Course Catalogue.

Layup (Storage) Best Practices for Steam-Water Touched Equipment

4 Professional Development Hours

After participating in this course, you will be able to do the following:

  • Understand the critical need to achieve proper layup conditions for stored equipment
  • Improve the long-term reliability (and availability factor) of new plant equipment by focusing on pre-commissioning layup methodology
  • Identify the various methods of layup and the pros and cons of each method
  • Develop an effective plan to layup different types of plant components (boilers, heat-recovery steam generators, superheaters, deaerators, steam turbines, etc.)
  • Evaluate with confidence what chemicals are recommended (and which are not) for layup
  • How to safely return to operation from a specific type of layup
  • Develop a layup Management Program for your plant to extend the life of equipment and reduce maintenance costs

Course Description:

Experience and research have shown that much, if not most, of all corrosion in steam-generating plants occurs during shutdown (or idle) periods while the plant is out of production. Unless adequate precautionary measures are taken, more corrosion damage can occur to a boiler and its auxiliary units during idle periods of storage than during long periods of operation. This corrosion can occur on both waterside and/or fireside surfaces.

Many boiler plants maintain backup capacity that must be immediately ready to supply steam should a mechanical problem occur on the main boilers. The challenge is to protect the integrity of the backup boilers while they are not being used. A significant amount of damage that occurs to boilers during their lifetime can be associated with idle periods and extended downtime. The typical chemical treatment applied during operational times provide protection for boilers from scale and corrosion is often unavailable when the boiler is sitting idle. The consequences of improper layup include both the questionable reliability and availability of the steam-generating plant when operation is resumed, as well as a reduction in the life span of the equipment and a concomitant increase in maintenance costs.

This course focuses on boiler systems of all pressures (and in a variety of industries) and discusses extended wet layup, short term layup, dry layup for very long outages for a wide range of equipment: from deaerators to feedwater heaters, from drainable and non-drainable superheaters to and steam turbines.

It also covers the proper start-up of idle boilers to minimize scale, corrosion and ensure adequate steam purity. The course also teaches how to assess the preferred layup method for a given situation, i.e. evaluation of the key factors that must be considered when selecting the correct type of layup. The various types of corrosion seen in idle boilers and auxiliary systems are discussed along with the appropriate chemical and mechanical treatment options. Several important case studies are reviewed. The course also addresses unique industry needs, such as those of cycling power plants.

The instructor was involved worldwide in dozens of layups of steam generation equipment in many industries, some in very remote areas of Central America and S.E. Asia. The insights gained proved invaluable for later projects in many parts of the world, including the U.S.A. and Canada.

Course Outline:

  • Understand the Corrosion Triangle
  • Learn how botched layups are implicated in many subsequent serious metallurgical failures
  • Learn about the different types of corrosion that are implicated during idle periods
  • Learn about the different types of layup and how to assess the preferred method for a given situation (evaluate the key factors that must be considered when selecting the correct type of layup)
  • Understand the critical importance of pre-commissioning layup
  • The Vital Few – the three key steps of a successful wet layup
  • Learn about the chemistry options of wet layup – the good, the bad, and the ugly
  • Learn how to implement an effective dry layup
  • Discover some unique needs of cycling power plants
  • Learn how to layup a variety of plant equipment – boilers of all sizes, HRSGs, deaerators, superheaters, steam turbines, etc.
  • Evaluate the need for ancillary equipment (dehumidifiers, steam sparging, nitrogen blanketing, etc.)
  • Case studies in industry

Who Should Attend

  • Plant Managers
  • Operation Managers
  • Maintenance Managers
  • Maintenance Engineers
  • Plant Engineers
  • Utility Engineers
  • Technologists
  • Project Managers in the Chemical, Petrochemical, Chemical Processing and other industries
  • Reliability Engineers
  • Stationary Engineers / Plant Operators
  • Risk Management Staff
  • Anyone involved in Plant Asset Management
  • Anyone involved in industrial steam generation systems and steam turbines
Course Rating

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Almost all of EPIC's courses offer :

  • Continuing Education Units (CEUs) and
  • Professional Development Hours (PDHs)

These course credits will help attendees earn training requirements for their associations or provincial governing bodies.

This course can be customized and delivered to a group at your facility saving time and money.
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