COURSE OVERVIEW:

The purpose of this course involves the specialized technical protocols required to protect high-energy fired equipment, such as boilers and process heaters, from catastrophic failure. Fired equipment represents a unique hazard profile due to the combination of fuel, ignition sources, and high-pressure process fluids. This program focuses on the Burner Management System (BMS) and the integrated safeguarding logic needed to prevent furnace explosions and tube ruptures.

The scope of this training encompasses the lifecycle of a combustion sequence, from pre-purge and pilot ignition to main flame monitoring and emergency shutdown. Participants will explore the technical requirements for flame scanners, fuel gas isolation valves, and air-fuel ratio interlocks. The curriculum is designed to address the stringent regulatory codes, such as NFPA 85 and API 556, which govern the safe operation of industrial combustion units.

Coverage includes the practical maintenance and testing of safety-critical combustion components. Attendees will examine the logic of "Master Fuel Trips" (MFT), the management of furnace pressure transients, and the integration of the BMS with the plant-wide Safety Instrumented System. By focusing on both the mechanical hardware and the complex sequencing logic, the course ensures that participants can manage fired equipment with the highest level of safety integrity.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Analyze the hazard profile and explosion risks of fired equipment.
• Differentiate between Burner Management Systems (BMS) and Combustion Control.
• Implement NFPA 85 and API 556 standards for fired heater safeguarding.
• Configure safe "Purge" and "Pre-ignition" sequences for furnaces.
• Select and maintain flame detection technologies (UV, IR, and Ionization).
• Execute Master Fuel Trip (MFT) logic for rapid fuel isolation.
• Implement redundant "Double Block and Bleed" fuel gas systems.
• Manage air-fuel ratio interlocks to prevent rich-combustion hazards.
• Troubleshoot failures in flame scanners and ignitor systems.
• Conduct proof testing of safety-critical combustion interlocks.
• Design furnace pressure protection and draft control safeguarding.
• Ensure compliance with SIL requirements for fired equipment safety.

TARGET AUDIENCE:

This course is intended for Boiler Operators, Instrument Engineers, Combustion Specialists, Maintenance Supervisors, and Safety Officers responsible for boilers and fired heaters.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.