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

Online course    22-Jun-2021    1:00 pm - 5:00 pm West Kazakhstan Time (GMT+5)


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 & 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 & steam turbines


  • Why layup? What is the importance of an effective layup?
  • Types of layup (“bottling up”, short-term wet, long-term wet, dry)
    • Advantages and disadvantages of each type
  • The critical step of pre-commissioning layup
  • The three key steps for a successful layup
  • What chemicals to use (and to avoid) in wet layup
  • Unique needs of power plants – challenges posed by cycling plants
  • How to carry an effective DRY layup
  • Layup of Auxiliary equipment (feedwater heaters, deaerators, condensate systems, superheaters, etc.)
  • Layup of steam turbines
  • Steam sparging, nitrogen blanketing
  • Returning to operation from various layup modes
  • Summary of BEST PRACTICES
  • Case study reviews

There will be two (2) 15-minute breaks.

The course fee is USD $195.00.

You can pay by credit card using either PayPal or Stripe. Click here to learn more.

All bookings are subject to acceptance of our Privacy Policy, Terms & Conditions and Cancellation & Refunds Policy.

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, regardless of whether such registration was made through 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 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


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

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