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Furnace Operations - SIM-FOP |
Discipline: Operations & Maintenance
Level: Foundation
Duration: 2 days
Instructor(s): Matthew Garvey, Donald Glaser |
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This interactive 2-day course combines elements of high fidelity, generic process simulators as well as a student-driven learning model centered around the INSTO Methodology. This course teaches operators how to build a mental model of various processes and stress critical thinking skills for operators that can be brought back to the control room. In this course each trainee will have access to their own generic simulators including an Air Cooler, Natural Draft Fired Heater, and Balanced Draft Fired Heater simulator. Trainees will have an opportunity to startup each piece of equipment as well as spend time troubleshooting common heater malfunctions. Furnace operations that promote both safety as well as optimization are stressed throughout the course. The material of the course is applicable to refineries, petrochemical sites, chemical plants, and any other facilities that operate industrial sized fired heaters. |
Designed For:
Console Operators, Outside Operators, Console Supervisors, and Young Engineers that work with fired heaters |
You Will Learn:
Participants will learn how to:
- Identify key operating points in natural draft and balanced draft (ID/FD) fired heaters
- Examine the different control points for natural draft fired heaters versus balanced draft fired heaters
- Build a mental model of the normal operations of an air cooler and two types of fired heaters
- Analyze trends and relate this information to various normal and abnormal situations for fired heaters
- Utilize the Think EQ.U.I.P.P.E.D.™ method to expand troubleshooting options while operating an air cooler or fired heaters
- Discuss and simulate HAZOP analyses on common troubleshooting scenarios with fired heaters focusing on specific mitigation techniques
- Assess critical safety concerns during the startup or restart of fired heaters as well as simulate these startup procedures
- Practice techniques for heater optimization including maximizing throughput while maintain a minimum, safe level of excess O2
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Course Content:
- A complete startup procedure for an air cooler, natural draft fired heater and balanced draft fired heater
- Switching an air cooler from speed to pitch control, as well as examining the effects of weather while operating an Air Cooler
- Simulate the effects to heater systems by changing heater throughput, heater outlet temperature demand and fuel gas pressure on the simulated systems
- Examining safety aspects of air to fuel ratio and the effects these parameters have on oxygen sensors in different types of heaters
- Operating these firing rates with varying levels of controls including simulated safety instrumented systems (SIS), simple cascade control, and complete manual control by the trainee
- Troubleshooting scenarios for heaters including uneven heating, coking, loss of burner(s), complete flame out
- HAZOP analysis on drastic changes to fuel gas BTUs and techniques to avoid flame out
- Simulate total and partial trips of fired heaters including loss of ID/FD fan systems in a balanced draft fired heater with an air preheater
- Integrated dynamic profitability analysis within the simulator to determine heater efficiency
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Instructors:
MATTHEW GARVEY holds the position of Engineering Manager, PetroSkills Simulation Solutions. Matthew delivers on-site training promoting operations excellence for refining and chemical plant personnel utilizing generic process simulators. The most popular courses that Matthew teaches focus on separation units and furnaces with a target audience of console operators.
Since 2014, Matthew has conducted over 75 training sessions for 800 process operators in the US and overseas. In addition to co-teaching these 2-Day Troubleshooting courses, Matthew develops and maintains the INSTO Methodology and generic simulator library of which these courses are centered around.
Matthew also works closely with institutions in the education sector to provide process operations and process safety training for both 4-year Chemical Engineering students, as well as 2-year Process Technology students. Matthew has been a member of the U.S. Military Academy's Chemical Engineering Advisory Board since 2015.
Since 2015, Matthew has had the opportunity to guest lecture for a Process Safety course offered at Columbia University on an annual basis. Matthew has co-authored 5 technical papers along with Dr. Robert Bozic (Columbia University) and Donald Glaser (Simulation Solutions) exploring the implementation of process simulation within the chemical engineering curriculum.
Specifically, Matthew's work with Columbia University has led to the 2019 creation of the "ChemE-Sports" competition which had 14 teams from different universities compete at the Annual AIChE Student Conference to promote process safety at the undergraduate level. Matthew holds a BS in Chemical Engineering from Rutgers University (2014) and is pursuing an MBA from University of Delaware (expected 2021).
DONALD GLASER holds the position of Vice President, Simulation Solutions. Don was the founder of Simulation Solutions, Inc. prior to its recent acquisition by PetroSkills. Don has spent his entire 46-year career in the business of developing and providing Operator Training Simulators and related Simulator-based Operations and Troubleshooting Courses.
Don’s former company has been a leader in providing PC based dynamic Simulators. These Simulators have been used in over 230 locations in 30 countries on 6 continents.
Don also developed a successful and proven comprehensive 5 step approach to Simulator-Based-Training called INSTO™. This immersive and collaborative approach combines innovative student-driven learning with simulator-based exercises that provide for “Hands-On/Minds-On Training for Operators.” Since 2011, Don has conducted over 85 training sessions for more than 800 process operators in the US and overseas.
Don also developed the market for both 4-year Chemical Engineering College and Universities as well as 2-year Process Technology colleges . Don has been a charter member of the United States Military Academy’s Chemical Engineering Advisory Board.
Don has authored or co-authored numerous articles and technical papers about Operator Training and is a recognized expert in this field. Don holds a BS in Chemical Engineering from Lafayette College, Easton, PA. (1974).
In-House Course Presentations
All courses are available for in-house presentation to individual organizations. In-house courses may be structured the same as the public versions or tailored to meet your requirements. Special courses on virtually any petroleum-related subject can be arranged specifically for in-house presentation. For further information, contact our In-House Training Coordinator at one of the
numbers listed below.
Telephone 1- 832 426 1234
Facsimile 1- 832 426 1244
E-Mail inhouse@petroskills.com
Public Course Presentations
How to contact PetroSkills:
1-800-821-5933 toll-free in North America or
Telephone 1-918-828-2500
Facsimile 1-918-828-2580
E-Mail registrations@petroskills.com
Internet www.petroskills.com
Address P.O. Box 35448, Tulsa, Oklahoma 74153-0448, U.S.A
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