COURSE OVERVIEW:

The meaning of advanced management of boiler system energy efficiency involves the systematic optimization of steam and hot water generation through sophisticated combustion control, heat recovery, and water quality management. This course explores the complex dynamics of fire-tube and water-tube boilers, focusing on how minor deviations in operating parameters can lead to massive energy waste. By applying advanced engineering logic, participants will learn to transform standard boiler operations into high-efficiency thermal power centers that minimize fuel consumption and emissions.

The scope of this training extends from the fuel delivery system to the final point of steam utilization, covering the entire thermal loop. It examines the technicalities of high-turn-down burners, condensing economizers, and automated blowdown systems that maintain peak performance. The course provides a deep dive into the chemistry of boiler feedwater and its direct correlation with scale formation and heat transfer resistance. Participants will also study the integration of digital twin technology and real-time oxygen trim controls to maintain optimal air-to-fuel ratios across varying load profiles.

Coverage includes comprehensive energy balancing techniques to account for all losses, including radiation, convection, and flue gas enthalpy. The course addresses the critical role of steam trap management and condensate return systems in overall plant efficiency. Attendees will gain practical knowledge on regulatory compliance regarding NOx and SOx emissions, as well as the economic evaluation of boiler room upgrades. By the end of the program, participants will be equipped to lead boiler efficiency audits and implement robust management systems that align with global energy standards like ISO 50001.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Calculate boiler thermal efficiency using both the Direct and Indirect (Heat Loss) methods.
2. Optimize combustion efficiency through advanced O2 and CO trim control systems.
3. Evaluate the performance of condensing and non-condensing economizers for flue gas heat recovery.
4. Implement automated blowdown control based on real-time conductivity measurements.
5. Analyze the impact of feedwater quality on heat transfer coefficients and fuel waste.
6. Design condensate recovery systems to maximize thermal energy and water recycling.
7. Conduct detailed steam trap surveys and calculate the cost of steam leakage.
8. Optimize boiler sequencing and load sharing for multi-boiler installations.
9. Assess the benefits of variable speed drives (VSD) on combustion air fans and feed pumps.
10. Mitigate common boiler losses including radiation, skin, and soot-related fouling.
11. Interpret flue gas analysis data to troubleshoot burner performance issues.
12. Formulate a technical and financial proposal for boiler house efficiency retrofits.

TARGET AUDIENCE:

This course is designed for Boiler Operators, Plant Engineers, Energy Managers, Utilities Supervisors, Facilities Managers, and Technical Consultants involved in the operation and maintenance of industrial or large commercial steam and hot water systems.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.