Boiler Failure Analysis for Non-Metallurgists (Live Training, not pre-recorded)
Online course 05-Mar-2026 9:30 am - 1:30 pm EST (Eastern Standard Time)
Main Learning Outcomes of this course:
After participating in this course, you will be able to:
- Differentiate between different types of failures in boilers (within a wide range of operating pressures), steam turbines and other equipment
- Understand the difference between deposition-driven failures and corrosion-based failures; also, how deposition may drive boiler corrosion
- Understand industry guidelines for boiler tube cleanliness
- Understand the fundamental principles of chemical treatment of boilers (various pressures & designs) and its potential for driving failure mechanisms
- Know the relationship(s) between boiler design aspects and boiler loading and the different types of failures.
- Understand the unique features, needs and challenges of high-pressure (hp) steam generators
- Know the different types of deposition and corrosion in hp steam plants
- Know the various industry guidelines regulating hp steam plants
- Understand key chemical treatment aspects of boiler feedwater, boiler water & steam condensate programs
- Understand the importance of good steam purity, risks and mitigation factors for failures
- Learn about water-steam cycle monitoring methods (instrumentation and monitoring) and their potential impact on failure avoidance
- Learn the main tools and equipment used for metallurgical failure analysis
- Relate different failures to their possible causes
- Understand damage mechanisms such as creep, fatigue, corrosion and flow-accelerated corrosion/erosion/LDI
- Understand cycle stresses associated with some types of boilers
Course Description
There are many reasons why boilers (or steam plant) and their ancillary equipment (e.g. superheaters, condensers, etc.) tubes can fail in service. The heat-transfer surfaces of a boiler should achieve an extended operating life provided the boiler circulation system is correctly designed and the chemical water treatment management is satisfactory. However, failures in boiler tubes and other boiler ancillary equipment (superheaters, reheaters, feedwater heaters, condensers, steam turbines, etc.) are surprisingly common and can lead to unscheduled boiler plant shutdowns, damaged equipment, very costly production losses and potentially catastrophic consequences impacting human life.
Understanding the various types of failures, how to identify them, how failures can occur and ways to prevent them is critical to the continual improvement of plant safety, performance, availability, and reliability, whilst reducing maintenance costs. The emphasis of this course is mainly on water-side failures, although fireside issues are also adequately addressed. The course covers failures in both the boiler proper as well as other selected auxiliary equipment (e.g. surface condenser).
The course is not intended to replace the need for a thorough metallurgical analysis conducted by a licensed metallurgist; instead, it seeks to enhance the practical technical knowledge of non-metallurgists in the investigative process of metallurgical failures in boiler systems as well as to enable better communication between any parties involved.
The author of this course has extensive experience (40+ years) with steam plant failures and was involved in many boiler plant troubleshooting situations worldwide, including expert witness experience.
Who Should Attend:
- Plant Engineers
- Utility Engineers
- Operation Managers, Maintenance Managers, Maintenance Engineers
- Technologists/technicians
- Consultants in the Power Generation, Petrochemical, Chemical Processing and other industries
- Reliability Engineers and Risk Management Staff
- Anyone involved in Plant Asset Management
- Operating personnel or anyone requiring a working level knowledge of failure mechanisms in boilers (wide range of operating pressures)
- Industrial and commercial liability insurance underwriters and claims adjusters and trial lawyers specializing in product/process liability cases
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Make sure to take a look at other upcoming courses:
Course agenda:
- General discussion on types of failures in steam plant boiler systems (within a wide range of operating pressure)
- Deposition-driven failures: water-formed and steam-formed deposits (discussion of case studies)
- Iron deposits, other metal oxide deposits, salts as deposits
- Interpreting deposition morphology in steam plant systems (boilers, steam turbines, etc.)
- Industry guidelines for boiler tube cleanliness
- Short-term overheating vs. long-term overheating
- Corrosion-based failures (many cases studies are discussed)
-Under-deposit corrosion: the 3 main types (caustic gouging, acid phosphate corrosion and hydrogen attack)
-Flow-assisted corrosion (FAC) vs. Erosion-corrosion; Liquid Droplet Impingement; cavitation
-Chelant corrosion
-Low-pH corrosion
-Oxygen corrosion
-Stress-corrosion Cracking
-Etc.
- Fundamental principles of chemical treatment of boilers (accord. to pressure & design)
- Steam is the only product of a boiler – how to mitigate steam-based failures.
- Relationship between boiler design aspects, boiler load and the different types of failures
- Steam plant damage mechanisms such as creep and fatigue
- High-pressure (hp) steam generators: unique features, needs and challenges
- Main industry guidelines regulating hp steam plants
- Key chemical treatment aspects of boiler feedwater, boiler water and steam condensate and their impact on failure mitigation and identification
- Definition of good steam purity, and risks and mitigation factors for failures
- Principal water-steam cycle monitoring methods (instrumentation and monitoring) and their role on steam plant failure avoidance
- Cycle stresses associated with certain types of boiler operation (e.g. power generation / combined-cycle plants)
- Fireside Corrosion
- Main tools and equipment used for metallurgical failure analysis
- Tips for selecting a water laboratory, a metallurgist and a metallurgical lab
- And much more…
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Make sure to take a look at other upcoming courses:
The course fee is USD $795.00.
You can pay by credit card using Stripe. Click here to learn more.
All bookings are subject to acceptance of our Privacy Policy, Terms & Conditions and Cancellation & Refunds Policy.
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Make sure to take a look at other upcoming courses:
Online Courses / Webinars Withdrawal, Cancellation and Rescheduling
By registering for an online training course or webinar organised by Industrial Water Treatment Academy (iwtA) you agree to the following Training Cancellation policy as well to our general Terms and Conditions and Privacy Policy (both available on our website iwtacademy.com), regardless of whether such registration was made through iwtacademy.com website or via email, telephone, or any other means.
If you wish to withdraw from an online training event (online course or webinar), you must first advise us by email, and include the official payment receipt. Our policies regarding refunds are:
- You may cancel online-based training bookings at any time.
- If you cancel more than 10 (ten) business days before the training event: the full amount will be refunded minus a US$75.00 and a US$35.00 administration charge for an online course and webinar, respectively.
- If you cancel between 3 and 9 business days before the training event: 50% of the full amount paid will be refunded.
- If you cancel less than 3 (three) business days in advance: you can request a non-refundable credit, valid for 12 months from the date of the original payment, which can be applied to a different iwtA online course or webinar. Credits are transferable within your company – simply contact the Registrar at info@iwtacademy.com with your request giving the name and email address of the co-worker taking your place.
- If an instructor is not available due to unforeseen circumstances, another instructor of equal ability (decided at the sole discretion of iwtA) will be substituted whenever possible; if a suitable instructor is unavailable, the course will be cancelled and rescheduled. iwtA reserves the right to cancel courses, change instructors, or change course content. If iwtA has to cancel a course due to unforeseen circumstances, a full refund will be issued to the registrant.
- No training booking will be final and confirmed until the full amount is paid either by credit card or bank transfer.
A Certificate of Completion will be awarded to all participants that attend a given online course or webinar in its entirety.
The Industrial Water Treatment Academy (iwtA) is currently in the initial stages of seeking an ANSI-accredited international standard certification in Continuing Education that will enable iwtA to award Continuing Education Units (CEUs) to its course participants. We expect this milestone to be reached by 2023.
You must make the payment through the intermediary (Paypal or Stripe) in USD or other foreign currency subject to exchange rates and/or service commissions.
Deverá efectuar o pagamento ao intermediário (Paypal ou Stripe) em USD ou outra moeda estrangeira sujeita às taxas de câmbio e/ou comissões pelo serviço.
Refunds and cancellation policy
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Online Courses / Webinars Withdrawal, Cancellation and Rescheduling
By registering for an online training course or webinar organised by Industrial Water Treatment Academy (iwtA) you agree to the following Training Cancellation policy as well to our general Terms and Conditions and Privacy Policy (both available on our website iwtacademy.com), regardless of whether such registration was made through iwtacademy.com website or via email, telephone, or any other means.
If you wish to withdraw from an online training event (online course or webinar), you must first advise us by email, and include the official payment receipt. Our policies regarding refunds are:
- You may cancel online-based training bookings at any time.
- If you cancel more than 10 (ten) business days before the training event: the full amount will be refunded minus a US$75.00 and a US$35.00 administration charge for an online course and webinar, respectively.
- If you cancel between 3 and 9 business days before the training event: 50% of the full amount paid will be refunded.
- If you cancel less than 3 (three) business days in advance: you can request a non-refundable credit, valid for 12 months from the date of the original payment, which can be applied to a different iwtA online course or webinar. Credits are transferable within your company – simply contact the Registrar at info@iwtacademy.com with your request giving the name and email address of the co-worker taking your place.
- If an instructor is not available due to unforeseen circumstances, another instructor of equal ability (decided at the sole discretion of iwtA) will be substituted whenever possible; if a suitable instructor is unavailable, the course will be cancelled and rescheduled. iwtA reserves the right to cancel courses, change instructors, or change course content. If iwtA has to cancel a course due to unforeseen circumstances, a full refund will be issued to the registrant.
- No training booking will be final and confirmed until the full amount is paid either by credit card or bank transfer.
A Certificate of Completion will be awarded to all participants that attend a given online course or webinar in its entirety.
The Industrial Water Treatment Academy (iwtA) is currently in the initial stages of seeking an ANSI-accredited international standard certification in Continuing Education that will enable iwtA to award Continuing Education Units (CEUs) to its course participants. We expect this milestone to be reached by 2023.
Privacy Policy
Luís Carvalho trading as Industrial Water Treatment Academy is committed to safeguarding your privacy. Contact us at info@iwtacdemy.com if you have any questions or problems regarding the use of your Personal Data and we will gladly assist you.
By using this site or/and our services, you consent to the Processing of your Personal Data as described in this Privacy Policy.
Table of Contents
- Definitions used in this Policy
- Data protection principles we follow
- What rights do you have regarding your Personal Data
- What Personal Data we gather about you
- How we use your Personal Data
- Who else has access to your Personal Data
- How we secure your data
- Information about cookies
- Contact information
Definitions
Personal Data – any information relating to an identified or identifiable natural person.
Processing – any operation or set of operations which is performed on Personal Data or on sets of Personal Data.
Data subject - a natural person whose Personal Data is being Processed.
Child - a natural person under 16 years of age.
We/us (either capitalized or not) – Luís Carvalho
Data Protection Principles
We promise to follow the following data protection principles:
- Processing is lawful, fair, transparent. Our Processing activities have lawful grounds. We always consider your rights before Processing Personal Data. We will provide you information regarding Processing upon request.
- Processing is limited to the purpose. Our Processing activities fit the purpose for which Personal Data was gathered.
- Processing is done with minimal data. We only gather and Process the minimal amount of Personal Data required for any purpose.
- Processing is limited with a time period. We will not store your personal data for longer than needed.
- We will do our best to ensure the accuracy of data.
- We will do our best to ensure the integrity and confidentiality of data.
Data Subject's rights
The Data Subject has the following rights:
- Right to information – meaning you have to right to know whether your Personal Data is being processed; what data is gathered, from where it is obtained and why and by whom it is processed.
- Right to access – meaning you have the right to access the data collected from/about you. This includes your right to request and obtain a copy of your Personal Data gathered.
- Right to rectification – meaning you have the right to request rectification or erasure of your Personal Data that is inaccurate or incomplete.
- Right to erasure – meaning in certain circumstances you can request for your Personal Data to be erased from our records.
- Right to restrict processing – meaning where certain conditions apply, you have the right to restrict the Processing of your Personal Data.
- Right to object to processing – meaning in certain cases you have the right to object to Processing of your Personal Data, for example in the case of direct marketing.
- Right to object to automated Processing – meaning you have the right to object to automated Processing, including profiling; and not to be subject to a decision based solely on automated Processing. This right you can exercise whenever there is an outcome of the profiling that produces legal effects concerning or significantly affecting you.
- Right to data portability – you have the right to obtain your Personal Data in a machine-readable format or if it is feasible, as a direct transfer from one Processor to another.
- Right to lodge a complaint – in the event that we refuse your request under the Rights of Access, we will provide you with a reason as to why. If you are not satisfied with the way your request has been handled please contact us.
- Right for the help of supervisory authority – meaning you have the right for the help of a supervisory authority and the right for other legal remedies such as claiming damages.
- Right to withdraw consent – you have the right withdraw any given consent for Processing of your Personal Data.
Data we gather
Information you have provided us with
This might be your e-mail address, name, billing address, home address etc – mainly information that is necessary for delivering you a product/service or to enhance your customer experience with us. We save the information you provide us with in order for you to comment or perform other activities on the website. This information includes, for example, your name and e-mail address.
Information automatically collected about you
This includes information that is automatically stored by cookies and other session tools. For example, your shopping cart information, your IP address, your shopping history (if there is any) etc. This information is used to improve your customer experience. When you use our services or look at the contents of our website, your activities may be logged.
Information from our partners
We gather information from our trusted partners with confirmation that they have legal grounds to share that information with us. This is either information you have provided them directly with or that they have gathered about you on other legal grounds. See the list of our partners here.
Publicly available information
We might gather information about you that is publicly available.
How we use your Personal Data
We use your Personal Data in order to:
- provide our service to you. This includes for example registering your account; providing you with other products and services that you have requested; providing you with promotional items at your request and communicating with you in relation to those products and services; communicating and interacting with you; and notifying you of changes to any services.
- enhance your customer experience;
- fulfil an obligation under law or contract;
We use your Personal Data on legitimate grounds and/or with your Consent.
On the grounds of entering into a contract or fulfilling contractual obligations, we Process your Personal Data for the following purposes:
- to identify you;
- to provide you a service or to send/offer you a product;
- to communicate either for sales or invoicing;
On the ground of legitimate interest, we Process your Personal Data for the following purposes:
- to send you personalized offers* (from us and/or our carefully selected partners);
- to administer and analyse our client base (purchasing behaviour and history) in order to improve the quality, variety, and availability of products/ services offered/provided;
- to conduct questionnaires concerning client satisfaction;
As long as you have not informed us otherwise, we consider offering you products/services that are similar or same to your purchasing history/browsing behaviour to be our legitimate interest.
With your consent we Process your Personal Data for the following purposes:
- to send you newsletters and campaign offers (from us and/or our carefully selected partners);
- for other purposes we have asked your consent for;
We Process your Personal Data in order to fulfil obligation rising from law and/or use your Personal Data for options provided by law. We reserve the right to anonymise Personal Data gathered and to use any such data. We will use data outside the scope of this Policy only when it is anonymised. We save your billing information and other information gathered about you for as long as needed for accounting purposes or other obligations deriving from law, but not longer than 10 years.
We might process your Personal Data for additional purposes that are not mentioned here, but are compatible with the original purpose for which the data was gathered. To do this, we will ensure that:
- the link between purposes, context and nature of Personal Data is suitable for further Processing;
- the further Processing would not harm your interests and
- there would be appropriate safeguard for Processing.
We will inform you of any further Processing and purposes.
Who else can access your Personal Data
We do not share your Personal Data with strangers. Personal Data about you is in some cases provided to our trusted partners in order to either make providing the service to you possible or to enhance your customer experience. We share your data with:
Our processing partners:
- Dynafish - our web developers
- Krystal Hosting - our web hosting providers
- PayPal - one of our payment processors
- Stripe - one of our payment processors
- Zoom - our webinar providers
We only work with Processing partners who are able to ensure adequate level of protection to your Personal Data. We disclose your Personal Data to third parties or public officials when we are legally obliged to do so. We might disclose your Personal Data to third parties if you have consented to it or if there are other legal grounds for it.
How we secure your data
We do our best to keep your Personal Data safe. We use safe protocols for communication and transferring data (such as HTTPS). We use anonymising and pseudonymising where suitable. We monitor our systems for possible vulnerabilities and attacks.
Even though we try our best we can not guarantee the security of information. However, we promise to notify suitable authorities of data breaches. We will also notify you if there is a threat to your rights or interests. We will do everything we reasonably can to prevent security breaches and to assist authorities should any breaches occur.
If you have an account with us, note that you have to keep your username and password secret.
Children
We do not intend to collect or knowingly collect information from children. We do not target children with our services.
Cookies and other technologies we use
We use cookies and/or similar technologies to analyse customer behaviour, administer the website, track users' movements, and to collect information about users. This is done in order to personalise and enhance your experience with us.
A cookie is a tiny text file stored on your computer. Cookies store information that is used to help make sites work. Only we can access the cookies created by our website. You can control your cookies at the browser level. Choosing to disable cookies may hinder your use of certain functions.
We use cookies for the following purposes:
- Necessary cookies – these cookies are required for you to be able to use some important features on our website, such as logging in. These cookies don't collect any personal information.
- Functionality cookies – these cookies provide functionality that makes using our service more convenient and makes providing more personalised features possible. For example, they might remember your name and e-mail in comment forms so you don't have to re-enter this information next time when commenting.
- Analytics cookies - these cookies are used to track the use and performance of our website and services
You can remove cookies stored in your computer via your browser settings. Alternatively, you can control some 3rd party cookies by using a privacy enhancement platform such as optout.aboutads.info or youronlinechoices.com. For more information about cookies, visit allaboutcookies.org.
We use Google Analytics to measure traffic on our website. Google has their own Privacy Policy which you can review here. If you'd like to opt out of tracking by Google Analytics, visit the Google Analytics opt-out page.
Contact Information
Supervisory Authority
Website: http://www.cnpd.pt/
Email: geral@cnpd.pt
Phone: +351 21 392 84 00
Changes to this Privacy Policy
We reserve the right to make change to this Privacy Policy.
Last modification was made January 24, 2021.
Industrial Water Treatment Academy (iwtA)
Terms of Use | Disclaimers
IF YOU DISAGREE WITH ANY OF THESE TERMS OR CONDITIONS, DO NOT USE THIS WEBSITE.
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Thank you for visiting our website. If you want to use www.iwtAcademy.com, you must agree to conform to and be legally bound by the terms and conditions described below. The Industrial Water Treatment Academy, henceforth referred as iwtA, is the sole owner of all Intellectual Property contained within and displayed in this website, including logos, downloadable collateral material such as but not limited to course marketing brochure, course & webinar content, etc.
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Refer to iwtA’s website for the Terms and Conditions of their cancellation conditions and charges, to be found under each individual product (online courses & webinars, in-classroom Public courses). Cancellation conditions and charges will be specified on the course/webinar web page or in the course/webinar brochure for the event.
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Please note that the content of this page can change without prior notice.
This Anti-Spam Policy was last updated on 04-01-2021.
TESTIMONIALS, CASE STUDIES & EXAMPLES
Testimonials, case studies, and examples that may be found at www.iwtAcademy.com are exceptional results, do not reflect the typical purchaser’s experience, do not apply to the average person and are not intended to represent or guarantee that anyone will achieve the same or similar results. If we have disclosed typical results based on information provided to us by a manufacturer or other reputable third-party source, you should presume that the typical results as stated are more reliable than the testimonials and examples found at www.iwtA.com and related websites. However, you should always perform due diligence and not take such results at face value. We are not responsible for any errors or omissions in typical results information supplied to us by our partners, manufacturers or other reputable third parties.
EXTERNAL LINKS POLICY
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This policy was last updated on 04-01-2021.
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- (s) posts adult or pornographic Content;
- (t) decompiles or reverse engineers or attempt to access the source code of the software underlying the Site, the Services or any other iwtA technology;
- (u) copies, archives, stores, reproduces, rearranges, modifies, downloads, uploads, creates derivate works from, displays, performs, publishes, distributes, redistributes or disseminates all or any part of the Site;
- (v) accesses the Site for the purposes of building a product using similar ideas, features, functions, interface or graphics as those found in the Site;
- (w) accesses the Site for the purposes of monitoring its availability, performance or functionality, or for any other benchmarking or competitive purposes; or
- (x) accesses the Site to upload any Content or computer code for the purposes of: (i) causing a breach of security to the Site; (ii) interfering with the proper working, functionality or performance of the Site; or (iii) preventing others from accessing or using the Site.
THIRD-PARTY SITES AND CONTENT
The iwtA Site may permit you to link to other websites or resources on the Internet, and other websites or resources may contain links to the Site. These other websites are not under iwtA control, and you acknowledge that iwtA is not responsible or liable for any third-party content, including but not limited to the accuracy, integrity, quality, usefulness, legality, appropriateness, safety or intellectual property rights of or relating to such third-party content or any other aspect of such websites or resources. The inclusion of any such link does not imply endorsement by iwTA or any association with its operators. You further acknowledge and agree that iwtA shall not be responsible or liable, directly or indirectly, for any damage or loss caused or alleged to be caused by or in connection with the use of or reliance on any such third-party content, goods or services available on or through any such website or resource. Access and use of third-party sites, including the information, material, products and services on third party sites or available through third party sites, is solely at your own risk.
CHANGES TO THE TERMS
iwtA may make changes to his Agreement from time-to-time. When these changes are made, iwtA will make a new copy of the Terms of Services available at https://iwtacademy.com/terms-and-conditions/ and any new additional terms will be made available to you from within, or through, the affected Services. You understand and agree that if you use the Services after the date on which the Agreement was modified or additional terms added, iwtA will treat your use as acceptance of the updated or modified Agreement.
POLICY CHANGES
The terms of this policy may change from time to time. If you disagree with the changes that have been made, please contact us (by e-mail, using a website contact form, or in writing by mail), and any changes made to this policy will not apply to information we have collected from you prior to making the changes.
If you are concerned about the topic covered by this policy, you should read it each time before you use our website. Any questions or concerns about this policy should be brought to our attention by sending an e-mail to info@iwtacademy.com and providing us with information relating to your concern.