Practical Boiler Control and Instrumentation

Description

This workshop introduces the basic practices of control systems and safety controls for industrial steam-generating boilers. It focuses on the control and safety requirements applicable to most types of boilers from small gas-fired units to large multi-fuel installations.

The workshop will provide training in how control and instrumentation are designed to manage the main variables such as drum water level, furnace draft, combustion fuel, and air conditions. Burner management systems are introduced with their principal features including flame safety systems.

The essential safety requirements for boilers and burners are identified and the corresponding safety interlocks are explained as practical solutions in accordance with the latest safety standards.

Pre-requisites
Fundamental knowledge of basic Boiler plant and operation thereof and some understanding of control systems.

Who Should Attend

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

Program Outline

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 include feedback, feedforward, 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 pulverizers, 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