Efficiency Improvement and Emissions Reduction Through A Specialized Training Program For Plant Engineers And Operators With An Emphasis On Fired Heater Safety

The AZTEC training program is designed to provide unit engineers and operators with a thorough understanding of the operation of process heating combustion systems (heaters and burners) to insure the continued realization of efficiency improvement and emissions reduction. Unlike many operator training courses, the AZTEC program provides key plant personnel with the skills and tools necessary to provide on-going training for everyone involved in the selection and operation of the equipment. The training program is structured around the TRAINER© Heater Simulator Training Software. As a part of the training/operations improvement AZTEC can provide continuing technical support.

The purpose of this section of the operator/engineer training program is to insure that all students have a basic understanding of the combustion process and how variations in that process can affect both the efficiency and safety of the fired process heater.  Topics such as typical fuel compositions, combustion air requirements, excess air, combustible mixtures, and fuel/air mixing are discussed.

The purpose of this section of the operator/engineering training program is to ensure that all students have a basic understanding of the heater components and their function and operation. Various heater features discussed include the stack, radiant section, convection section, fuel system, and air supply system. The change in the performance of these components as there is offering parameters are changed is emphasized.

The purpose of this section of the operator/engineering training program is to ensure all students had a basic understanding of the burner components and their function and operation. Various burner compounds discussed include the burner block (tile), the fuel tips, fuel discharge ports, flame holding devices, and air register assemblies.  The function of each one of these components and the effect of various operating parameters on the component design is explained in detail. Both operational and safety issues that result from improper design are emphasized.

The purpose of the problem solving section of the operator/engineering training program is to solidify the concepts presented in the first three sections of the training by using the Trainer © Fired Heater Simulator. The use of the simulator enables the students to make any changes (including weather changes) that might occur during the operation of a process heater/burner system and then see the effect of those changes on the heater operation.  The use of the simulator helps the student identify potential safety issues and teaches the student how to safely correct the situation. 

Course content can be varied depending on the plant requirements.