VIRTUAL INSTRUCTOR LED TRAINING (VILT)

ROOT CAUSE ANALYSIS FOR BOILERS AND STEAM CYCLE FAILURES

15 - 19 MARCH 2021 | 5 half-day training, 4 hours per session (total 20 hours)

About The Course

Identifying and correcting the root cause of failures in boilers and steam power plant equipment is essential to help reduce the chance of future problems. A comprehensive assessment is the most effective method of determining the root cause of a failure. For example, a tube failure in a boiler is usually a symptom of other problems. To fully understand the root cause of the failure, one must investigate all aspects of boiler operation leading to the failure in addition to evaluating the failure itself. When a boiler tube failure occurs, the root cause of the failure must be identified and eliminated.

 

This course starts by providing an in-depth understanding of root cause analysis methodology. This includes how to identify the problem, contain and analyze the problem, define the root cause of the problem, define and implement the actions required to eliminate the root cause, and validate that the corrective actions prevented recurrence of the problem. Many practical examples on how to apply root cause analysis for various industrial problems are discussed in detail. The course then provides an in-depth explanation of all failure mechanisms that occur in steam power plants including corrosion, erosion, creep, cavitation, under-deposit attacks, stress corrosion cracking, hydrogen embrittlement, flow accelerated corrosion, etc.  This course also provides a thorough explanation of all the failure mechanisms that occur in boilers and steam power plant equipment including steam turbines, condensers, feedwater heaters, etc. The symptoms of the failures, possible causes, components typically affected and solutions are also provided in this course. This includes boiler waterside, fireside and general boiler failure mechanisms as well as all the causes and prevention of all steam turbine failures, condensers, and feedwater heaters. The course also includes detailed study of many case histories of failures in boilers, steam turbines, condensers and feedwater heaters.

Course Fees

Early bird:

SGD 3,099 for 5 days

 

Normal price:

SGD 3,299 for 5 days

Learning Outcomes

  • Root Cause Analysis Methodology: Understand root cause analysis methodology including: identification of the problem, defining the problem, understanding the problem, identification of the root cause of the problem, providing corrective action, and monitoring the system.

 

  • Applying the Root Cause Analysis Method to Industrial Problems: Learn by studying many practical examples how to apply the root cause analysis method to various industrial problems.

 

  • Damage Mechanisms in Boilers and Steam Power Plant Equipment: Gain a thorough understanding of all the damage mechanisms that occur in boilers and all steam power plant equipment including turbines, condensers and feedwater heaters. These mechanisms include corrosion, erosion, flow accelerated corrosion, stress corrosion cracking, creep, under-deposit attack, cavitation, hydrogen embrittlement, etc.

 

  • Symptoms of Failures in Boilers and Steam Power Plant Equipment, Possible Causes, Components Typically Affected, and Solutions: Learn about all the symptoms of failures in boilers and steam power plant equipment including steam turbines, condensers, and feedwater heaters, their possible causes, components typically affected and proven solutions.

 

  • Case Histories of Failures in Boilers, Steam Turbines, Condensers, and Feedwater Heaters: Learn by studying many case histories how failures occur in boilers, steam turbines, condensers, and feedwater heaters and the corrective actions taken to deal with them.

Training Methodology

The instructor relies on a highly interactive training method to enhance the learning process.  This method ensures that all the delegates gain a complete understanding of all the topics covered.  The training environment is highly stimulating, challenging, and effective because the participants will learn by case studies which will allow them to apply the material taught to their own organization.

 

Each delegate will receive a copy of the following materials written by the instructor:

 

  1. Excerpt of the relevant chapters from the “POWER GENERATION HANDBOOK” second edition published by McGraw-Hill in 2011 (800 pages)
  2.  Excerpt of the relevant chapters from the “POWER PLANT EQUIPMENT OPERATION AND MAINTENANCE GUIDE” published by McGraw-Hill in 2012 (800 pages)
  3. ROOT CAUSE ANALYSIS FOR BOILERS AND STEAM CYCLE FAILURES  MANUAL (includes practical information and case histories – 500 pages)

Who Should Attend

  • Engineers of all disciplines
  • Managers
  • Technicians
  • Maintenance personnel
  • Other technical individuals

Expert Course Faculty

Your specialist course leader has more than 32 years of practical engineering experience with Ontario Power Generation (OPG), one of the largest electric utility in North America. He was previously involved in research on power generation equipment with Atomic Energy of Canada Limited at their Chalk River and Whiteshell Nuclear Research Laboratories.

 

While working at OPG, he acted as a Training Manager, Engineering Supervisor, System Responsible Engineer and Design Engineer. During the period of time, he worked as a Field Engineer and Design Engineer, he was responsible for the operation, maintenance, diagnostics, and testing of gas turbines, steam turbines, generators, motors, transformers, inverters, valves, pumps, compressors, instrumentation and control systems. Further, his responsibilities included designing, engineering, diagnosing equipment problems and recommending solutions to repair deficiencies and improve system performance, supervising engineers, setting up preventive maintenance programs, writing Operating and Design Manuals, and commissioning new equipment.

 

Later, he worked as the manager of a section dedicated to providing training for the staff at the power stations.  The training provided by him covered in detail the various equipment and systems used in power stations.

 

In addition, he has taught courses and seminars to more than four thousand working engineers and professionals around the world, specifically Europe and North America. He has been consistently ranked as “Excellent” or “Very Good” by the delegates who attended his seminars and lectures.

 

He written 5 books for working engineers from which 3 have been published by McGraw-Hill, New York.  Below is a list of the books authored by him;

  • Power Generation Handbook: Gas Turbines, Steam Power Plants, Co-generation, and Combined Cycles, second edition, (800 pages), McGraw-Hill, New York, October 2011.
  • Electrical Equipment Handbook (600 pages), McGraw-Hill, New York, March 2003.
  • Power Plant Equipment Operation and Maintenance Guide (800 pages), McGraw-Hill, New York, January 2012.
  • Industrial Instrumentation and Modern Control Systems (400 pages), Custom Publishing, University of Toronto, University of Toronto Custom Publishing (1999).
  • Industrial Equipment (600 pages), Custom Publishing, University of Toronto, University of Toronto, University of Toronto Custom Publishing (1999).

 

Furthermore, he has received the following awards:

  • The first “Excellence in Teaching” award offered by PowerEdge, Singapore, in December 2016
  • The first “Excellence in Teaching” award offered by the Professional Development Center at University of Toronto (May, 1996).
  • The “Excellence in Teaching Award” in April 2007 offered by TUV Akademie (TUV Akademie is one of the largest Professional Development centre in world, it is based in Germany and the United Arab Emirates, and provides engineering training to engineers and managers across Europe and the Middle East).
  • Awarded graduation “With Distinction” from Dalhousie University when completed Bachelor of Engineering degree (1983).

 

Lastly, he was awarded his Bachelor of Engineering Degree “with distinction” from Dalhousie University, Halifax, Nova Scotia, Canada. He also received a Master of Applied Science in Engineering (M.A.Sc.) from the University of Ottawa, Canada. He is also a member of the Association of Professional Engineers in the province of Ontario, Canada.

TOPICS TO BE COVERED

Purposes of Root Cause Analysis, Identifying the Root Cause of  a Problem Using the Problem Solving Process, Corrective Actions, Using 5W2H Approach, Examples of Root Cause Analysis in Manufacturing, Assembly Line, Shipping Company, Project Not Completed on Time and High Substance Count 

 

Steam Cycle Damage Mechanisms, Corrosion Process, Types of Corrosion, Cavitation, Erosion, Under-Deposit Attack, Hydrogen Embrittlement, Stress Corrosion Cracking

 

Boiler Waterside Failure Mechanisms, Boiler Fireside Failure Mechanisms, General Boiler Failure Mechanisms

 

Causes and Prevention of Steam Turbine Blade Failures, Deposition on Steam Turbine Blades, Stress Corrosion Cracking, Steam Turbine Rotor Vibration Failures

 

Steam Power Plant Condenser Failure Mechanisms, Case Studies of Failures in Thermal Power Plant Boilers

This training course will be conducted as a Virtual Instructor Led Training (VILT). Delegates will receive a confirmation email after successful registration. 
Soft copy course materials & Certification of Completion will be provided to registered participants. 

Unique Features with powerEDGE Training

  • Pre-Course Questionnaire (PCQ) to help us focus on your learning objectives
  • Detailed course & reference manual for continuous learning and sharing
  • Practical exercises & case examples to better understand the principles
  • Limited class size to ensure one-to-one interactivity
  • Assessment at the end of the course to help you develop a personal action plan