COURSE OVERVIEW:

The Boiler Control and Burner Management Systems (BMS) course provides an in-depth exploration of the automation and safety logic required for industrial steam generation. Boilers are high-energy assets that demand a precise balance of combustion efficiency and rigorous safety protection. This course distinguishes between the Basic Process Control System (BPCS), which manages continuous variables like drum level and steam pressure, and the Burner Management System (BMS), which handles the discrete safety interlocking required for startup, operation, and emergency shutdown.

The scope of this training includes the detailed analysis of combustion control strategies, ranging from simple single-element drum level control to complex three-element systems and cross-limited fuel-air ratio control. Participants will examine the functional requirements of NFPA 85 (Boiler and Combustion Systems Hazards Code), learning how to design and audit the safety logic for furnace purging, leak testing, and flame monitoring. The curriculum provides a technical deep dive into the selection and application of flame scanners, igniters, and safety shut-off valves (SSVs).

This coverage emphasizes the critical integration between safety and efficiency. Attendees will learn how to optimize boiler performance through O2 trim and variable speed drive control while ensuring that the BMS remains an independent, high-integrity safety layer. The course addresses the systematic troubleshooting of boiler trips, the calibration of safety-critical instrumentation, and the documentation requirements for regulatory compliance. By mastering both the continuous and discrete control aspects, the program prepares participants to operate and maintain boiler plants at peak safety and reliability levels.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Differentiate between Boiler Control Systems and Burner Management Systems (BMS).
• Implement three-element drum level control to manage "swell and shrink" effects.
• Design fuel-air ratio control strategies for optimal combustion efficiency.
• Apply NFPA 85 standards to the design and operation of BMS logic.
• Configure automated furnace purge sequences to prevent explosive atmospheres.
• Select and maintain flame detection systems (UV, IR, and Ionization).
• Audit the safety interlock matrix for fuel gas and fuel oil systems.
• Implement O2 trim control to minimize excess air and reduce fuel costs.
• Manage boiler master control for steam header pressure stabilization.
• Troubleshoot boiler trips and identify root causes in the safety logic.
• Perform proof-testing of safety shut-off valves and pressure switches.
• Ensure compliance with environmental emission standards through precise control.

TARGET AUDIENCE:

This course is intended for Boiler Plant Engineers, Control System Specialists, Maintenance Technicians, Safety Engineers, and Senior Plant Operators responsible for the safe and efficient operation of industrial boilers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.