COURSE OVERVIEW:

Steam system assessment and performance improvement is a critical discipline for enhancing energy efficiency, reducing operational costs, and ensuring the mechanical reliability of industrial thermal networks. Steam is a primary energy carrier in process plants, yet many systems operate with significant inefficiencies due to leaks, poor insulation, or improperly sized components. This course provides the technical methodology to conduct a holistic audit of the entire steam loop from the boiler house to the end-users and back through the condensate return system.

The scope of this course covers the thermodynamics of steam, including the differences between saturated and superheated states and the energy potential contained within each. Participants will learn how to identify energy "thieves" such as failed steam traps, uninsulated valves, and excessive venting. The Coverage includes the mechanical design of steam piping, the importance of proper drainage to prevent water hammer, and the optimization of pressure-reducing stations to match process requirements accurately.

Furthermore, the training addresses the economic and environmental benefits of performance improvement. Attendees will learn how to calculate the "cost of steam" and justify capital projects such as flash steam recovery or heat exchanger upgrades using return-on-investment (ROI) analysis. By the end of this program, participants will be equipped with the diagnostic tools and engineering knowledge to transform their steam systems into highly efficient, safe, and reliable assets that support the plant’s sustainability goals.

COURSE OBJECTIVES:

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

1. Explain the fundamental properties of steam and the Rankine cycle.
2. Conduct a comprehensive steam system energy balance.
3. Identify and quantify energy losses from leaks and radiation.
4. Evaluate the performance of steam boilers and combustion efficiency.
5. Assess the health of the steam distribution network and insulation.
6. Diagnose and optimize pressure-reducing valve (PRV) stations.
7. Implement an effective steam trap management and testing program.
8. Identify and mitigate the causes of water hammer and pipe stress.
9. Evaluate the benefits of condensate recovery and flash steam use.
10. Calculate the "Cost of Steam" and the ROI of efficiency projects.
11. Utilize ultrasonic and thermographic tools for system assessment.
12. Design and size steam piping for optimal velocity and pressure drop.
13. Ensure the safety of steam systems through proper relief valve care.
14. Develop a continuous improvement roadmap for thermal efficiency.

TARGET AUDIENCE:

This course is intended for Utility Engineers, Energy Managers, Boiler House Supervisors, Maintenance Technicians, and Process Engineers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.