Course at a Glance

Schedule

Code: CBI
Course Length: 3 Months

In this interactive 3 month LIVE ONLINE course, you will learn:

  • Boiler safety control and start-up interlocks
  • Principal boiler control functions
  • Types of boilers in current use
  • Typical boiler control diagrams and their design intentions
  • Hazards associated with boiler systems
  • Principles of open and closed loop/feed forward
  • Setting up and tuning of boiler control loops
  • Safety concepts to identify principles and design
  • Impacts of level, quality and stability in boiler feed water control
  • Impact of pressure and temperature as a means of control
  • Furnace draft measurement and control with protection against implosions
  • Impact of stoichiometric burn ratio and lean air requirements
  • How to improve burner efficiency using control and analysers
  • Distinguish burner rod and ultra violet flame detection
  • Steam demand and firing rate control
  • Main steam and reheat steam temperature control are influenced
  • Flue gas analysis and fuel combustion trimming controls have on the system
  • Advanced control strategies for improved boiler plant efficiency
     

 

Course Details

Overview

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

The program will examine how control and instrumentation is designed to manage the main variables such as drum water level, furnace draft, stoichiometric fuel combustion and air assist conditions. Burner management systems are introduced with their principal features including flame detection, purge, pilot and main burner safety systems during start up and running operations.

The essential safety requirements for boilers and burners are identified and the corresponding safety interlocks with respect to purge, fuel rich, double block and bleed are explained as practical solutions in accordance with the latest safety standards.

 

Course Outline

MODULE 1: INTRODUCTION

  • Objectives of boiler controls
  • Overview of boiler types

MODULE 2: ESSENTIALS OF BOILER PROCESSES

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

MODULE 3: REVIEW OF PROCESS CONTROL

  • Principles of sensors and transmitters with examples of boilers
  • Closed loop control principles including feedback, feedforward, ratio and limiting
  • Control system hardware and software tools

MODULE 4: INSTRUMENTATION RELEVANT TO BOILERS

  • 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

MODULE 5: FEEDWATER CRITERIA 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

MODULE 6: FURNACE AIR

  • Performance requirements; pressures and temperatures
  • Characteristic responses and means of control

MODULE 7: DRAFT CONTROL

  • Pressure measurement methods and the pressure profile
  • Temperature control and the impact of dew point
  • Protection against implosion

MODULE 8: COMBUSTION CONTROLS

  • The combustion process and its requirements for efficiency and safety
  • Coal, oil and gas firing types
  • Stoichiometric air and excess air requirements

MODULE 9: FUEL OPTIMISATION

  • Fuel-air ratio control and its measurements
  • Firing rate controls and cross limiters for improving dynamic response
  • Methods for measurements of boiler efficiency using analysers
  • Application of optimising controllers

MODULE 10: BURNER MANAGEMENT SYSTEMS

  • Safety and performance requirements of pulverisers, 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

MODULE 11: STEAM TEMPERATURE CONTROL

  • Superheater and attemperator arrangements
  • Essential control requirements
  • De-superheater controls

MODULE 12: STEAM PRESSURE AND BOILER LOAD CONTROLS

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

 

 

Learning and Teaching

Benefits of eLearning to Students

  • Cost effective: no travel or accommodation necessary
  • Interactive: live, interactive sessions let you communicate with your instructor and fellow students
  • Flexible: short interactive sessions over the Internet which you can attend from your home or office. Learn while you earn!
  • Practical: perform exercises by remotely accessing our labs and simulation software
  • Expert instructors: instructors have extensive industry experience; they are not just 'academics'
  • No geographical limits: learn from any location, all you need is an Internet connection
  • Constant support: from your instructor(s) and a dedicated Learning Support Officer for the complete duration of the course
  • International insight: interact and network with participants from around the globe and gain valuable insight into international practice 


Benefits of eLearning to Employers

  • Lower training costs: no travel or accommodation necessary
  • Less downtime: short webinars (60-90 minutes) and flexible training methods means less time away from work
  • Retain employees: keep staff who may be considering a qualification as full time study
  • Increase efficiency: improve your engineering or technical employees’ skills and knowledge
  • International insight: students will have access to internationally based professional instructors and students

 

How Does it Work?

EIT eLearning courses involve a combination of live, interactive sessions over the Internet with a professional instructor, set readings, and assignments. The courses include simulation software and remote laboratory applications to let you put theory to practice, and provide you with constant support from a dedicated Learning Support Officer.


Practical Exercises and Remote Laboratories

As part of the groundbreaking new way of teaching, our online engineering courses use a series of remote laboratories (labs) and simulation software, to facilitate your learning and to test the knowledge you gain during your course. These involve complete working labs set up at various locations of the world into which you will be able to log to and proceed through the various practical sessions.

These will be supplemented by simulation software, running either remotely or on your computer, to ensure you gain the requisite hands-on experience. No one can learn much solely from lectures, the labs and simulation software are designed to increase the absorption of the materials and to give you a practical orientation of the learning experience. All this will give you a solid, practical exposure to the key principles covered and will ensure that you obtain maximum benefit from your course.

 

Endorsed by ISA

School of Industrial Automation