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.
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
MODULE 12: STEAM PRESSURE AND BOILER LOAD CONTROLS
Pressure and flow response characteristics
Single boiler load control
Multiple boiler installations and load sharing controls
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In order to meet the exacting demands of the oil and gas, mining, manufacturing and downstream processing industries, modern plants are equipped with systems and devices which are needed to measure and regulate variables such as temperature, pressure, flow, humidity, liquid level, velocity and density. Industrial Automation provides the technology to control and monitor a process plant using such concepts as feedback, cascade, feedforward and advanced process control. Here at the Engineering Institute of Technology (EIT), we have developed industry-focused programs in the form of vocational diplomas, advanced diplomas and graduate certificates, all the way up to Masters level in the higher education sector.
There is a critical shortage of automation, instrumentation and control engineers, technicians and technologists around the world now due to the retirement, restructuring and rapid growth in new technologies and industries. The respected International Society of Automation (ISA) organization estimated that at least 15,000 new automation engineers are needed annually in the USA alone.
In keeping with the philosophy of EIT, students in this school are exposed to the practical, up-to-the-minute knowledge and skills demanded by leading industries worldwide, with online instrumentation courses. EIT does not just cater to a generic student body, instead all of our online instrumentation courses are specific to industry. The programs cover a large range of topics and are suited to anyone needing an intensive and practical look at all facets of industrial automation, instrumentation and process control.
The short courses that form part of EIT's professional development series are designed to provide students with critical knowledge and practical tools that can be immediately applied to the workplace. They are ideal to up-skill and/or cross-skill in a particular area or technology and are not accredited programs.
Students in EIT's School of Industrial Automation, Instrumentation and Process Control study subjects which include: process control, instrumentation, control valves, process plant layout and piping design, tuning of process loops, SCADA, PLCs, advanced process control (APC), boiler control, hazardous areas, safety instrumentation (IEC 61511 and IEC 61508), HAZOPs, industrial data communications, networking, deviceNet and Fieldbus, industrial wireless, radio telemetry systems, shielding/EMC/EMI, and noise reduction.
I: Vocational Education & Training (VET) program
II: Higher Education program
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