Heat Exchangers & Fired Heaters , Operations & Maintenance

Heat Exchangers & Fired Heaters , Operations & Maintenance

OBJECTIVES
 Identify and list applicable codes and standards for fired process heaters
 Determine the mechanical limitations of heaters
 Describe the theoretical and practical aspects of burners and combustion air supply, common and complex instrumentation applications, heater operation, and tube and refractory design
 Explain key operating parameters
 Employ techniques to minimize emissions, corrosion and fouling
 Shell & tube heat exchangers Construction & performance
 Implement safe practices and identify safety issues
 Identify typical problems and possible causes
 Identify key inspection and turnaround items.

COURSE OUTLINE

Heat Exchangers
 Fundamentals of Heat Exchangers
 Types of Heaters & Configuration
 Development & Service Categories
 Vertical and Cabin Style Heaters
 Heat exchangers leak test
 Types of flow through heat exchangers
 Vapor blanketing
 Heat flux limits

Fired Heater Applications
 Natural Gas Process Plants
 Average versus peak heat flux & coking
 Oil Refineries
 Heat integration & air preheat
 Design Considerations and Data Sheets
 Process Conditions

 Total Duty Calculations

Heaters Duty and Efficiency
 Heaters units
 Heaters types
 Heater Duty-Q
 Heater Efficiency Measurement & Improvement
 Effects of heat exchangers operating variables , pressure & temperature
 Heater Efficiency Measurement & Improvement

Draft and Excess Air Control
 Dampers & Draft Control
 Excess Air Control

Combustion and Burners
 Burners: Design and Types
 Low & Ultra-Low NOx Burners
 Flue Gas Recirculation
 Burner Orientation
 Heat Release, Fuels and Burner Data
 Emissions

Refractory
 Refractory Purpose
 Refractory Types
 Dry-Out

Shell & Tube Heat Exchangers
 Tubes – Shell – Baffles
 Strategic for optimizing heat exchangers performance
 Fluid routing through shell or tube heat exchangers
 Factor that effect heat exchangers

Safety Systems
 Burner Management Systems
 Purging
 Pilots and Ignition Systems
 Dedicated Flame-Monitoring Systems

Operations and Monitoring
 Safe Practices
 Commissioning and Start-up Procedures
 Heater Operation
 Controlled Heater Shutdown
 Emergency Shutdown
 Heater Monitoring

Routine Inspections, Maintenance
 Inspections : Flame test , flash light test , water spray test , CO test , AGA test
 Maintenance
 Pigging & Steam – Air Decoking

Troubleshooting
 Broken crimped rings
 Leaking heat exchangers seams
 Cracks
 Rust Perforations
 Wall thickness
 Missing screw securing
 Broken gaskets
 Maintenance
 Pigging & Steam – Air Decoking