2014 boiler session_all

POWER
BOILER INSPECTION SEMINAR SERIES
Session 1: Boiler Inspection Fundamentals
June 2 – 3, 2014
2014
Information covered can be applied to
coal, oil, gas, and waste-fired boilers – industrial or utility.
DoubleTree Hotel Chattanooga
407 Chestnut Street • Chattanooga, TN 37402
Focus on your...
Understanding of Multiple Boiler Designs
Technical Knowledge of Boiler Stresses and Locations
Boiler Pre-outage and Outage Inspection Plans

Description
Session I of the Boiler Inspection Seminar series is designed to benefit personnel recently assigned to the
task of maintaining the boiler and its auxiliaries. Emphasis is on common points for all boiler inspections.
Who will benefit most from participating?
• Maintenance personnel
• Maintenance planning personnel
• Engineering personnel
• Operations personnel
The lessons focus on the following systems and equipment:
• Large coal, oil or gas-fired boilers
• Modern industrial boilers with gas tight furnaces and superheater assemblies
• Circulating Fluidized Bed Boilers
• Heat Recovery Steam Generators
This course begins with boiler design variations, based on application and fuel. Topics then focus on steel
selection, water treatment and steam quality. The central theme in this session is pressure part failure
mechanisms, causes and prevention.
Course Objectives
At the successful completion of the training, the student will be able to:
• List the most common stresses that limit boiler component life
• Differentiate the causes for multiple points of stress that can rapidly diminish pressure part reliability
(fuel, water quality, material selection, operator error, past maintenance practices)
• Identify critical inspection points both common to different boiler designs and unique to a variety of
fossil fuels
• Prioritize planning activities to maximize plant equipment reliability
Content
Fundamentals of boilers are addressed from multiple perspectives:
• Steam generator design principles
• Fossil fuel combustion concerns as well as ash and slag issues
• Causes of boiler tubing deterioration
• External fossil fuel corrosion of boiler pressure part tubing
• Internal boiler water corrosion of pressure part tubing
• Heat recovery steam generator (HRSG) technology versus standard fossil fuel boilers
• Boiler and power plant environmental concerns
• Operator and maintenance demands
Alstom’s TTT-M Materials Testing Center will be utilized during the session to provide a better
understanding of the processes involved in the analysis of high pressure, high temperature pressure parts.

Schedule/Agenda Session 1 – Boiler Inspection Fundamentals
Monday, June 2nd
7:00 am – 8:00 am Registration/Breakfast
8:00 am – 10:00 am Common Boiler Inspection Points
10:00 am – 12:00 noon Industrial vs. Utility Inspection
12:00 noon – 1:00 pm Lunch
1:00 pm – 3:00 pm Waterside and Fireside Attack
3:00 pm – 5:00 pm Structural Fatigue and Failures
Tuesday, June 3rd
7:00 am – 8:00 am Breakfast
8:00 am – 11:00 am Lab Tour
11:00 am – 12:00 noon Review of Tour Notes
1:00 pm – 1:30 pm Fuel, Air and Flue Gas System Deterioration
1:30 pm – 2:00 pm Emission Compliance Impact on Boilers
2:00 pm – 2:30 pm Feedwater and Boiler Water Chemistry Basics
2:30 pm – 4:00 pm Development of Pre-outage and Outage Inspection Lists
4:00 pm – 5:00 pm Summary
SEMINAR CANCELLATION POLICY
Cancellations must be received no later than two weeks prior to the scheduled course date to receive full refund. If cancellation occurs within
two weeks of but prior to start of classes, a $250.00 fee will be charged. Alternately, you may opt to carry a credit in the amount of the full course fee
which may be applied to courses offered within the 12 month period following the originally scheduled course. There will be no refunds for “no shows”
once classes have begun. Substitutions of students may be arranged at any time prior to the start of classes.
Alstom reserves the right to cancel courses up until two weeks prior to the scheduled course date. Full refunds of the course fee will be made
in such event. However, Alstom will not be liable for cancelled travel tickets, lodging costs or related penalties or charges.
Operation and Maintenance Training Department
Alstom Power Inc.
200 Great Pond Drive
Windsor, CT 06095
Instructor
Ken Barna
Ken has been associated with the Power Industry
for 26 years (22 +years with Alstom and 3+ years
with DUKE Energy). During his time at Alstom
DUKE, Ken has conducted numerous inspections
on varying fossil fuel (Coal, oil, gas, liquor)
designed boilers and refuse burning boilers. He
also has managed many site projects with regard
to retrofitting pressure parts and/or burners.
In addition to this maintenance work, Ken has
spent many hours in the control room working
with the Operations Dept. solving combustion
and/or steam flow problems. Ken has developed
and delivered training programs for Alstom Field
Service Engineers and customers located in US
and overseas. Ken has a BS degree in Mechanical
Engineering from West Virginia University.
Mark Williams
Mark has been with Alstom since 2007, Mark
serves as the Technical Services Area Manager for
the Cincinnati district. In this role he coordinates
maintenance support, condition assessment, and
performance testing services for steam generating
equipment. Mark uses his experiences as a
maintenance manager in the Army and field service
engineer to help customers solve their operations
and maintenance issues. During his time as a field
service engineer he focused on boiler inspections
and pulverizer testing. Mark has a B.S. degree
in Electrical Engineering from the United States
Military Academy at West Point.
Bruce Carlton
Bruce has been in a power systems related role for
21 years and with Alstom since 2005. Currently,
Bruce is responsible for Technical Services in
the South East USA, as well as international
accounts. While with Alstom he has been involved
with utility boiler inspections, including CFB’s,
pulverizer rebuilds, boiler retrofits, and new
boiler commissioning. Bruce has developed and
delivered training for customers located in the US
and overseas. Bruce received his BS in Chemical
Engineering from Purdue University.
Schedule of Upcoming Sessions
Session 2 – Boiler Component Failure Causes and Corrective Repairs Seminar
June 4–6, 2014, Chattanooga, TN
Session 3 – Pressure Part Failure Analysis and Prevention Seminar
Questions on which seminar is best for you? Call your local area service manager.

Alstom Power Inc. • 355 Satellite Blvd., N.E. • Suite 500 • Suwanee, GA 30024
www.alstom.com/power
Participation
Name: ____________________________________ Position:____________________________
Company: ____________________________________ Plant:_____________________________
Billing Address: ___________________________________________________________________
Street / P.O. Box
___________________________________ _________ _______________________
City State Zip Code
Phone: ________________ Fax: ________________ Email: _____________________________
Payment
q Visa q Master Card q American Express
Card Number _____________________________ Security Code___________ Expires _____________
q Check made out to Alstom Power Inc. and mailed to:
Teresa McKinley
Alstom Power Inc.
355 Satellite Blvd., N.E.
Suite 500
Suwanee, GA 30024
Signature: ______________________________________________________________________
Register Soon! Space is Limited!
2014 Boiler Inspection Seminar Series – Session 1
Boiler Inspection Fundamentals
June 2–3, 2014 • DoubleTree Hotel Chattanooga • 407 Chestnut Street • Chattanooga, TN 37402
Registration Form
Register for Hotel rooms (at your expense) as follows:
1. Make your reservations at the DoubleTree Hotel Chattanooga by May 13th, 2014 by calling 1.423.308.2508 or go to
www.Chattanooga.DoubleTree.com, after entering your arrival and departure dates: select “add special rate codes”, under “group codes” enter
ASP, then select “Check Availability” to book your room.
2. A block of rooms has been reserved for seminar attendees. The special Alstom Seminar rate is $119.00 per night plus tax.
Note: The Alstom rates are valid up to three days prior to the seminar or departing three days after the seminar (subject to availability).
Seminar Includes:
• Breakfast and Lunch each day
• Seminar Attendance
• Boiler Inspection Seminar Manual
$995.00 (USD) per person for registrations received by April 25, 2014.
$1145.00 (USD) per person for registrations received after April 25, 2014.
Register by April 25th and save $150 on your seminar fee! All registrations must be received by May 13th, 2014.
Register for the Seminar as follows:
1. Fax completed form to Teresa McKinley at 678.318.1263 or
2. Call Teresa McKinley at 678.318.1250 or
3. E-mail info below to teresa.a.mckinley@power.alstom.com

POWER
Session 2: Boiler Component Failure
Causes and Corrective Repair
June 4 – 6, 2014
2014
Focus on your...
Boiler Inspection Plans
Technical Knowledge of Boiler Hardware Failure Causes
Boiler and Auxiliaries Repair Activities

Description
This seminar is designed to benefit personnel responsible for inspecting, operating and maintaining the boiler and its
auxiliaries. Emphasis is on the details of inspection and preventative measures to improve component reliability.
Who will benefit most from participating?
• Maintenance personnel
• Maintenance planning personnel
• Engineering personnel
• Operations personnel
Course Pre-requisite:
• Attended Boiler Inspection Fundamentals Seminar or has previous knowledge in this area
The lessons focus on the following systems and equipment:
• Large coal, oil or gas-fired boilers
• Modern industrial boilers with gas tight furnaces and superheater assemblies
• Key auxiliary system components such as: hanger supports, ductwork, casing, access doors, burner/windbox
assemblies including fuel firing hardware, air heaters, soot blowing equipment, internal baffles, boiler water circulating
pumps, and trim piping
This course progressively addresses the subject of boiler inspections starting with the fundamentals of inspecting
thick-wall (headers/drums), thin-wall (tubes) pressure parts as well as sub-components closely associated with
reliable operation. Topics address the stresses from the standpoints of the fireside, waterside, and structural supports
over a range of thermal conditions. Each topic includes activities that must take place before, during and after the
boiler outage. Predictive maintenance (inspection and analysis) will be the primary focus, but critical recommendations
will address preventative and corrective maintenance.
Course Objectives
At the successful completion of the training, the student will be able to:
• Identify the many causes for boiler and auxiliaries deterioration and failure
• Prioritize activities and plan ways to maximize boiler system reliability
• Identify critical repairs that prevent pressure part damage
• Better understand the relationships between fuel, maintenance and operations
Content
Throughout the series of boiler lessons, subjects are detailed for the benefit of predictive, preventative and corrective boiler
and auxiliaries maintenance. Some examples are below:
• Predictive: – Determining the life expectancy of an overheated header
– Conducting effective inspections to help justify component refurbishment or replacement
• Preventative: – Limiting drum carryover of salts that can damage superheater tubes and turbine blading
– Reducing the incidents of component failures by understanding component design and operation
• Corrective: – How to systematically document repeat component failures until a root cause is found
– How to execute outage work to improve component performance
Alstom’s Manufacturing Facility will be utilized during the session to provide a better understanding of the processes involved in
the fabrication of high-pressure, high-temperature pressure parts.

Alstom Power Inc.
Windsor, CT 06095
Instructors
Schedule of Upcoming Sessions
Session 3 – Pressure Part Failure Analysis and Prevention Seminar
Questions on which seminar is best for you? Call your local area service manager.
Schedule/Agenda Session 2 – Boiler Component Failure Causes and Corrective Repairs
Wednesday, June 4th
7:00 am – 8:00 am Registration/Breakfast
8:00 am – 10:00 am Converting Inspection Lists into Inspection Plans
10:00 am – 12:00 noon Boiler Pressure Part Inspection and Repair
– Thin-walled Pressure Parts
12:00 noon Lunch (class concludes at lunch)
Thursday, June 5th
8:00 am – 10:00 am Boiler Pressure Part Inspection and Repair
– Thick-walled Pressure Parts
10:00 am – 12:00 noon Combustion-Related Components: Inspection and Repair
– Fuel Preparation, Feeders, Pulverizer, Buners and Windboxes
1:00 pm – 5:00 pm Lab vs Field Analysis (Case Studies and Shop Tour)
Friday, June 6th
8:00 am – 9:00 am Boiler Auxiliaries Inspection and Repair
– Air Systems, Fans, etc.
– Flue Gas, Ash Removal, Air Heaters, etc.
– Dead Air Spaces, Bottom Ash Hoppers
9:00 am – 9:30 am Factors Unique to Oil and Gas-Fired Boilers
9:30 am – 10:00 am Factors Unique to HRSG’s
10:00 am – 11:30 am Summary
Ken Barna
Ken has been associated with the Power Industry
for 26 years (22 +years with Alstom and 3+ years
with DUKE Energy). During his time at Alstom
DUKE, Ken has conducted numerous inspections
on varying fossil fuel (Coal, oil, gas, liquor)
designed boilers and refuse burning boilers. He
also has managed many site projects with regard
to retrofitting pressure parts and/or burners.
In addition to this maintenance work, Ken has
spent many hours in the control room working
with the Operations Dept. solving combustion
and/or steam flow problems. Ken has developed
and delivered training programs for Alstom Field
Service Engineers and customers located in US
and overseas. Ken has a BS degree in Mechanical
Engineering from West Virginia University.
Mark Williams
Mark has been with Alstom since 2007, Mark
serves as the Technical Services Area Manager for
the Cincinnati district. In this role he coordinates
maintenance support, condition assessment, and
performance testing services for steam generating
equipment. Mark uses his experiences as a
maintenance manager in the Army and field service
engineer to help customers solve their operations
and maintenance issues. During his time as a field
service engineer he focused on boiler inspections
and pulverizer testing. Mark has a B.S. degree
in Electrical Engineering from the United States
Military Academy at West Point.
Bruce Carlton
Bruce has been in a power systems related role for
21 years and with Alstom since 2005. Currently,
Bruce is responsible for Technical Services in
the South East USA, as well as international
accounts. While with Alstom he has been involved
with utility boiler inspections, including CFB’s,
pulverizer rebuilds, boiler retrofits, and new
boiler commissioning. Bruce has developed and
delivered training for customers located in the US
and overseas. Bruce received his BS in Chemical
Engineering from Purdue University.

Participation
Name: ____________________________________ Position:____________________________
Company: ____________________________________ Plant:_____________________________
Billing Address: ___________________________________________________________________
Street / P.O. Box
___________________________________ _________ _______________________
City State Zip Code
Phone: ________________ Fax: ________________ Email: _____________________________
Payment
Teresa McKinley
Alstom Power Inc.
Suite 500
Suwanee, GA 30024
Signature: ______________________________________________________________________
Boiler Inspection Fundamentals
Registration Form
Seminar Includes:
$995.00 (USD) per person for registrations received by April 25, 2014.
$1145.00 (USD) per person for registrations received after April 25, 2014.
Register by April 25th and save $150 on your seminar fee! All registrations must be received by May 13th, 2014.

POWER
Session 3: Pressure Part Failure Analysis and Prevention
June 17 – 19, 2014
2014
Focus on your...
Boiler pressure part conditions
from a field and lab perspective

Description
Content
Course Objectives
This seminar is designed to benefit personnel responsible for
inspecting and maintaining the boiler and its auxiliaries.
Emphasis is on common points for all boiler inspections.
Who will benefit most from participating:
• Maintenance Personnel
• Maintenance Planning Personnel
• Plant Engineering Personnel
• NDE and Metallurgical Staff
• Corporate Engineering
• Welding Engineering
Course pre-requisite:
Attended previous Boiler Inspection Fundamentals and NDE
Condition Assessment Seminar or has previous knowledge in
power plant inspection and maintenance.
The Boiler Inspection Seminar Series progressively addresses
the subject of boiler inspection starting with the fundamentals
of inspecting thick-wall (headers/drums) and thin-wall (tubes)
pressure parts as well as those sub-components closely
associated with reliable operation.
In the Advanced assessment phase of this series of courses the
lessons will take stress analysis to a higher level where
component life and integrity assessment can be projected
beyond the traditional 30-year period, factoring in the risks
associated with cyclic operation.
The Lessons for Session 3, Pressure Part Failure Analysis
and Prevention Seminar, apply a laboratory focus on the
following systems and equipment:
• high energy piping
• high temperature headers
• superheater and reheater tubing and their oxide scale layers
• economizer tubing and headers
• water wall headers and tubing including flame spray or
cladding layers
• steam and mud drums
• dissimilar metal welds, and welding in general
• superheater and reheater desuperheaters.
This course will give the participants an opportunity to ask
how laboratory analyses (both metallurgical and computer
based) can be applied to the entire plant cycle, including
components such as deaerator tanks or turbine blades.
At the completion of Session 3, Pressure Part Failure Analysis
and Prevention Seminar, the student
will be able to:
• Identify both failure mechanism and/or component-based
assessment techniques to be applied to any failure.
• Apply timely and cost effective repair, modification and/or
replacement decisions for aged boiler components.
• Share in the process of relevant case study examples of
failure mechanisms and learn where deceptive appearances
of similar failures may mislead proper corrective actions.
• Address the more complex condition assessment challenges
with older boilers.
• Recognize when site evaluation of issues such as welding
problems, high temperature excursions or localized stress
concentration can be corrected before potential failures
cripple the power plant.
Predictive
• Determining remaining life expectancy using laboratory
analysis and computer-based models
Preventative
• Identifying the root cause of tube failures so as to prevent
repeat failures
Corrective
• Determining when a flawed weld repair is the cause
of secondary failure
• Implementing proper plan to eliminate future failures
Alstom’s professionals at our labs (Windsor, Critical
Technologies and Chattanooga, TTT-M Materials Testing Center)
not only have the expertise in high-temperature
material behavior, but also can demonstrate the best
ways to integrate their developed understanding of the
issues and interrelationships of operation, design and
related concerns of power generation.
Predictive, preventative and corrective boiler and auxiliaries maintenance tasks are addressed from the
perspective of pre-outage, outage and post-outage periods:

Alstom Power Inc.
Windsor, CT 06095
Instructors Session 3 – Pressure Part Failure Analysis and Prevention Seminar
Schedule/Agenda Session 3 – Pressure Part Failure Analysis and Prevention Seminar
Tuesday, June 17th
Gerard (Jerry) Chase
Jerry graduated from Worcester Polytechnic
Institute with a Bachelor’s degree in Mechanical
Engineering and began his engineering career at
the United Illuminating Company in New Haven,
Connecticut. Initially assigned to their downtown
Mechanical Engineering group performing power
plant improvement projects, he later worked
as a results engineer at UI’s Steel Point and
Bridgeport Harbor Stations. In 1980, he joined
Combustion Engineering in their Performance
Design group, focusing principally on boiler
pressure part evaluation and retrofit design. From
1989 until 1996 he served as district manager
for Field Service Engineering in the Northeast
U.S. Since 1996, he has managed a variety of the
company’s Engineering groups, including Service
Performance Design, Performance Testing,
Ash Systems Engineering, IC Engineering and
Pulverizer Service Engineering. He currently
serves as Chief Engineer for Alstom Power,
Boiler Area Center. Jerry has been a licensed
Professional Engineer since 1981. Jerry was a
2009 recipient of the “Distinguished Engineer of
the Year Award” presented by Alstom Power and
the Hartford, CT section of the American Society
of Mechanical Engineers.
Todd Smith
Todd has been wiith Alstom since 2007 and
is Manager of the Condition Assessment
Department and responsible for proposal
deveolpment, field support, business
development and engineering support. He
previously worked in the marine engineering field
aboard Navy contract ships. Todd has support
of the CA methodology and processes, including
header inspection, link/lead inspection, and
tubing assemblies.
Randy Wilson
Randy has been with Alstom since 2001, Randy
is responsible for the day-to-day operations of
the Alstom - Materials Technology Center. Randy
oversees the business providing metallurgical
testing, RD, root cause failure analysis and
remaining life evaluations of power generation
equipment through metallurgical laboratory
and field investigations. In addition to power
generation experience, Randy has experience
in the metallurgical testing business and
foundry business, including technical oversight,
management and quality control. Randy received
his BS degree from the University of Alabama
in Metallurgical Engineering and has also
completed additional metallurgical engineering
course work.
7:00 am – 8:00 am Full Breakfast/Registration
8:00 am – 8:45 am Introduction
9:00 am – 10:15 am CA Fundamentals
10:30 – 10:50 Water Chemistry
10:50 – 11:20 am Fuel vs. Pressure Part Corrosion
11:35 – 12:00 noon Lay Up Procedures
12:00 – 1:00 pm Lunch
1:00 – 2:00 pm Boiler Materials
2:15 – 3:00 pm Tube Failure Overview
3:00 – 3:30 pm DMWs
3:45 – 4:15 pm Material Processing
4:30 – 5:00 pm Case Studies
Wednesday, June 18th
7:00 am – 8:00 am Full Breakfast
8:00 am – 11:00 am Tube Failure Session
11:00 am – 12:00 noon Tube Failure Identification
ID – 10-20 samples in group
12:00 – 1:00 pm Lunch
1:00 – 4:00 pm Lab Tour
4:00 – 5:00 pm Questions/Follow-up of Lab Tour
Thursday, June 19th
7:00 am – 8:00 am Full Breakfast
8:00 am – 9:30 am NDE Overview
9:45 am – 11:00 am Headers DSH
11:15 – 12:00 noon Piping Hangers
12:00 – 1:00 pm Lunch
1:00 – 2:30 pm Piping Case Studies
2:45 – 4:30 pm Headers Case Study

Participation
Name: ____________________________________ Position:____________________________
Company: ____________________________________ Plant:_____________________________
Billing Address: ___________________________________________________________________
Street / P.O. Box
___________________________________ _________ _______________________
City State Zip Code
Phone: ________________ Fax: ________________ Email: _____________________________
Payment
Teresa McKinley
Alstom Power Inc.
Suite 500
Suwanee, GA 30024
Signature: ______________________________________________________________________
Pressure Part Failure Analysis and Prevention Seminar
Registration Form
Seminar Includes:
$995.00 (USD) per person for registrations received by May 2, 2014.
$1145.00 (USD) per person for registrations received after May 2, 2014.
Register by May 2 and save $150 on your seminar fee! All registrations must be received by May 29th, 2014.

2014 boiler session_all

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