Steam Boilers, Steam & Condensate Systems 16Hour Masterclass

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
Requirements
There are no strict prerequisites for enrolling in this masterclass. Whether you are an experienced engineer or new to steam systems, boilers, and condensate recovery, this course is designed to accommodate learners of all levels
What you need to succeed
A basic understanding of industrial operations is helpful, but no prior knowledge of steam or condensate systems is required
An interest in improving energy efficiency and operational safety in plant environments
A desire to learn practical, real-world skills from experienced professionals
This masterclass is structured to guide you step-by-step through foundational concepts and gradually introduce more advanced techniques, making it accessible for beginners while still being valuable for seasoned professionals looking to enhance their expertise
With this flexible approach, anyone interested in improving their knowledge of steam, boiler, and condensate systems can confidently join and succeed in the course
Description
Unlock the full potential of your steam and condensate systems with this 16-hour masterclass packed with real-world case studies, engineering best practices, and extensive visuals.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 SystemsIn 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 systemsEstimating and measuring steam consumption for process equipment, tanks, and plant itemsPipe sizing for steam distribution and effective drainage strategiesThe importance of steam traps, strainers, and understanding steam hazardsBy 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 BoilersThis 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 efficiencyBoiler fittings, mountings, and steam headersFeedwater conditioning, controlling TDS (Total Dissolved Solids), and heat recovery from boiler blowdownManaging water levels and automatic level control systems in steam boilersTroubleshooting guidelines and operation best practices in accordance with ASME and other standardsIn 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 SystemsEfficient 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 wasteBest practices for layout and sizing of condensate return linesPumping condensate from vented receivers and how to lift condensate over obstaclesEnsuring efficient condensate system operation and troubleshootingBy 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 scenariosExtensive visuals and animations to simplify complex topicsEngineering best practices with downloadable resources and design templatesNumerous quizzes and solved problems to reinforce learning and ensure concept masteryDelivered by experienced engineers with hands-on expertise in steam systems and boilersBy completing this masterclass, you will gain the confidence and expertise needed to manage and troubleshoot your steam, boiler, and condensate systems effectively. This course will help you avoid costly mistakes and ensure the safe, efficient, and reliable operation of your plant.Enroll now and take the next step in your professional development !WR TrainingSpread the wings of your knowledge
Overview
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 Waterhammer (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 condensate 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 2
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
Lecture 319 Download me
This masterclass is ideal for a wide range of professionals looking to deepen their understanding of steam systems, boilers, and condensate recovery. You will find the course content valuable if you are:,Engineers and Technicians working in process plants, power generation, petrochemicals, or any industrial sector that relies on steam systems for energy and production,Plant Managers and Operators responsible for the operation, maintenance, and optimization of steam and condensate systems and looking to improve plant efficiency and reduce operational costs,Maintenance Personnel tasked with troubleshooting and maintaining steam boilers and condensate systems, ensuring their reliable and safe operation,Energy Efficiency Specialists focused on maximizing energy recovery and minimizing waste through effective condensate recovery and steam system optimization,New Engineers or Graduates looking to build a strong foundation in steam and condensate systems, preparing for a career in industries like refining, chemical processing, or power generation,Anyone Seeking Practical Knowledge in steam, boiler, and condensate systems, even without prior experience, to boost their technical skills and understanding of industrial energy systems,Whether you're a beginner aiming to grasp the fundamentals or an experienced professional seeking advanced insights, this course offers valuable knowledge and real-world applications that will elevate your skills and enhance your career
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