The Boiler and Heat Reclaim course is an in-depth Training on heated-water and low-pressure steam boilers, this custom Class will also cover heat reclaim including absorption chiller pairing. The Class will also prepare the Techs to pass their respective Boiler Operator exams.

- Boilers -

Knowledge in the operation, maintenance, repair, the economics of basic systems including the use of steam, the energy source to produce the steam, the distinction between industrial and utility boilers, and a good concept of how steam is generated from a heat source other than combustion within a boiler

a. Steam Cycle - The Boiler Operator should know the Rankine Cycle, the effects of reheat cycles, and regenerative feed water heating.

b. Fuel/Energy Source - The Boiler Operator should know the types of fossil fuels used in a boiler, coal, oil, gas as well as the heat derived from nuclear fuel such as uranium.

c. Utility Boilers - The Boiler Operator should know that utility boilers are those plants that generally supply electricity to most of the United States. These boilers are most often fired with coal but are also fired with fuel oil and gas. Utility boilers have reheat cycles and require very elaborate water treatment systems.

d. Industrial Boilers - The Boiler Operator should know industrial boilers are most often used for process steam, such as heating, driving operating turbines, for fans or pumps, and other process work.

e. Cogeneration - The Boiler Operator should know that cogeneration is a system in which fuel is used to produce energy and the heat from the fuel is then directed to be used by a boiler to conserve energy and achieve the maximum efficiency from the heat generated.

Centrifugal chillers represent a significant HVAC investment for the building owner, and each type of machine requires specific operating, servicing, and maintenance practices to protect the investment. This course is intended for service technicians and operators of Carrier 19 series centrifugal chillers. The course covers fundamental principles of centrifugal chillers with in-depth coverage of the operation and service techniques associated with most Carrier centrifugal chillers produced over the last 30 years. Carrier chiller models covered include 19D low-pressure chillers and 19E, F, 19XL, XR and 19XRV high-pressure chillers. Participants learn how to operate, maintain, troubleshoot, and service both the low- and high-pressure machines (including PIC controls). Studies include centrifugal refrigeration cycles, compressor theory, lubrication cycles, purge operation, refrigerants, heat exchangers, and heat transfer. The course also covers troubleshooting techniques and equipment needed to record and analyze machine temperatures and pressures; performance using heat exchanger approaches; waterside flow rate analysis; maintenance requirements; and logging machine data. This course is classroom instruction and includes numerous exercises using the classroom information to analyze performance. Successful completion of this course is required in order to attend the SER 130 Centrifugal Disassembly and Reassembly course. This course is for HVAC technicians with a minimum of one year of field experience or a graduate of an HVAC training program. Students are expected to have basic math skills and a basic understanding of HVAC tools (gages and digital thermometers) and troubleshooting equipment.

HVAC technicians taking this class will learn how to best operate, maintain, troubleshoot, and service Carrier’s complete line of scroll and screw 30 series air- and water-cooled chillers and 23XRV chillers.

• Topics include chiller refrigeration cycle, compressor theory, cooler heat transfer, and water- and air-cooled condensers

• Analyze performance by recording and analyzing refrigerant and water pressures and temperatures and calculating GPM flows

• Refrigerant controls, adjustments, charging, capacity control and capacity testing, and operation

• Troubleshooting of the electrical system, including timers, temperature controllers, and operating and safety controls

HVAC technicians who take this class will learn how to best operate, maintain, troubleshoot, and service Carrier’s 23XR/XRV water-cooled screw chillers.

• Topics cover the chiller refrigeration cycle, compressor theory, drive theory, cooler heat transfer, and water-cooled condensers

• Operation and function of the compressors, muffler, condenser, coolers, economizers, metering devices, oil concentrator and accessories are covered

• Analyze performance by recording and analyzing refrigerant and water pressures and temperature

• Distinguish between chiller and system problems and to quickly diagnose problems using service logs

• Set up and adjust the controls for optimum system performance

• Recommended pre-start and startup procedures, and operational and field issues will be covered

Summary:

This (2) two-day course (1.4 CEU) is designed to assist in the education and development of the individual that has the responsibilities for the day to day operation and maintenance of their boiler and the ancillary equipment. The Student will gain the knowledge and understanding of how to properly operate the equipment safely but more efficiently. This course will also provide the proper sequence of operation or timing that will assist in the troubleshooting area and reduce downtime and increase reliability.

Objectives:

Gain knowledge and understanding of boilers, ancillary equipment and their operation

Expedite Troubleshooting situations and increase reliability

Understanding of Electrical circuitry and Sequencing

Preventative maintenance scheduling

Detailed Outline:

Thermodynamics

Thermodynamic principles, BTU definition, Two states of heat, Steam tables, Boiler Horsepower definition, Impact of feedwater, Heat transfer

Boiler Overview

Types and applications, ASME codes, Boiler design and principles of operation; Firetube boilers – Dryback vs. Waterback, Industrial water tube boilers – D, O and A types, Commercial water tube boilers, Modular boilers

Combustion

Theory and chemistry of combustion, Guidelines for setting combustion, Flue gas analysis, Effects of ambient air on combustion settings

Burners

Types and construction of burners, Integral head Burner, Jet Burner, Burner Turndown, Cams and linkages, Single point positioning, Parallel positioning, Fuel delivery systems, Gas and Oil components

Boiler Room Equipment

Cost of steam, Ancillary equipment, Efficiency gains

Steam Load Demand

Maximum instantaneous demand, Startup load vs. running load, Impact on boiler capacity, Shrink and swell, Tube and tube sheet stress, Possible solutions

The course covers a basic understanding of the Turbocor compressor technology, and major component functions. It provides knowledge of tools needed to access compressor operation data such as Service Monitoring Tool (SMT software) and provides an understanding of the compressor control system. The course also includes compressor commissioning procedures, troubleshooting, and maintenance guidelines and compressor service requirements.