Boiler Control and Instrumentation Course

Course Overview:

This course covers the fundamentals, including the participants being taught the techniques to enhance the safety and efficiency of the boiler through their chemistry as well as water treatment methods. 

This course includes a thorough understanding of scale, corrosion, carryover control. The details that are taught about the components of a boiler include heat exchange, combustion, and how to select the appropriate burner. 

The course offers detailed instruction on best practices during operation, as well as how to measure pressure and flow, and install and use safety systems and instruments for measuring temperature and level. 

It also includes calculations streamlining, blowdown regulation, and carrying out inspections utilizing both NDT and destructive methodologies. The program is aimed at ensuring that the boiler inspectors, the operators and the safety officers are able to operate the boiler systems as well as prevent hazards.

Course Objectives:

Upon completion of this course, participants will have an understanding of the chemistry of boiler water treatment for scale, corrosion, and carryover control, with external and internal water treatment The participant will have a strong understanding of efficiency calculation, boiler inspection either destructive or non-destructive test. The principal will have also a strong understanding of all control loops of boiler operation.

Who Should Attend?

• Boiler Inspectors
• Steam Plant Operators
• Maintenance Engineers / Managers
• Operation Managers
• Safety Officers
• Boiler Design Engineer

Course Outlines:

Introduction

• Fire-tube boilers
• Water-tube boilers

Boiler basics and steaming process

• Component of boiler
• Mass and energy balance
• Routing of combustion gas inside the boiler.

Heat transfer

• Conduction
• Convection
• Radiation
• Superheated steam
• Latent heat
• Sensible heat

Review of combustion Fundamentals

• Excess air & flue gases relation

Burners

• Selection of burners
• Atomizing of burners
• Oil burner
• Gas burner
• NOX burner
• Reduction of NOX emission

Boiler Operation

• Burner shutdown when steam pressure C.O.P is reached
• Boiler shutdown procedures
• Short-term shutdown
• Shutdown for cold Restart
• Safety system fuel and air supply control system
• Procedures for selection of burner control system

Basic instrumentation

• Pressure measurement
• Level measurement
• Temperature measurement
• Flow measurement

Boiler control application

Level drum control

• One element control
• Two element control
• Three element control

Generator control

• Level control
• Temperature control

Fuel/air ratio control

• Series limited control
• Parallel limited control
• Lead flag firing control
• Oxygen trim control
• Main header control
• Water treatment

The external water treatment process

• Ion exchange process
• Duration
• Evaporation

Internal water treatment

• lime soda process
• phosphate treatment
• feeding of chemical continuing treatment

Blowdown

• intermittent and continuous blowdown
• control of blowdown
• blowdown heat recovery

Efficient boiler operation

• Efficiency calculation
• Direct method
• Indirect method

Heat transfer calculation

Boiler & combustion systems hazards codes

Boiler inspection

• Destructive test
• Non-destructive test
• Preventation of boiler explosions / implosions NFPA8502 Troubleshooting