After completing this program, participants will have a solid understanding of the fundamental procedures for industrial steam generating boiler safety controls and controls systems. It focuses on the safety and control standards that apply to the majority of boiler types, ranging from huge multi-fuel systems to small gas-fired units. Additionally, instruction on the design of controls and instrumentation for managing the primary variables—such as air conditions, combustion fuel, furnace draft, and drum water level—will be given. According to the most recent safety standards, the fundamental safety requirements for burners and boilers are established, and the related safety interlocks are described as workable solutions.

Course Objectives:

Understand the objectives of the principal boiler control functions

Recognize and understand typical boiler control diagrams and their design intentions.
Contribute to the setting up and tuning of boiler control loops.
Identify principles and design concepts governing:
Boiler feed water control
Furnace draft measurement and control
Steam demand and firing rate control
Main steam and reheat steam temperature control
Flue gas analysis and fuel combustion trimming controls
Importance of boiler safety control and start-up interlocks
Explore advanced control strategies for improved boiler plant efficiency

Who Should Attend?

Senior boiler plant operators, repairers and installers
Control system engineers
Instrumentation engineers and technicians
Boiler plant commissioning engineers
Operation, maintenance, inspection and repair specialists
Mechanical engineers and technicians
Design engineers
Consulting engineers

Course Outlines:

Essentials Of Boiler Processes

Objectives of boiler controls
Overview of boiler types
Boiler processes in block diagrams to show key inputs and output variables
Hazards of boiler operations
The main control functions in boilers and furnaces

Review Of Process Control And Instrumentation Relevant To Boilers

Principles of sensors and transmitters with examples for boilers
Closed loop control principles including feedback, feedfoward, ratio and limiting.
Control system hardware and software tools.
Safety instrumented controls and the impact of IEC 61511
Instrumentation diagrams and symbols per ISA and SAMA.
Distributed control systems and the separation of safety systems

Feedwater And Drum Level Control

Performance requirements: Level, quality, stability
Characteristic responses of drum level
Level control solutions, 1, 2 and 3 element types
Level measurement problems and practices
Drum level safety systems

Furnace Air And Draft Controls

Performance requirements; pressures and temperatures
Characteristic responses and means of control
Pressure measurement methods and the pressure profile
Temperature control and the impact of dew point
Protection against implosion

Combustion Controls

The combustion process and its requirements for efficiency and safety
Coal, oil and gas firing types.
Stoichiometric air and excess air requirements
Fuel-air ratio control and its measurements
Firing rate controls and cross limiters for improving dynamic response
Methods for measurements of boiler efficiency using analyzers
Application of optimizing controllers

Burner Management Systems

Safety and performance requirements of pulverizes, burners and igniters.
Furnace safety standards and regulations
Flame monitors and flame failure detection
Start up protection and sequencing
Furnace supervisory controls and shutdown systems

Steam Temperature Control

Superheater and attemperator arrangements
Essential control requirements
De-superheater controls

Steam Pressure And Boiler Load Controls

Pressure and flow response characteristics
Single boiler load control
Multiple boiler installations and load sharing controls

Filters