Fuel gas/Fuel oil pressure, Excess air, 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 air-fuel ratio
• Compu-NOx technology for energy efficiency.
• Saving from the Air fuel ratio control
• Saving from the exit gas temperature
• Saving from replacing burners with new, efficient burners 

Module 5:
 

• Water quality and requirements of the 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.
   

Module 6
 

• Casing losses and thermography monitoring.
• Casing losses estimation.
• Unaccounted losses
• More thermal loss sources: failed Valves, steam Leaks, etc
• Supply Lines and Condensate
• Thermal insulation. 

Module 7
 

• 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