COURSE OVERVIEW:

Industrial furnace operation is a critical component of refinery and petrochemical processing, requiring a deep understanding of combustion chemistry and heat transfer mechanics. This course explores the fundamental principles governing how furnaces transform fuel into thermal energy while maintaining structural integrity. Participants will examine the relationship between burner management, draft control, and process fluid temperatures to ensure efficient energy utilization within the facility.

The scope of this training extends beyond routine operation to cover the intricate balance of air-to-fuel ratios and the physical dynamics of flame patterns. Coverage includes an in-depth look at different furnace configurations, including cabin and vertical cylindrical types, as well as the metallurgy of process tubes. By understanding these elements, operators can minimize coke formation and prevent localized overheating, which are common precursors to equipment failure.

Safety and environmental compliance form the third pillar of this curriculum. The course provides a comprehensive look at modern control systems, including Emergency Shutdown (ESD) logic and nitrogen purging protocols. We will address the latest troubleshooting methodologies for identifying draft instabilities, high tube metal temperatures, and burner malfunctions, ensuring that participants can respond decisively to abnormal conditions while maintaining regulatory emission standards.

COURSE OBJECTIVES:

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

1. Identify different types of industrial furnaces and their specific process applications.
2. Interpret furnace piping and instrumentation diagrams (P&IDs) with high accuracy.
3. Calculate furnace thermal efficiency and identify areas of heat loss.
4. Manage burner management systems (BMS) for safe startup and shutdown sequences.
5. Regulate excess air levels to optimize combustion and reduce fuel consumption.
6. Monitor and interpret tube metal temperature (TMT) readings to prevent sagging or bowing.
7. Execute proper decoking procedures to restore heat transfer performance.
8. Troubleshoot flame instability and impingement issues on process tubes.
9. Adjust draft control dampers to maintain the necessary firebox pressure.
10. Evaluate the impact of fuel gas composition changes on burner performance.
11. Implement emergency response actions for "loss of flame" or "positive pressure" events.
12. Conduct pre-firing inspections of refractory linings and structural supports.
13. Analyze flue gas components to ensure compliance with environmental NOx and SOx limits.

TARGET AUDIENCE:

Process Engineers, Furnace Operators, Maintenance Technicians, Safety Officers, and Plant Supervisors involved in the operation and upkeep of fired heaters and industrial furnaces.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.