To provide the background knowledge needed to design, operate and maintain the water treatment processes used for heating and cooling applications at peak efficiency with minimal dating or outages

Why is a boiler water treatment program required?

• There are three critical points to consider in the operation of any boiler plant:
• Corrosion removes metal from heat-exchange surfaces. There is no mechanism to put it back. When there is no longer sufficient wall thickness, the component will fail and in the process, operating staff can be injured or killed and production can be brought to an abrupt stop.
• Deposition on heat-exchange surfaces prevents the heat from going where it should. That loss of heat transfer results in higher production costs and once the margin of reserve is gone, production will be limited.
• There is an inherent sampling problem in all systems. It is not possible to take a sample from the region where active corrosion or deposition could be occurring. Is it possible to take meaningful data?

Boiler design and the role of water treatment:

• The various classes of boilers and their special needs.
• The boiler as a concentrating mechanism.
• Guidelines and needs for different pressures.
•  Workshop on boiler mass-balance calculations.

How to finalize simple routine analyses to find water losses?

• Refreshmentsand networking:
• Alkalinity.
• Why do we need alkalinity control and how do we apply it?
• Coping with the mixed metallurgy that minimized the original capital cost.

Dissolved oxygen:

• Oxygen is the food for corroding carbon steel
• Mechanical versus chemical methods for removing dissolved oxygen
• Oxygenating chemistry: is it a contradiction or a better way?

Internal versus external treatment:

• How to keep the boiler clean. Do we utilize hardware or chemicals?
• Workshop on calculating energy lost through blowdown.
• How to calculate the energy lost through blow down? How do you reduce it?

Optimizing the chemical treatment program:

• Performing a mass balance.
• Improved phosphate programs to avoid hideout.
• Monitoring the operation.
• Start-up, shutdown and transient conditions.
• Carryover with steam.

Why is cooling-water treatment program required?

• There are three critical points to consider in the operation of any cooling system:
•  corrosion removes metal from heat-exchange surfaces. There is no mechanism to put it back. When there is no longer sufficient wall thickness, the component will fail and in the process, production can be brought to an abrupt stop.
• Deposition of heat-exchange surfaces prevents the heat from going where it should. That loss of heat transfer results in higher production costs and once the margin of reserve are gone, production will be limited.
• There is an inherent sampling problem in all systems. It is not possible to take a sample from the region where active corrosion or deposition could be occurring. Is it possible to take meaningful data?

Cooling system designs and the role of water treatment:

• Contact and non-contact cleaning.
• Once-through cleaning.
• Recirculation or cooling tower systems.
• Closed loop recirculation systems.

Refreshments and networking.

Workshop on cooling system calculations.

• How to calculate chemical consumption and water usage?

Selected cooling systems

• HVAC systems.
• Major industrial systems.
• High and low heat load systems.
• Direct contact with process fluids.
• Closed loops for critical systems.
• Electrical generation.

Refreshments and networking.

Performance monitoring.

• Use of alternative plant equipment and test sections.
• Commercial monitoring instruments.
• Workshop on monitoring heat-exchanger cleanliness:

Can we assess the cleanliness of a steam condenser or HVAC chiller without having to shut down and open them up?

In-service cleaning

• Off-line procedures:
• Chemical cleaning.
• Mechanical procedures.
• On-line procedures:
• Chemical cleaning
• Mechanical properties.

Plant utilities or off-sites are a vital service to the operation of most major industrial plants. Unfortunately, they are usually ignored until they cause problems, and then it can be too late. The plant will suffer a major derating or outage that could have been avoided. This course is a must for the key personnel at any plant that relies upon reliable cooling water and steam production. This would include:

• Petrochemical, including refineries and gas separation.
• Coal-fired, gas-fired and combined cycle electrical generation
• Plant utilities for a wide variety of production facilities including pulp and paper, food processing, iron and steel, etc. Manufacturers of boilers, cooling towers, and heat exchangers