A boiler simulator for improved operator training : final report 2016/001
Abstract
A boiler simulator training package ready for use by industry has been developed during this project.
After some fine tuning to accommodate site specific details and interaction with existing factory
control systems (if requested by the sites), the simulator will be ready for use by factories for
operator training. Models of the different boiler station components that form the basis of the back end of the
simulator were developed. These models calculate the heat transfer and steam generation through
the different boiler components, water/steam, gas and air side pressure changes through the boiler
along with shrink and swell in the boiler steam drum. These models can be incorporated into the
distributed control systems (DCSs) of factories with the assistance of factory instrumentation staff. A user manual describing the operation of the simulator along with a training program that goes
through common scenarios encountered during operation of a sugar factory boiler has been written. Use of the simulator will improve the skill level of operators and increase the effectiveness of
operator training. There will be a reduced risk of damage to boilers and lost production. With
improved operator performance the number of incidents should reduce. This will improve the
financial performance of the industry, the public perception of the industry and in the long term,
reduce insurance costs.