Intensive 2-Day Training Course
for Facility Operators
DIRECT-FIRED HEATERS: OPERATOR TRAINING
COURSE FACILITATOR
Roger Newnham
President – OnQuest Canada ULC
C. Eng., F.I.Mech.E., Eur. Ing.
Roger Newnham has over 35 years of experi-ence in the petroleum and petrochemical in-dustries, 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 Associa-tions, FEANI. 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
OPERATING THE DIRECT-FIRED HEATER
OnQuest’s Direct-Fired Heater Training Course
for Operators is intended for facility operators,
managers, and supervisory personnel at petro-chemical 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 applica-tions, 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 ther-mal design.
Understanding Burners
Reviews burner types, components, flame stabiliz-ing and shapstabiliz-ing, along with applications, air sup-ply 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 con-siderations; and discusses retrofits, fuel supply sys-tems, and safety.
Combustion Air: Supply and Control
Introduces natural and mechanical draft consider-ations, 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, tempera-ture controls, draft measurement, flue gas analysis, and safety instrumentation, including burner man-agement 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 temper-ature, 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 technolo-gies 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 tempera-ture), 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. A long established technology, direct-fired heaters
have a history of successful operation at plants around the world. But combustion and heat trans-fer 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 pro-cess 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 con-struction, process-flow parameters, and other vari-ables 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.
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
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 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
OUR CURRICULUM
LEARN MORE
For more information, please email [email protected]
or call +1 (909) 451-0514.
OUR CURRICULUM
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 pub-lished 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 them-selves and evaluate what they have learned. Upon completion, attendees will understand all heater and safety systems terminology.
Direct-Fired Heater Training
from a Recognized Authority
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.
HOUSTON
9595 Six Pines Dr., Ste. 8210 The Woodlands, TX 77380
Tel. +1 (281) 889-3005
LOS ANGELES
180 East Arrow Highway San Dimas, CA 91773 Tel. +1 (909) 451-0500 CALGARY 3582 118th Avenue S.E. Calgary, Alberta T2Z 3X1 Tel. +1 (403) 252-2676
