DIRECT-FIRED HEATERS: OPERATOR TRAINING. Intensive 2-Day Training Course for Facility Operators

Transcription

1 DIRECT-FIRED HEATERS: OPERATOR TRAINING Intensive 2-Day Training Course for Facility Operators

2 COURSE FACILITATOR Roger Newnham President OnQuest Canada ULC C. Eng., F.I.Mech.E., Eur. Ing. REPRESENTATIVE CLIENTS INCLUDE: n Adco n BP n Caltex n Chevron n Conoco Phillips n Co-Op Refinery Complex n Dow Chemical n Exxon Mobil n Gasco n Hibernia n Husky n Inter Oil n Interquisa n IRPC n Khalda Petroleum n Kuwait Oil n North Atlantic Refining n PNG Refinery n Pertamina n Petro Canada n Petro China n Petrojam n Petronas n PTT n Qatar Petroleum n Shell n Sonatrach n Syncrude n Suncor n Takreer n Thai Oil n Valero n Zadco Roger Newnham has over 35 years of experience in the petroleum and petrochemical industries, beginning his career as a mechanical engineer, then becoming a project engineer on direct-fired heater design, engineering, and installation. For the past 25 years he has been president of Born Heaters Canada (now OnQuest Canada). Newnham is also the author of a series of books on direct-fired heaters, including, n Direct-Fired Heaters: A Practical Guide to their Design and Operation, n Direct-Fired Heaters: Operator Training Manual n Direct-Fired Heaters: Improving Efficiency and Lowering Emissions. Newnham is a Fellow of the Institute of Mechanical Engineers and of the European Federation of National Engineering Associations, FEANI.

3 OPERATING THE DIRECT-FIRED HEATER OUR PROGRAM FOR OPERATORS A long established technology, direct-fired heaters have a history of successful operation at plants around the world. But combustion and heat transfer technologies are continually evolving. New engineered solutions for a complex new world of energy production dictate the increased use of fired heaters in a wide range of specialized process applications. Reducing downtime and maintenance costs are top priorities. Improving thermal efficiency can lead to significant energy savings, and can also help reduce harmful air emissions. One way to realize efficiency is through improved design. Another is to increase the operational know-how of on-site plant personnel, through focused training on fired-heater design and construction, process-flow parameters, and other variables that affect operation. Direct-fired heaters consume significant amounts of energy. Variables ranging from feed-stocks to furnace temperature to flow-rates and pressure affect operating costs, emissions, and the consistency of process outputs. Optimizing your operations is vital. OnQuest s Direct-Fired Heater Training Course for Operators is intended for facility operators, managers, and supervisory personnel at petrochemical refineries and gas processing facilities. This two-day course is specifically designed to help plant operators better understand the function of direct-fired heaters, explaining the principles of combustion, the characteristics of different designs, and methods of operations, including important controls and guidelines to optimize and improve heater efficiency. We also review techniques to operate more safely and meet emission guidelines. Subject areas include: Direct-Fired Heaters: An Introduction Describes direct-fired heaters and their applications, reviews factors governing choice of design, and discusses applicable API 560 & 530 codes and standards. Radiant and Convection Zones: Design Includes review of thermal design, and combining radiation, convection and conduction for total thermal design. Understanding Burners Reviews burner types, components, flame stabilizing and shaping, along with applications, air supply and control, how to identify a need for burner changes or upgrades, and how to implement them. Fuel & Feed Stocks Examines different fuel types and their impact on burner and heater design; reviews emission considerations; and discusses retrofits, fuel supply systems, and safety. Combustion Air: Supply and Control Introduces natural and mechanical draft considerations, design and use of dampers, the potential impacts of changes of service on fired-heater duty, and stack design (draft, static wind load, dynamic load, emissions impacts). Instrumentation and Safety Devices Reviews fuel and process flow controls, temperature controls, draft measurement, flue gas analysis, and safety instrumentation, including burner management systems. Efficiency Improvements Discusses maintenance protocols and schedules, burner modifications, improved controls, additions, convection surface, and air preheat. Tube Design Examines available data on stresses, creep and elastic design, determination of tube metal temperature, selection of tube material and wall thickness, and selection of tube size. Heater Operation, Testing, and Tune-up Reviews startup protocols, troubleshooting, routine checks, efficiency testing, test data and methods to improve operating efficiency. Emissions Control Previews the types of available control technologies and techniques, the impact of fuel selection, and choosing a control method. Refractory Overview of refractory types, selection, installation, and design to reduce heat loss and corrosion. Corrosion and Fouling Describes fireside corrosion (low and high temperature), fouling, design methods to mitigate impacts, tube side (types of corrosive attack), and ways to minimize and remove fouling. Process Troubleshooting Details on ways to review and improve operational processes to reduce downtime and maintenance.

4 OUR CURRICULUM DAY ONE Heat Transfer and Fired Heaters n Fundamentals of Heat Transfer n Types of Heaters & Configuration n Development & Service Categories n Vertical and Cabin Style Heaters Direct-Fired Heater Applications n Natural Gas Process Plants n Oil Refineries n Design Considerations and Data Sheets n Process Conditions n Total Duty Calculations Heater Duty and Efficiency n Heater Duty-Q n Heater Efficiency Measurement & Improvement Draft and Excess Air Control n Dampers & Draft Control n Excess Air Control DAY TWO Safety Systems n Burner Management Systems n Purging n Pilots and Ignition Systems n Dedicated Flame-Monitoring Systems Operations and Monitoring n Safe Practices n Commissioning and Start-up Procedures n Heater Operation n Controlled Heater Shutdown n Emergency Shutdown n Heater Monitoring Routine Inspections, Maintenance Troubleshooting n Inspections n Maintenance n Pigging & Steam Air Decoking Troubleshooting n 24 Working Examples Combustion and Burners n Burners: Design and Types n Low & Ultra-Low NOx Burners n Flue Gas Recirculation n Burner Orientation n Heat Release, Fuels and Burner Data n Emissions Refractory n Refractory Purpose n Refractory Types n Dry-Out LEARN MORE For more information, please [email protected] or call +1 (909)

5 Direct-Fired Heater Training from a Recognized Authority WHAT YOU LL LEARN OnQuest s two-day fired-heater training course is thoroughly researched and carefully structured to provide practical and exclusive training applicable to facilities operators and technicians, managers, and operating facility superintendents who work with direct-fired heaters, furnaces and waste heat recovery units, and burner management systems. This two-day course is based on the recently published book, Direct-Fired Heaters: Operator Training Manual a copy of which will be provided to each attendee as part of their enrollment. At the end of the training, attendees will be able to: n Identify and list applicable codes and standards for fired process heaters n Determine the mechanical limitations of heaters n Describe the theoretical and practical aspects of burners and combustion air supply, common and complex instrumentation applications, heater operation, and tube and refractory design n Explain key operating parameters n Employ techniques to minimize emissions, corrosion and fouling n Implement safe practices and identify safety issues n Identify typical problems and possible causes n Identify key inspection and turnaround items. Question-and-answer modules at the end of each learning session allow participants to test themselves and evaluate what they have learned. Upon completion, attendees will understand all heater and safety systems terminology.

6 SOLUTIONS FOR THE NEW WORLD OF ENERGY OnQuest is an industry leader in process engineering and applied combustion technology for clients in the energy industry. We specialize in turnkey EPC for small and mid-sized liquefied natural gas (LNG) plants, facilities for hydrocarbon reforming including for hydrogen, ammonia and methanol production and renewable energy facilities such as bio-fuels and waste-to-energy plants. OnQuest also designs direct-fired furnaces and related combustion technologies, including waste heat recovery systems, burner management systems, NOx reduction technologies and thermal oxidizers. We are experts in revamps and retrofits of existing furnace units. OnQuest has delivered solutions for most of the major energy producing companies, and has a growing presence in the market for renewable, environmentally sustainable energy. We are distinguished by our ability to manage projects on a lump-sum, fixed-price basis from concept to commissioning. LOS ANGELES 180 East Arrow Highway San Dimas, CA Tel. +1 (909) CALGARY th Avenue S.E. Calgary, Alberta T2Z 3X1 Tel. +1 (403) HOUSTON 9595 Six Pines Dr., Ste The Woodlands, TX Tel. +1 (281)