COURSE OVERVIEW:

The purpose of this course is to provide practical technical expertise in the instrumentation and control strategies required for the safe and efficient operation of industrial boilers. Boilers are high-energy systems that demand rigorous control of pressure, level, and combustion to prevent catastrophic failure while maximizing fuel efficiency. This program focuses on the technical "loops" that govern boiler performance, ensuring that participants understand how sensors, controllers, and valves interact to manage steam demand.

The scope of this training encompasses the essential variables of boiler operation, including Drum Level, Fuel-Air Ratio, and Steam Pressure. Participants will explore the diverse range of sensing technologies used in the high-temperature boiler environment, alongside the Burner Management Systems (BMS) that ensure safe ignition and shutdown. The curriculum is specifically designed to address both traditional analog control and modern PLC-based combustion management, emphasizing the importance of redundant safety interlocks.

Coverage includes the practical aspects of tuning 3-element level control, managing oxygen trim for combustion efficiency, and troubleshooting burner flame failures. Attendees will learn how to maintain safety relief valves, calibrate high-pressure transmitters, and comply with international boiler codes (such as ASME). By focusing on the practicalities of boiler instrumentation, the course ensures that participants can maintain a reliable steam supply while protecting personnel and equipment from the hazards of high-pressure steam generation.

COURSE OBJECTIVES:

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

• Analyze the critical control loops in an industrial steam boiler.
• Implement 1-element, 2-element, and 3-element Drum Level Control.
• Optimize combustion efficiency through Fuel-Air Ratio and O2 Trim.
• Identify the components and logic of a Burner Management System (BMS).

• Manage Boiler Master Control and Steam Header Pressure.
• Understand the role of Feedwater and Condensate measurement.
• Calibrate high-temperature thermocouples and pressure transmitters.
• Troubleshoot "Flame Out" and "Low Water" safety shutdowns.
• Execute periodic testing of Safety Relief Valves (SRV).
• Implement Shrink and Swell compensation in drum level logic.
• Maintain Boiler Water Quality through automated Blowdown control.
• Adhere to ASME and NFPA standards for boiler safety and control.

TARGET AUDIENCE:

This course is intended for Boiler Technicians, Power Plant Operators, Mechanical Engineers, and Instrumentation Specialists.

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.