Overview

Operation of furnaces - SIM-FOP

About the Course

A student-driven learning paradigm based on the INSTO Methodology is combined with high fidelity, generic process simulators in this interactive, two-day course. This training stresses critical thinking abilities for operators that may be applied in the control room while teaching operators how to create mental models of diverse processes. Each student in this course will have access to a personal generic simulator, which may include a model of an air cooler, a natural draft fired heater, or a balanced draft fired heater. Each piece of equipment will be available for the trainees to start up, and they will also have time to spend fixing frequent heating issues. The course emphasizes furnace operations that support both safety and optimization. Refineries, petrochemical sites, chemical factories, and any other establishments that use industrial-sized fired heaters can use the course content.

Target Audience

Young Engineers who work with fired heaters, Outside Operators, Console Supervisors, and Console Operators

Course Objectives

Participants will pick up skills in:

• Identify the critical operating points for heaters that use balanced and natural drafts (ID/FD).
• Compare the various control points for balanced draft versus natural draft burning heaters.
• Create a mental model of how two different types of fired heaters and an air chiller operate normally. 
• Examine patterns and connect this data to numerous instances of normal and aberrant behavior for fired heaters. When using an air cooler or fired heaters, use the Think EQ.U.I.P.P.E.D.TM strategy to increase your range of possible troubleshooting solutions.
• Discussing and simulating HAZOP evaluations of typical troubleshooting situations with burning heaters while concentrating on particular mitigating methods
• Consider important safety issues while starting up or restarting fired heaters, and practice these starter techniques.
• Utilize heater optimization approaches, such as maximizing throughput while maintaining a minimal, safe level of extra oxygen

Course Outlines

• a detailed setup guide for an air cooler, a heater fired by natural draft, and a heater fired by balanced draft Changing an air cooler's pitch control from speed to it, as well as looking at how the weather affects an air cooler,
• By altering heater throughput, heater outlet temperature requirement, and fuel gas pressure on the simulated systems, you may model the effects on heater systems.
• examining the safety implications of the air to fuel ratio and how these factors affect the oxygen sensors in various types of heaters
• Operating these firing rates under various degrees of control, such as full trainee manual control, simple cascade control, and simulated safety instrumented systems (SIS).
• Uneven heating, coking, loss of one or more burners, and complete flame out are just a few of the heater troubleshooting possibilities.
• HAZOP study of fuel gas BTU fluctuations that are significant and methods to prevent flame out
• In a balanced draft fired heater with an air preheater, simulate full and partial trips of fired heaters, as well as loss of ID/FD fan systems.
• Simulator includes a dynamic profitability study to measure the effectiveness of the heater.