Furnace and Fire Heater Training

Introduction

This program has been developed to provide an in-depth, yet practical review of the art and science of Combustion Techniques in fuel-fired heaters. Optimization of fired heaters is critical to meet the con­flicting requirements of reducing operation costs, increasing production throughput, and meeting environmental requirements. This course introduces the principles and practices associated with combustion techniques in furnaces and boilers with emphasis on enabling participants to improve the thermal efficiency of their furnaces and meet­ing environmental compliance targets. Different aspects in combustion techniques, fuels character­istics, flame structures, flow and mixing in flames, fuel atomization and combustion of fuel sprays, gaseous combustion, fuel burners, and combustion control systems, measuring techniques in evalu­ating flame performance, troubleshooting, and guidelines for safe, efficient operation and environ­mental management of furnaces will be covered. Information on how to properly adjust burners for maximum efficiency, safe operation, and a minimum level of emissions is presented.

Objectives

The attendees will be able to manipulate every ther­mal unit and will make more effective contribu­tion to the operation of any thermal unit. They will learn the basics of the combustion techniques in both Furnaces and Boilers, evaluating the unit performance and efficiency. Special focus is on the economical aspects of the thermal unit uti­lization, for example:

• Fuel consumption 
• The optimization of the fuel and air mixture.
• The Energy management system for both the furnaces- boilers units, and the different ways of increasing the unit efficiency

 Also, this course is designed to help attendees:

• Develop a complete understanding of the con­cepts underlying combustion technology and energy conservation methodology.
• Be familiar with the different factors affecting fur­nace efficiency and gas emissions.
• Be familiar with the environmental requirements related to fuel-fired furnaces
• Monitor furnaces combustion processes, unit efficiencies, and evaluate emission levels.
• Be familiar with the best practice of furnace safe operation, optimization, and environmen­tal management.
• Understand and integrate instruments and controls to optimize the operation of furnaces.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

• All Engineers who's working on oil and gas pumps
• O&M staff for centrifugal pumps.
• Technical, troubleshooting and QA engineers
• CMMS planner

Course Outline

Specific topics include:

• Basic concepts of combustion: This part of the training is directed to identify the nature of combustion, types of flames, and energy calculations using the first low concepts. What is meant by flame stability? Gain a basic under­standing of how to control the flame behavior and the characteristics associated with each kind of flames.
• Gas and Oil-Fired Furnace combustion techniques: study the Burner types, performance, and Energy balance of both the gas and oil furnaces. it also includes teaching the performance map the burn­ers.
• Furnace Design: Teach the participants the design concepts of the different furnaces types, including the burner's design, locations, heat transfer, and the flow gas pattern.
• Boilers: Show the attendees the fundamental re­lated to the Boilers from the different perspectives points, for example type of Boilers- Combustion for boilers- Heat transfer in boilers and Economic of boiler operation.
• Furnaces, Boilers and Unit efficiencies: show the attendees how to modulate the furnaces and boilers, and performing energy balance for each unit

Course Daily Agenda:

Day 1:

• Course Introduction & Pre-assessment
• Basic Concepts of Combustion
• Introduction to Fired Heater
• ​General Types 
• Fire Box
• Convection
• Stack
• Burners

Burner’s Characteristics

• Flame shape o  Combustion value o  Stability o  Drive o  Turndown rat
• Burners used for gaseous fuels firing
• Atmospheric o Air aspiration gas burners
• With the independent supply of gas & air to the mixture

Day 2:

• Types of Furnaces and Boilers
• Fired Heater Engineering
• Fluid Flow
• Heat Transfer
• Fuels
• Design Guidelines
• Gas and Oil Furnaces Combustion Techniques
• Case Study

Day 3:

• Furnaces and Boilers fuels
• Energy Balance and Furnace Modeling
• Furnaces Design
• Boilers Type and Flow Gas Pattern
• Improve the Efficiency of Fired Heaters
• Excess Air
• Burner Types
• Flame types
• Energy Conservation Methodology

Day 4:

• Furnace Operation, Control, and Instrumentation 
• Optimization for Efficient Furnaces and Minimum Emission Levels
• Maintenance and Troubleshooting of Fuel-Fired Heaters
• Fired Heater Safety
• Case Study
• Reducing NOx Emissions

Day 5:

• Gas Emissions From Fuel-Fired Heaters
• Environmental Legislation and Safety Requirements  of Fuel-Fired Heaters
• Revamping Fired Heaters
• Upgrade Convection Section
• Upgrade Instrumentation and Controls
• Maximizing Furnace Life
• Designing for Improved Maintenance
• Course Closing & Final Assessment