Furnace

Furnace Tutorial

The interactive Furnace tutorial provides an overview, fundamental principles, control principles and operating principles for a heating furnace, using voice, video, animation and graphics. The topics covered are:

Overview

Purpose of Furnace
Applications of Furnace
Types of Furnace

Furnace System

Introduction
Combustion Device
Heater Tubes
Heat Transfer Sections
Draft Device and Stack

Furnace Performance

Introduction
Combustion Air
Burner
Damper and Air Registers
Fuel Temperature and Oil to Steam Ratio
Fuel Composition

Pre-Startup Operation

Inspection of Furnace
Inspection of Associated Lines
Inspection of Rotational Equipment
Preparation of Fuel System

Startup Operation

Introduction of Process Fluid
Damper and Air Registers
Purging
Burner Ignition
Stabilization

Shutdown Operation

Burner Shutdown
Pilot Burner Shutdown
Post Shutdown

Emergency Shutdown Operation

Introduction
Leakage of Process Fluid
Leak in Economizer/Damage to Structure
Malfunction of External Equipment
Flame-Out of All Burners

Key Monitoring Parameters

Introduction
Flame Color
Miscellaneous

Furnace Simulation

The Furnace simulation is based upon a rigorous and high-fidelity mathematical process model that provides a realistic dynamic response for a heating furnace.

Process Overview:

The simulated furnace unit is a typical natural draft furnace widely used in oil refineries and petrochemical plants.

Fuel oil or fuel gas is burned with air in 10 floor-mounted burners. The hot flue gas heats the process feed flowing through the heater tubes in the radiation and convection sections. Recoverable heat from the flue gas is further removed in the superheater section before the flue gas leaves the furnace through the stack.

Major Operations for Trainee Practice:

Startup and Shutdown Operations

Normal Operations
Emergency Shutdown Operations
Troubleshooting Equipment, Instrument and Control Valve Malfunctions
Malfunction Recovery Actions

Simulation Features:

Burner Flame Out and Unstable Flame Conditions
Variable Fuel Characteristics and Heating Values
Detailed Radiation and Convection Section Heat Transfer
Metal Temperature Calculation and Hot Spot Identification
Interlock/Safeguard System
Plant Alert and Monitor

High Coil Metal Temperature
Explosive Situation
Black Smoke in Stack
Abnormal Ignition

Equipment Details
Stoichiometric Combustion Model
Dynamic Display of Flame Color and Length
Simulation of Tube Coking and Leaks

Document Actions

Top of page