Description

IES-PCI-416

3 Element Boiler Control Trainer is an advanced industrial training system designed to demonstrate boiler automation and process control using PLC-based three-element control strategy.

This system enables real-time control and monitoring of drum level, steam flow, and feedwater flow, making it ideal for understanding complex industrial process control systems. It is widely used in engineering colleges, process control labs, and industrial training centers.

Technical Specifications

• PLC-Based Control System – Industrial PLC controller designed for implementing three-element control strategy, enabling simultaneous monitoring and control of feedwater flow, steam flow, and drum level.
• Feed-Water Tank – Process tank with 30 liter capacity used for storing and supplying water to the boiler drum and feedwater control system.
• Centrifugal Pump System – Two ½ HP centrifugal pumps operating on single-phase 110/230 V AC, 50/60 Hz supply for feedwater circulation and process simulation.
• Process Piping Network – Industrial ¾″ CPVC / ½″ stainless steel piping system equipped with multiple ball valves (approx. 10 Nos.) and leak-proof fittings for reliable fluid handling.
• Control Valve System – Two two-way globe type control valves (½″ / ¾″ size) designed for accurate flow regulation within the process control loop.
• Flow Measurement Unit – Rotameter flow meter with measurement range 100–1000 LPH for monitoring feedwater flow rate.
• Temperature Measurement System – RTD temperature sensor with measurement range 0–200 °C used for monitoring temperature conditions within the boiler drum system.
• Level and Pressure Measurement Instruments – Industrial level sensors for drum and feedwater monitoring along with glycerin-filled pressure gauges (0–10 kg/cm² range) for accurate pressure indication.
• Instrumentation and Air Supply System – Includes current/voltage signal source (4–20 mA / 0–10 V) for calibration, air compressor with 20 L tank (~2 CFM, 1 HP motor), and FRL unit (0–10 kg/cm²) for regulated pneumatic supply.
• Boiler Drum and Mechanical Structure – Non-IBR boiler drum with electrical input below 75 W and output capacity approximately 200 kg/h, mounted on a rigid floor-standing MS structure with heavy-duty caster wheels and locking brakes for stability and mobility.

KEY FEATURES & LEARNING OBJECTIVES

• 3-Element Control Strategy (Drum Level + Steam Pressure + Feed-Water Flow)
• Stable operation under load disturbances
• Combustion/energy efficiency concepts (air-to-fuel ratio—conceptual training)
• PLC-based automation with manual/auto modes
• Safety interlocks, alarms, and troubleshooting exercises
• Industrial-grade components and realistic process behaviour

RANGE OF EXPERIMENTS

• Drum level control with 3-element strategy
• Feed-water/steam flow coordination under load changes
• Manual vs automatic control modes
• Alarm handling and safety interlocks
• Signal simulation and loop checking (4–20 mA)
• PLC logic verification and troubleshooting

GENERAL

• • Application: Boiler Automation & Process Control Training
  • Mounting: Floor-mounted mobile trainer
  • Safety: Interlocks, alarms, regulated air supply, pressure-rated components, proper earthing