Download Steam Boilers, Steam & Condensate Systems 16Hour Masterclass 2024
Steam Boilers, Steam & Condensate Systems 16Hour Masterclass video course download. A comprehensive guide to design operation optimization and troubleshooting of boiler plants steam and condensate systems. Designed and delivered by industry experts with hands-on experience, this course is perfect for engineers, plant managers, and technicians aiming to master the intricacies of steam systems, boilers, and condensate recovery.
Why take this course?
Steam and condensate systems are essential to the efficiency, safety, and productivity of process plants. This masterclass will equip you with the knowledge and skills to design, operate, maintain, and optimize these systems to enhance energy efficiency and ensure trouble-free operations. Throughout the course, you’ll be guided by in-depth technical descriptions, detailed animations, step-by-step instructions, and numerous solved problems that emphasize key learning points.
PART 1: Steam Systems
In this part, we will dive deep into steam systems, which form the foundation of efficient plant operations. You will learn how to design, size, and maintain steam systems, ensuring they are optimized for safety, energy efficiency, and operational excellence.
Topics include:
- Steam plant overview and the properties of steam (including superheated steam and steam quality)
- Heat transfer principles in steam and condensate systems
- Estimating and measuring steam consumption for process equipment, tanks, and plant items
- Pipe sizing for steam distribution and effective drainage strategies
- The importance of steam traps, strainers, and understanding steam hazards
By the end of Part 1, you’ll have a solid understanding of how to manage your steam distribution system from the boiler to the point of use and through condensate recovery.
PART 2: Steam Boilers
This section is dedicated to steam boilers, focusing on the design, control, and efficient operation of these critical systems. Whether you’re dealing with shell boilers or other boiler types, this module offers the insights needed to ensure reliable performance and safety.
Topics covered include:
- Overview of the boiler house and boiler efficiency
- Boiler fittings, mountings, and steam headers
- Feedwater conditioning, controlling TDS (Total Dissolved Solids), and heat recovery from boiler blowdown
- Managing water levels and automatic level control systems in steam boilers
- Troubleshooting guidelines and operation best practices in accordance with ASME and other standards
In this part, you’ll gain valuable insights from real-world industrial scenarios, learning what worked and what didn’t during boiler startup, debottlenecking, and troubleshooting.
PART 3: Condensate Systems
Efficient condensate recovery is key to maximizing the energy potential of your steam systems. In this final part, you’ll explore everything from condensate return line layouts to pumping methods and system optimization.
Topics include:
- Condensate recovery strategies to reduce energy waste
- Best practices for layout and sizing of condensate return lines
- Pumping condensate from vented receivers and how to lift condensate over obstacles
- Ensuring efficient condensate system operation and troubleshooting
By mastering these concepts, you’ll be able to design and operate condensate systems that maximize plant efficiency while minimizing downtime and operational costs.
Key Features of the Masterclass:
- Real-world case studies showcasing actual plant scenarios
- Extensive visuals and animations to simplify complex topics
- Engineering best practices with downloadable resources and design templates
- Numerous quizzes and solved problems to reinforce learning and ensure concept mastery
- Delivered by experienced engineers with hands-on expertise in steam systems and boilers
What you’ll learn
- Design and optimize steam systems for safe, efficient, and reliable operation in process plants
- Calculate and measure steam consumption across various plant items, equipment, and processes
- Size and layout steam distribution pipes and manage steam mains, ensuring proper drainage and expansion control
- Understand the properties of steam, including superheated steam and steam quality, and apply this knowledge to heat transfer applications
- Select and maintain steam traps and strainers to ensure efficient steam system operation and reduce energy loss
- Identify potential hazards of steam and implement preventive measures to ensure system safety
- Operate and troubleshoot steam boilers based on an in-depth understanding of boiler design, construction, and controls
- Optimize boiler efficiency through best practices in combustion, water treatment, and heat recovery systems
- Manage boiler water levels and implement automatic level control systems, alarms, and safety measures
- Recover and reuse condensate effectively, reducing energy consumption and operational costs
- Design and size condensate return lines, avoiding pressure drops and ensuring smooth condensate flow
- Pumping and lifting condensate efficiently, minimizing energy loss and ensuring proper system operation
- Apply real-world troubleshooting techniques to resolve common issues in steam, boiler, and condensate systems
- Utilize engineering best practices to improve the overall performance and safety of steam and condensate systems
Course content
- Section 1: Steam plant overview
- Lecture 1 Introduction
- Lecture 2 The boiler
- Lecture 3 Feedwater
- Lecture 4 Blowdown
- Lecture 5 Level control
- Lecture 6 The flow of steam to the plant
- Lecture 7 Steam quality
- Lecture 8 Pressure reduction
- Lecture 9 Steam at the point of use
- Lecture 10 Process control
- Lecture 11 Condensate removal
- Lecture 12 Before you proceed to the next section
- Section 2: What is steam?
- Lecture 13 Introduction
- Lecture 14 Triple point
- Lecture 15 Ice
- Lecture 16 Water
- Lecture 17 Steam
- Lecture 18 Enthalpy of evaporation
- Lecture 19 Enthalpy of saturated steam
- Lecture 20 Saturated steam tables
- Lecture 21 Dryness fraction
- Lecture 22 The steam phase diagram
- Lecture 23 Flash steam
- Lecture 24 Mass and energy conservation
- Lecture 25 Before you proceed to the next section
- Section 3: Superheated steam
- Lecture 26 Introduction
- Lecture 27 Superheated steam tables
- Lecture 28 Superheated steam for heat transfer applications
- Lecture 29 Sizing example
- Lecture 30 The effect of reducing steam pressure
- Lecture 31 The Mollier chart
- Lecture 32 Steam expansion through a turbine
- Lecture 33 Before you proceed to the next section
- Section 4: Steam quality
- Lecture 34 Introduction
- Lecture 35 Correct quantity
- Lecture 36 Correct temperature and pressure
- Lecture 37 Air and other incondensable gases
- Lecture 38 Other sources of air in the steam and condensate systems
- Lecture 39 Cleanliness of steam
- Lecture 40 Dryness of steam
- Lecture 41 Waterhammer
- Lecture 42 Before you proceed to the next section
- Section 5: Heat transfer in steam and condensate systems
- Lecture 43 Modes of heat transfer
- Lecture 44 The overall heat transfer coefficient “U”
- Lecture 45 Temperature difference
- Lecture 46 Barriers to heat transfer
- Lecture 47 Temperature gradients across layers
- Lecture 48 Defining the overall heat transfer coefficient “U”
- Lecture 49 Before you proceed to the next section
- Section 6: Methods of estimating steam consumption
- Lecture 50 Introduction
- Lecture 51 Calculation
- Lecture 52 Non-flow type applications
- Lecture 53 Flow type applications
- Lecture 54 Before you proceed to the next section
- Section 7: Measurement of steam consumption
- Lecture 55 Steam flowmeter
- Lecture 56 Condensate pump
- Lecture 57 Collecting condensate
- Lecture 58 Thermal rating
- Lecture 59 Before you proceed to the next section
- Section 8: Steam consumption of process tanks
- Lecture 60 Introduction
- Lecture 61 Energy requirements
- Lecture 62 Example of heat consumption of tanks – part 1
- Lecture 63 Before you proceed to the next section
- Section 9: Heating process equipment with steam coils and jackets
- Lecture 64 Introduction
- Lecture 65 Submerged steam coils
- Lecture 66 Example of heat consumption of tanks – part 2
- Lecture 67 Other steam coil layouts
- Lecture 68 Control valve arrangement
- Lecture 69 Steam jackets
- Lecture 70 Before you proceed to the next section
- Section 10: Heating tanks by steam injection
- Lecture 71 Introduction
- Lecture 72 Size of the steam bubbles
- Lecture 73 Head of liquid over steam injection point
- Lecture 74 Steam bubbles velocity
- Lecture 75 Temperature of the liquid
- Lecture 76 Sparge pipes
- Lecture 77 Example of heat consumption of tanks – part 3
- Lecture 78 Steam injectors
- Lecture 79 Example of heat consumption of tanks – part 4
- Lecture 80 Before you proceed to the next section
- Section 11: Steam consumption of pipes
- Lecture 81 Introduction to steam consumption of pipes
- Lecture 82 Steam mains
- Lecture 83 Warmin-up load
- Lecture 84 Running-up load
- Lecture 85 Before you proceed to the next section
- Section 12: Steam consumption of plant items
- Lecture 86 Heat exchangers
- Lecture 87 More about shell and tube heat exchangers
- Lecture 88 More about plate and frame heat exchangers
- Lecture 89 Tracer lines
- Lecture 90 Sizing tracer lines
- Section 13: The boiler house
- Lecture 91 Introduction to the boiler house
- Lecture 92 Boiler types
- Lecture 93 Shell boilers
- Lecture 94 Lancashire boilers
- Lecture 95 Economic boilers – Two-pass, dry back
- Lecture 96 Economic boilers – Three-pass, wet back
- Lecture 97 Packaged boilers
- Lecture 98 Reverse flame
- Lecture 99 Shell boiler summary
- Lecture 100 Water tube boilers
- Lecture 101 Alternative water tube boiler layouts
- Lecture 102 Steam generators
- Lecture 103 Economizers
- Lecture 104 Superheaters
- Lecture 105 Before you proceed to the next section
- Section 14: Boiler ratings
- Lecture 106 Introduction
- Lecture 107 “From and at” rating
- Lecture 108 “From and at” rating – Worked example
- Lecture 109 kW rating
- Lecture 110 kW rating – Worked example
- Lecture 111 Before you proceed to the next section
- Section 15: Boiler efficiency and combustion
- Lecture 112 Introduction
- Lecture 113 Heat exported in steam
- Lecture 114 Heat provided by the fuel
- Lecture 115 Heat losses
- Lecture 116 Burners
- Lecture 117 Oil burners
- Lecture 118 Gas burners
- Lecture 119 Burner control systems
- Lecture 120 Safety
- Lecture 121 Before you proceed to the next section
- Section 16: Boiler fittings and mountings
- Lecture 122 Introduction
- Lecture 123 Boiler name-plate
- Lecture 124 Safety valves
- Lecture 125 Stop valves
- Lecture 126 Feedwater check valve
- Lecture 127 Boiler water quality control
- Lecture 128 Pressure gauge
- Lecture 129 Gauge glasses
- Lecture 130 Maintenance of gauge glasses
- Lecture 131 Water level control
- Lecture 132 Air vents
- Lecture 133 Vacuum breakers
- Lecture 134 Before you proceed to the next section
- Section 17: Steam headers and off-takes
- Lecture 135 Introduction to steam headers
- Lecture 136 Steam off-takes
- Lecture 137 Water carryover
- Lecture 138 Warm-up
- Lecture 139 Preventing one boiler pressurizing another
- Lecture 140 Ensuring proper steam distribution
- Lecture 141 Steam header characteristics
- Lecture 142 Before you proceed to the next section
- Section 18: Water properties
- Lecture 143 Introduction
- Lecture 144 Hardness and salts
- Lecture 145 pH value
- Lecture 146 Before you proceed to the next section
- Section 19: Water for the boiler
- Lecture 147 Introduction
- Lecture 148 Good quality steam
- Lecture 149 Carryover
- Lecture 150 External water treatment
- Lecture 151 Ion exchange
- Lecture 152 Base exchange softening
- Lecture 153 Dealkalisation
- Lecture 154 Demineralisation
- Lecture 155 Water quality vs treatment process
- Lecture 156 Before you proceed to the next section
- Section 20: Feedtank and feedwater conditioning
- Lecture 157 Introduction
- Lecture 158 Worked example
- Lecture 159 Feedtank design
- Lecture 160 Feedtank construction
- Lecture 161 Condensate return
- Lecture 162 Flash steam
- Lecture 163 Steam injection
- Lecture 164 Feedtank vent
- Lecture 165 Feedtank take-off
- Lecture 166 Miscellanious
- Lecture 167 Water level control
- Lecture 168 Deaerators
- Lecture 169 Summary of feedtank components
- Lecture 170 Before you proceed to the next section
- Section 21: Controlling TDS in the boiler water
- Lecture 171 Introduction
- Lecture 172 Boiler water sampling
- Lecture 173 Conductivity measurement in the boiler
- Lecture 174 Deciding on the required boiler water TDS
- Lecture 175 The blowdown rate
- Lecture 176 Controlling the blowdown rate
- Lecture 177 “Closed loop” TDS control systems
- Lecture 178 Before you proceed to the next section
- Section 22: Heat recovery from boiler blowdown
- Lecture 179 Introduction to heat recovery
- Lecture 180 Energy flowrate in blowdown
- Lecture 181 Flash steam
- Lecture 182 Recovering and using flash steam
- Lecture 183 Heat recovery from residual blowdown
- Lecture 184 Design considerations
- Lecture 185 Summary – Total energy saving
- Lecture 186 More about heat exchangers: Plate type
- Lecture 187 More about heat exchangers: Shell and tube type
- Lecture 188 Before you proceed to the next section
- Section 23: Water levels in steam boilers
- Lecture 189 Introduction
- Lecture 190 Boiler water level
- Lecture 191 Methods for detecting water levels in steam boilers
- Lecture 192 Level gauge glass
- Lecture 193 Magnetic
- Lecture 194 Switch contact
- Lecture 195 Reed contact
- Lecture 196 Optoelectronic switch
- Lecture 197 Hydrostatic pressure
- Lecture 198 Capillary systems
- Lecture 199 Radars
- Lecture 200 Radiometric sensors
- Lecture 201 Before you proceed to the next section
- Section 24: Automatic levels control systems
- Lecture 202 ON / OFF control
- Lecture 203 Modulating control
- Lecture 204 Variable speed feedwater pump
- Lecture 205 Single element water level control
- Lecture 206 Two element water level control
- Lecture 207 Summary of modulating level control
- Lecture 208 Before you proceed to the next section
- Section 25: Water level alarms
- Lecture 209 Introduction to water level alarms
- Lecture 210 LOW water alarm
- Lecture 211 HIGH water alarm
- Lecture 212 Before you proceed to the next section
- Section 26: Installation of level controls
- Lecture 213 Introduction
- Lecture 214 External chambers
- Lecture 215 Internal protection tubes
- Lecture 216 Before you proceed to the next section
- Section 27: Pipe sizing for steam distribution
- Lecture 217 Introduction
- Lecture 218 The working pressure
- Lecture 219 Pressure reduction
- Lecture 220 Standards and wall thickness
- Lecture 221 Pipe material
- Lecture 222 Pipe sizing
- Lecture 223 Worked example using the Moody chart
- Lecture 224 Oversized steam pipes
- Lecture 225 Undersized steam pipes
- Lecture 226 Sizing a steam pipe: Pressure factor method
- Lecture 227 Sizing a steam pipe: Steam pipeline sizing chart
- Lecture 228 Sizing steam pipes on velocity: Principles
- Lecture 229 Sizing steam pipes on velocity: Worked example
- Lecture 230 Sizing superheated steam pipes
- Lecture 231 Sizing a steam pipe: Using formulae and equations
- Lecture 232 Before you proceed to the next section
- Section 28: Steam mains and drainage
- Lecture 233 Introduction to steam mains and drainage
- Lecture 234 Piping layout
- Lecture 235 Water hammer (reminder)
- Lecture 236 Branch lines
- Lecture 237 Drop leg
- Lecture 238 How to drain steam mains
- Lecture 239 Steam leaks
- Lecture 240 Before you proceed to the next section
- Section 29: Steam pipe expansion and support
- Lecture 241 Allowance for expansion
- Lecture 242 Piping flexibility
- Lecture 243 Expansion fittings
- Lecture 244 Pipe support spacings
- Lecture 245 Before you proceed to the next section
- Section 30: Steam traps
- Lecture 246 Overview of steam traps
- Lecture 247 Float traps
- Lecture 248 Thermostatic traps
- Lecture 249 Thermodynamic traps
- Lecture 250 Inverted bucket traps
- Lecture 251 Testing of steam traps
- Lecture 252 Maintenance of steam traps
- Lecture 253 Energy losses in steam traps
- Lecture 254 Before you proceed to the next section
- Section 31: Strainers
- Lecture 255 Overview of strainers
- Lecture 256 Wye strainers
- Lecture 257 Basket strainers
- Lecture 258 Strainer screens
- Section 32: Hazards of steam
- Lecture 259 Introduction to hazards of steam
- Lecture 260 Purging with steam
- Lecture 261 Blanketing with steam
- Lecture 262 Hazards from condensing steam
- Lecture 263 Water from steam
- Lecture 264 Thermal expansion
- Lecture 265 Stresses in equipment
- Lecture 266 Before you proceed to the next section
- Section 33: Condensate recovery
- Lecture 267 Introduction to condensate recovery
- Lecture 268 Calculating the amount of flash steam from condensate
- Lecture 269 Live steam / Flash steam
- Lecture 270 Why return condensate and reuse it ?
- Lecture 271 The financial value or returning condensate
- Lecture 272 Before you proceed to the next section
- Section 34: Layout of condensate return lines
- Lecture 273 Introduction to layout of condensate return lines
- Lecture 274 Drain lines to steam traps (1/3)
- Lecture 275 Sizing a drain line to a thermostatic trap
- Lecture 276 Drain lines to steam traps (2/3)
- Lecture 277 Drain lines to steam traps (3/3)
- Lecture 278 Discharge lines from traps
- Lecture 279 Common return lines
- Lecture 280 Draining into flooded lines
- Lecture 281 Discharge lines at different pressures
- Lecture 282 Before you proceed to the next section
- Section 35: Sizing condensates return lines
- Lecture 283 Introduction
- Lecture 284 Sizing drain lines to traps
- Lecture 285 Sizing drain lines to traps – Worked example
- Lecture 286 Sizing discharge lines from traps
- Lecture 287 Factors affecting the two-phase flow
- Lecture 288 Condensate pipe sizing chart
- Lecture 289 Sizing for falling discharge lines – Worked example
- Lecture 290 Sizing for rising discharge lines – Worked example
- Lecture 291 Sizing for vented discharge lines – Worked example
- Lecture 292 Common return lines – Falling lines
- Lecture 293 Common return lines – Rising lines
- Lecture 294 Falling common line – Apply your knowledge
- Lecture 295 Rising common line – Apply your knowledge
- Lecture 296 Before you proceed to the next section
- Section 36: Pumping condensate from vented receivers
- Lecture 297 Introduction to pumping condensate from vented receivers
- Lecture 298 Pumping terminology
- Lecture 299 Cavitation in centrifugal pumps experiment
- Lecture 300 Head exercise with a positive displacement pump
- Lecture 301 Centrifugal condensate pumps
- Lecture 302 Sizing a condensate recovery unit
- Lecture 303 Sizing the discharge pipe for a condensate recovery unit
- Lecture 304 Positive displacement condensate pumps
- Lecture 305 More on positive displacement condensate pumps
- Lecture 306 Pump application
- Lecture 307 Sizing a mechanical condensate pump
- Lecture 308 Condensate pump sizing exercise
- Lecture 309 Sizing the discharge pipe for a mechanical condensate pump
- Lecture 310 Sizing the discharge pipe for a mechanical condensate pump – Worked example
- Lecture 311 Sizing the discharge pipe for a mechanical condensate pump – Worked example
- Lecture 312 Assessing a larger pump and a smaller delivery line
- Lecture 313 Condensate velocities
- Lecture 314 Best practices for long delivery lines
- Lecture 315 Before you proceed to the next section
- Section 37: Lifting condensate
- Lecture 316 Lifting condensate from a steam main
- Lecture 317 Contaminated condensate
- Lecture 318 Before you proceed to the next section
- Section 38: Downloadable resources
Course details
- Video quality: MP4 | Video: h264, 1280 × 720
- Audio quality: Audio: AAC, 44.1 KHz, 2 Ch
- Last updated 11/2024
- Video duration: 16h 3m
- Number of lessons: 38 sections, 319 lectures
- Language: Language: English
- Compressed file size: 6.8 GB
