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.