Manufacturing, Engineering and Technology Fabrication and Extraction

Crowe Tower Solution Deaeration Process Operation Training

SAQA US 110443 | NQF 3 | Credits 12 | Duration 9 Days
From $1,798 per delegate

Description

This course equips learners with the knowledge and skills required to operate the deaeration process in a Crowe Tower solution within a chemical or water treatment environment. It covers the principles of deaeration, process control, safety protocols, and troubleshooting to ensure efficient and safe operation.

Learning Outcomes

  • Apply the principles of deaeration to control oxygen and other dissolved gases in solution.
  • Demonstrate correct startup, shutdown, and normal operation of the Crowe Tower deaeration process.
  • Analyze process parameters to maintain optimal deaeration efficiency and product quality.
  • Evaluate potential hazards and implement appropriate safety procedures during operation.
  • Troubleshoot common operational issues and recommend corrective actions.
  • Implement monitoring and recording procedures in compliance with standard operating guidelines.

Target Audience

Process operators, technicians, and shift supervisors involved in the operation of deaeration systems in chemical, water treatment, or industrial plants.

Prerequisites

None — open enrollment.

Course Outline

Day 1: Introduction to Deaeration Principles

Objectives:
• Understand the purpose and importance of deaeration in water treatment.
• Identify the key components of a deaeration system.
• Explain the basic principles of gas solubility and Henry's Law.
• Describe the role of temperature and pressure in deaeration.

Topics:
• Overview of water treatment processes
• Fundamentals of dissolved gases in water
• Henry's Law and gas solubility
• Thermal and vacuum deaeration principles
• Introduction to Crowe Tower design
• Safety considerations in deaeration operations

Day 2: Crowe Tower System Components and Layout

Objectives:
• Identify and describe the function of each major component of the Crowe Tower.
• Understand the flow path of water and steam within the system.
• Explain the role of packing, trays, and internals.
• Recognize auxiliary equipment such as pumps, valves, and instrumentation.

Topics:
• Crowe Tower vessel and internals
• Packing types and tray designs
• Steam injection and distribution systems
• Condensate and vent systems
• Pump types and operation
• Valve types and applications
• Instrumentation for level, flow, temperature, and pressure

Day 3: Operating Principles and Control Strategies

Objectives:
• Describe the operating cycle of a Crowe Tower deaerator.
• Explain control loops for level, pressure, and temperature.
• Understand the relationship between steam flow and deaeration efficiency.
• Identify normal operating parameters and setpoints.

Topics:
• Startup and shutdown procedures
• Normal operation and steady-state conditions
• Level control strategies
• Pressure and temperature control
• Steam flow control and optimization
• Monitoring dissolved oxygen levels
• Alarm and trip settings

Day 4: Water Quality Testing and Monitoring

Objectives:
• Perform sampling procedures for dissolved oxygen and other parameters.
• Use testing equipment such as DO meters and chemical test kits.
• Interpret test results to assess deaeration performance.
• Understand the impact of poor deaeration on downstream equipment.

Topics:
• Sampling techniques and safety
• Dissolved oxygen measurement methods
• pH, conductivity, and other relevant tests
• Chemical dosing for oxygen scavenging
• Data logging and trend analysis
• Troubleshooting based on water quality data

Day 5: Troubleshooting and Problem Solving

Objectives:
• Diagnose common operational issues such as high DO, pressure fluctuations, and carryover.
• Implement corrective actions for typical faults.
• Understand the impact of fouling, scaling, and corrosion.
• Apply root cause analysis techniques.

Topics:
• Common malfunctions and symptoms
• High dissolved oxygen causes and remedies
• Pressure and temperature deviations
• Carryover and foaming issues
• Fouling and scaling mitigation
• Corrosion mechanisms and prevention
• Root cause analysis methodology

Day 6: Maintenance and Inspection Procedures

Objectives:
• Plan and execute routine maintenance tasks for the Crowe Tower system.
• Inspect internals for wear, damage, and fouling.
• Understand the importance of preventive maintenance.
• Document maintenance activities and findings.

Topics:
• Preventive maintenance schedules
• Inspection of packing and trays
• Cleaning methods for fouled internals
• Valve and pump maintenance
• Instrument calibration
• Safety during maintenance
• Maintenance record keeping

Day 7: Safety, Health, and Environmental Compliance

Objectives:
• Identify hazards associated with deaeration operations.
• Apply safe work practices and use appropriate PPE.
• Understand environmental regulations related to water discharge.
• Respond to emergencies such as steam leaks or chemical spills.

Topics:
• Hazard identification and risk assessment
• Personal protective equipment requirements
• Lockout/tagout procedures
• Handling of chemicals (e.g., oxygen scavengers)
• Steam safety and burn prevention
• Environmental compliance and reporting
• Emergency response plans

Day 8: Advanced Operation and Optimization

Objectives:
• Optimize deaeration efficiency through parameter adjustments.
• Understand energy conservation opportunities.
• Analyze system performance using data trends.
• Implement best practices for continuous improvement.

Topics:
• Energy efficiency in deaeration
• Heat recovery and condensate return
• Performance benchmarking
• Data analysis for optimization
• Variable load operation
• Integration with boiler feedwater system
• Case studies of optimization

Day 9: Integration, Assessment, and Capstone

Objectives:
• Integrate all knowledge into a comprehensive operational plan.
• Demonstrate competence through a capstone exercise.
• Complete a written assessment covering all course content.
• Prepare for unit standard assessment.

Topics:
• Review of key concepts
• Capstone practical exercise
• Written knowledge assessment
• Practical skills demonstration
• Feedback and improvement plan
• Certification requirements

Practicals

28 hours of practicals To be conducted online or on-campus or in-house
Overview

Hands-on practical sessions are essential for developing competence in operating, monitoring, and troubleshooting the Crowe Tower deaeration system. Learners will engage in simulated and real equipment exercises to apply theoretical knowledge, ensuring they can safely and effectively manage deaeration processes.

Practical Activities
  • System Component Identification and Walkthrough — Learners conduct a physical walkthrough of a Crowe Tower system, identifying all major components and tracing flow paths. (4h)
  • Startup, Shutdown, and Normal Operation — Learners perform supervised startup and shutdown procedures, and maintain normal operation while monitoring key parameters. (8h)
  • Water Quality Sampling and Testing — Learners collect water samples from various points and perform dissolved oxygen, pH, and conductivity tests using standard equipment. (6h)
  • Troubleshooting and Corrective Actions — Learners diagnose simulated faults (e.g., high DO, pressure drop) and implement corrective actions under supervision. (6h)
  • Maintenance and Inspection Simulation — Learners perform simulated inspection of tower internals and conduct routine maintenance tasks on auxiliary equipment. (4h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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