Course Description

DURATION

21 hours (Three (3) days)

TARGET GROUP

This course is intended for process engineers, industrial and environmental engineers, general mechanical engineers, energy managers, operation engineers and senior plant operators.

TARGETED INDUSTRY/INDUSTRIES

Oil & Gas, Petrochemicals, Power Plant, Refineries, Renewal Energy Plant, Co-Generation Plant and all industries that using fired machinery such as boilers, fired heaters and flares.

CERTIFICATION

This course can be certified under the Continuing Professional Development (CPD) Program by the Board of Engineers, Malaysia (BEM).

COURSE OVERVIEW

The course will discuss the fundamentals of fuels and combustion technologies, and provide context into the necessity for sustainable development of conventional fuel use.

This course also will provide engineers with an opportunity to develop their understanding of fuels and combustion technologies.

COURSE OBJECTIVE

This course aims at providing the basics for understanding combustion phenomena. This includes thermodynamics, chemical kinetics, ignition, fluid dynamics and the formation of pollutants. From the knowledge in these areas it is possible to reach an understanding for energy related and environmental problems connected to real life combustion.

The course also will focus on oil and gas burners and it takes the audience through basic concepts of combustion and the design of large burners that handle several tons of fuel per hour. The module also covers concepts of multi-fuel burners and principles of fuel cost optimization.

COURSE OUTCOMES

At the end of the course, the delegates will be able to: –

• Develop a complete understanding of the concepts underlying combustion technology and energy conservation methodology.
• Learn characteristics of flame structures and stabilization in furnaces and boilers.
• Analyze different types of combustion devices for different types of fuel.
• Monitor furnaces and boilers combustion processes and evaluate unit efficiencies.
• Evaluate the needs for new burners to meet design objectives.
• Understand and integrate instruments and controls into advanced combustion systems.
• Improve knowledge to perform overall energy balance testing of combustion system.
• Be familiar with guidelines for safe and efficient operation of furnaces and boilers.
• Be familiar with the best practices of furnaces and boilers operation and troubleshooting.
• Appreciation of excess air control and its effect on boiler efficiency, stack emissions and NOx control.
• Contribute to enhancement of operational safety.
• Appreciation of combustion process in boilers, furnaces and fired heaters.
• Understanding of design, construction and operation of oil & gas burners.
• Understanding burner controls, protections and safety system.

TRAINING METHODOLOGY

• Lecture
• Pre- and Post-Test
• Classroom discussions
• Case study

COURSE CONTENTS

Introduction to Combustion Techniques

• Basic of Combustion
• Fuel Characteristics
• Air Fuel Ratio
• Heat Balance
• Combustion Efficiency
• Flame Temperature

Burner Design and Atomization

• Burners’ Functions
• General Flammability
• Flame Stabilization Principles
• Qualitative Models of Main Flame Zone Processes
• Pressure Jet Atomizers
• Steam Atomizers and its Capacity Graph

Stack and Draught

• Stack Flue Gas Exit Velocity
• Air Pollution Meteorology
• Plume Types
• Stack Draught Calculation

Furnaces

• Furnaces, Principle Parameters and Parts
• Thermal Rating Aspects of Furnaces
• Furnace Heat Flux and Temperature Limits
• Furnace Types
• Operational Aspects

Flue Gas Side Cleaning

• Types of Soot blowers
• Soot blowers Maintenance
• Operational Recommendation

Air Preheaters

• Introduction
• Types of Air Preheaters
• Operational Aspects
• Commissioning
• Start-up and Shut-down
• Temperature Control

Pre-Commissioning, Start-up and Daily Operation

• Pre-Commissioning Checks
• Basic Commissioning Rules
• Purging and Gas Testing
• Program for Start-up

Trial for Ignition Time (TFIT)

• Calculation Procedure
• Calculation Method
• Safety Aspect During Burner Ignition

Flame Safeguard

• Thermal System
• Pressure Sensitive System
• Flame Ionization System
• Flame Radiation System

Steam Boilers

• Fired Boilers
• Design Principles
• Construction Features
• Process Control and Operation
• Boiler Maintenance and Troubleshooting
• Waste Heat Boilers

Fuels and its Systems

• Gaseous Fuel Systems
• Liquid Fuel Systems
• Sulphur Emissions
• Smoke, Particulates and NOx
• Fired Heater Corrosion

Energy Conservation on Fired Equipment

• Introduction
• Efficiency
• Radian Loss
• Stack Loss
• Achieving Optimum Efficiencies of Existing Equipment
• Burners
• Maintaining Clean Heat Transfer Surfaces
• Furnace Monitoring