3-ELEMENT BOILER CONTROL TRAINER – IES-PCI-416

IES-PCI-416

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