Electrical Skills Series
Instrumentation Skills Series
Mechanical Skills Series
Regulatory Compliance Series
Basic Skills Series

Boiler Control

This comprehensive INVOLVEĀ® multimedia training program was produced in association with the Instrument Society of America USA). This program trains participants in the operation and maintenance of boilers and their associated safety systems.

Audience: This program is excellent for training instrument technicians as well as for the multi-craft training needs of process and manufacturing.

Boiler Systems


Prerequisites: This lesson is designed for participants familiar with process operations and industrial process control.

Description: This lesson focuses on the principles of operation of boiler systems and teaches the thermodynamic principles governing steam generation and heat transfer. Basic boiler components and operations will also be covered. The lesson provides a detailed overview of how steam is generated on the water side of the boiler as well as the fundamentals of combustion and how energy is converted in the boiler's furnace.

Objectives:

  • Give a description of a typical boiler and related system
  • Describe the function of a boiler
  • Define the following terms: enthalpy, sensible heat, latent heat, latent heat of vaporization, saturation temperature, superheating, critical pressure, British Thermal Unit (BTU), and steam quality
  • Describe the flow of water and energy when given a general description of a typical steam system
  • Explain how each system contributes to the production of steam when given a block diagram of a typical boiler
  • Show the flow paths for inputs and outputs through the system when given a block diagram of a basic boiler
  • Identify the basic types of boilers when given descriptions of common features of the boilers
  • Describe common applications for the different boiler types
  • Explain the functions of the various components in a boiler when given their descriptions
  • Explain how components such as economizers and preheaters conserve heat energy and maximize the efficiency of steam production while minimizing cost when given a description of the principles that govern efficient steam production and optimal use Of fuel
  • Explain why feedwater must be treated before it enters the boiler when given a description of the effects of corrosion and scale on boiler components
  • Describe the principles of combustion in a boiler furnace
  • Explain the functions of the components in the fuel and air systems
  • Identify the most common types of boiler fuels and describe their physical characteristics and heat values when given descriptions of the three major categories of boiler fuels
  • Describe the various methods for preparing the fuel for use in a boiler
  • Describe the principle by-products of combustion and how each is measured
  • Explain the importance of monitoring emissions

Boiler Controls


Prerequisites: This lesson is designed for participants familiar with process operations and industrial process control.

Description: This lesson focuses on the control systems of boilers and teaches the importance of proper drum level and basic methods for controlling that level. Shrink and swell will be explained. Furnace draft control and basic control strategies for liquid, gas and solid fuel boilers will also be covered as well as the fundamentals of combustion testing. The lesson also provides information about steam temperature control and unit management systems.

Objectives:

  • Explain the relationship between steam demand, feedwater flow, and drum level
  • Identify the problems caused by low drum water level
  • Identify the problems caused by high drum water level
  • Explain the terms "shrink" and "swell" and their associated control problems
  • Identify the major components and functions in each of the following drum level control systems: single,element, two-element and three-element control systems
  • Identify the various sensors used to measure steam drum level in a high pressure drum boiler
  • Explain why steam drum level transmitters are density or temperature compensated and how this is accomplished
  • Describe the function of the demand loop
  • Describe the function of
  • Furnace draft control
  • Describe the control systems used in gas and liquid fuel boilers
  • Describe the control systems used in solid fuel boilers
  • Describe the purpose of and basic steps for a combustion test
  • Explain the purpose of controlling steam temperature
  • Identify the instruments and interconnections used to control steam temperature
  • Describe boiler-following unit control
  • Describe turbine-following unit control, and describe the coordinated unit control system

Troubleshooting Boiler Controls


Prerequisites: This lesson is designed for participants familiar with process operations and industrial process control.

Description: This lesson teaches how to troubleshoot various boiler control systems. Problems that might be encountered in each phase of boiler operation from startup to shut, down will be discussed. The lesson also covers permissives, interlocks, shutdown systems and their associated logic.

Objectives:

  • Identify the conditions that must be met prior to initiating boiler startup
  • Explain the purpose of each step in a typical operation
  • Troubleshoot cause of startup failure
  • Troubleshoot the source of the problem
  • Identify the safety concerns with improper furnace pressure and methods for detecting and correcting furnace pressure problems
  • Troubleshoot the problem if given a problem with furnace pressure
  • Troubleshoot the problem if given a problem with drum level
  • Identify the safety concerns with high steam pressure and methods for relieving pressure
  • Explain the purpose of each step in a typical shutdown operation, given a sequential description of the tasks involved in shutting down a boiler
  • Identify parameters that could cause an emergency shutdown
  • Describe methods of troubleshooting the cause of a shutdown.
  • The effects of corrosion and scale on boiler components
  • Describe the principles of combustion in a boiler furnace
  • Explain the functions of the components in the fuel and air systems
  • Identify the most common types of boiler fuels and describe their physical characteristics and heat values when given descriptions of the three major categories of boiler fuels
  • Describe the various methods for preparing the fuel for use in a boiler
  • Describe the principle by-products of combustion and how each is measured
  • Explain the importance of monitoring emissions