TRAINING.

Overview

After participating in this course, you will be able to:

• Implement effective tuning procedures for PID controllers to maintain optimal steam plant performance and enhanced steam plant efficiency.
• Analyze the impact of thermodynamics and steam system design on overall plant controllability.
• Optimize boiler drum level and master pressure control.
• Design and tune deaerators and boiler feed pump systems.

Description
As energy costs continue to rise, optimizing steam production is more important than ever for the manufacturing industry. Reducing the amount of vented or condensed steam and minimizing the number of boilers in operation can significantly improve profitability. However, closing the steam system to enhance plant efficiency can also increase variability in steam quality, which may affect process operations.

Understanding and implementing effective control strategies and tuning procedures are vital to maintaining a stable and efficient steam plant. Participants will explore various control strategies, including PID tuning, combustion control, cross-limiting logic, and boiler drum level tuning. You will learn to make your steam control systems more integrated, responsive, robust, and energy-efficient through practical applications and process simulations.

By the end of this course, you will be equipped with the skills to optimize control systems for furnaces, boilers, and steam plants. You'll gain insights into steam system dynamics and advanced controls, ensuring your plant operates smoothly and effectively. This comprehensive understanding will enable you to implement best practices and improve plant efficiency.

Who Should Attend
This course is ideal for a wide range of professionals directly or indirectly involved in operating, designing, or maintaining steam plants, boilers, and related systems. It is especially beneficial for process engineers responsible for optimizing plant operations and enhancing production efficiency. Control Engineers will gain valuable insights into the latest control strategies and tuning techniques to improve system performance and reliability.

Instrumentation personnel tasked with maintaining and calibrating control systems will find the course helpful in understanding the intricacies of steam control systems and implementing best practices. Facility and Utility Engineers who oversee plant utilities will benefit from learning how to optimize steam generation and distribution, thereby reducing energy costs and improving overall plant efficiency.

Consulting Engineers who provide expert advice on steam plant design and optimization will enhance their ability to recommend advanced control solutions and best practices for energy management. Technicians and Technologists involved in the day-to-day operation and maintenance of steam systems will gain practical skills and knowledge to troubleshoot and optimize boiler and steam plant performance.

Please note: You can check other time zones here.

Syllabus

Welcome, Introduction, Workshop Preview, Learning Outcomes and the Assessment Method

Steam Plant and Boiler Overview

• Essential components and functions of steam plants.
• Overview of boiler types and their applications.
• Key operational parameters and performance metrics.
• Understanding Boiler ratings.

Steam System Dynamics

• Understanding steam flow and pressure dynamics.
• Impact of load changes on steam system stability.
• Heat transfer principles in steam generation.
• Interaction between steam supply and process demand.

Fundamentals of PID tuning for steam systems

• Basics of PID control and tuning parameters.
• Step-by-step procedure for tuning PID controllers.
• Application of feedforward and feedback controls.
• Practical examples of PID tuning in steam systems.

Steam Process Controls

• Open loop and closed loop Steam Heat exchanger systems.
• Jacketed vessel temperature control.
• Instantaneous and semi-instantaneous Steam/water heaters.
• Control type selection.

Boiler ancillary equipment

• Pressurized and Atmospheric Deaerators.
• Layout of Boiler feed pump systems.
• Economizers, Superheaters & Steam Accumulators.
• TDS Blowdown control.

Combustion Control, Cross-Limiting logic and O2 Trim / Furnace Draft Control

• Principles of combustion and air-fuel ratio control.
• Implementation of cross-limiting control logic.
• Oxygen trim control for optimal combustion efficiency.
• Combustion controls for various boiler capacities.

Boiler Drum Level and Master Pressure Control Tuning

• Importance of accurate drum level control.
• Effects of shrink-swell on drum level dynamics.
• Tuning methods for drum level controllers.
• Master pressure control strategies.

Boiler Efficiency Monitoring

• Direct vs Indirect boiler efficiency monitoring.
• Tracking efficiency.
• Analysis of losses.
• Instrumentation & Control requirements.

Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes

Instructor

Gerardo Monge, P.Eng.

Gerardo is a highly skilled Mechanical Engineer specializing in Energy Systems, dedicated to advancing sustainable and efficient energy solutions. Strong background in energy sources, fluid mechanics, and system optimization, who has played a vital role in designing, analyzing, and implementing innovative energy technologies.

Holding a B.Sc. degree in Mechanical Engineering from the University of Notre Dame, I have developed expertise in renewable and non-renewable energy systems, HVAC design, energy efficiency improvements, and power generation technologies. During my 30 years at Spirax Sarco Canada, I have been involved in projects ranging from managing energy, plant operations and automation projects to engineering design, application solutions, field installation and commissioning.

At present I am teaching applied energy management which contributes to optimizing energy usage in industrial applications, reducing carbon footprints, and enhancing operational efficiency.