COURSE OVERVIEW:

The Boiler Operation, Fuel Control, and Safety Systems course is a high-level technical program designed to integrate the principles of thermal energy generation with advanced automation and protection logic. Industrial boilers are the heart of many utility systems, requiring a sophisticated understanding of how fuel dynamics, air ratios, and feedwater systems interact under varying load conditions. This course provides a comprehensive roadmap for managing these variables to ensure continuous steam availability while maintaining the highest possible standards of operational safety and fuel efficiency.

The scope of this training focuses heavily on the precision of fuel control mechanisms and the integration of multi-fuel systems within a single boiler environment. Participants will examine the transition between different fuel types, the impact of varying calorific values on combustion stability, and the calibration of high-accuracy flow meters for fuel accounting. The curriculum details the engineering requirements for safety instrumented functions (SIF) that protect the boiler from overpressure, furnace explosions, and dry-firing, ensuring that all control actions are governed by a robust safety matrix.

This coverage extends to the optimization of the entire boiler house through the use of advanced control strategies such as oxygen trim, cross-limiting, and drum level pressure compensation. Attendees will learn how to analyze stack gas composition to minimize environmental impact and maximize thermal recovery. By focusing on the critical relationship between fuel control precision and the reliability of safety interlocks, the program equips participants with the expertise needed to manage complex boiler plants in the power generation, refining, and petrochemical sectors.

COURSE OBJECTIVES:

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

• Analyze the relationship between fuel quality, combustion efficiency, and steam output.
• Configure advanced fuel-air cross-limiting control loops to prevent fuel-rich mixtures.
• Implement precise drum level control using pressure and temperature compensation.
• Design safety interlock matrices in accordance with SIL and NFPA requirements.
• Optimize burner performance for low NOx and CO emissions.
• Manage complex multi-fuel switching sequences without process interruption.
• Troubleshoot fuel gas and fuel oil pressure regulation and metering issues.
• Conduct functional proof-testing of safety shut-off valves and flame scanners.
• Implement O2 and CO trim control to achieve peak thermal efficiency.
• Analyze the root causes of furnace pressure fluctuations and draft instability.
• Evaluate the performance of economizers and air pre-heaters in the energy cycle.
• Ensure regulatory compliance through automated data logging and safety reporting.

TARGET AUDIENCE:

This course is intended for Control and Instrumentation Engineers, Senior Boiler Operators, Energy Managers, Maintenance Supervisors, and Safety Professionals involved in the management of high-capacity 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.