PROCESS TECHNOLOGY TRAINING GUIDE - John Zink Hamworthy Combustion

PROCESS TECHNOLOGY TRAINING GUIDE

2011–2012

TABLE OF CONTENTS

What Sets Us Apart ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2Testimonials •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3

PROCESS BURNERSProcess Burner Fundamentals (PB107) •••••••••••••••••••••••••••••••••••••••••• 4Advanced Process Burners (PB108) •••••••••••••••••••••••••••••••••••••••••••••• 4Process Burners Custom (PB116) ••••••••••••••••••••••••••••••••••••••••••••••••• 5Fired Heater Reliability Management: Advanced Operation and Risk Assessment (PB134) ••••••••••••••••••••••••••••••••••••••• 5Cracking Furnaces – Reaction and Combustion Fundamentals (PB135) ••••••••• 6Fundamentals of Steam Methane Reforming Furnaces (PB136) ••••••••••••••••• 6Process Burners (PB150; PB159; PB161) ••••••••••••••••••••••••••••••••••••••••••• 7Process Burner Theory (PB155) •••••••••••••••••••••••••••••••••••••••••••••••••• 7Process Burner Operations (PB156) •••••••••••••••••••••••••••••••••••••••••••••• 8Furnace Refractory Fundamentals (PB158) •••••••••••••••••••••••••••••••••••••• 8 Process Burner Operator Training (PB171) ••••••••••••••••••••••••••••••••••••••• 9Burner Management Systems (PB177) •••••••••••••••••••••••••••••••••••••••••• 10Fired Process Heaters (PB181) ••••••••••••••••••••••••••••••••••••••••••••••••••• 10

FLARESProcess Flares (FL102)••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12Process Flare Operations (FL119) •••••••••••••••••••••••••••••••••••••••••••••••• 12

THERMAL OXIDIZERS Thermal Oxidizers (TO110) ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 13Thermal Oxidizer Operations (TO126) ••••••••••••••••••••••••••••••••••••••••••• 13

VAPOR CONTROL Vapor Combustion Systems (VC103) •••••••••••••••••••••••••••••••••••••••••••• 14Vapor Control Systems (VC106) ••••••••••••••••••••••••••••••••••••••••••••••••• 14Landfill Flares (LF105) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 14

OTHER Process Troubleshooting, The SL+1l2 Method (PB175) ••••••••••••••••••••••••••• 9Combustion Dynamics (CO137) •••••••••••••••••••••••••••••••••••••••••••••••••••1 1CFD Modeling (CO113) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10Industrial Combustion Pollution and Control (CO149) •••••••••••••••••••••••••••1 1Mass Transfer (KG178) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 14Troubleshooting Vibration of Industrial Machinery (EQ173) •••••••••••••••••••• 15High-Pressure Boiler Fundamentals (BB174) •••••••••••••••••••••••••••••••••••• 15OSHA 10-Hour General Industry Outreach Training (SA176) •••••••••••••••••••• 15

Books written by John Zink Employees ••••••••••••••••••••••••••••••••••••••• 16Logistics••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 17

Mention Promotion Code JZI2012 when registering to receive a FREE gift!©2011 John Zink Company, LLC

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M 9/19/11 PB107 PB171

Tu 9/20/11 PB107 PB171

W 9/21/11 PB108

Th 9/22/11 PB108

F 9/23/11 PB134 PB134

M 9/26/11 FL102

Tu 9/27/11 FL102

W 9/28/11 FL102

Th 9/29/11 TO110

F 9/30/11 TO110

Tu 10/11/11 VC106

W 10/12/11 VC106

Th 10/13/11 VC106

Tu 3/27/12 VC106

W 3/28/12 VC106

Th 3/29/12 VC106

W 4/11/12 LF106

Th 4/11/12 LF106

M 4/16/12 KG178

Tu 4/17/12 KG178

W 4/18/12 KG178

Th 4/19/12 KG178

F 4/20/12 KG178

M 4/23/12 PB107 PB171

Tu 4/24/12 PB107 PB171

W 4/25/12 PB108

Th 4/26/12 PB108

F 4/27/12 PB134 PB134

Tu 6/5/12 PB181

W 6/6/12 PB181

Th 6/7/12 PB181

F 6/8/12 PB181

Tu 9/18/12 VC106

W 9/19/12 VC106

Th 9/20/12 VC106

M 9/24/12 TO110

Tu 9/25/12 TO110

W 9/26/12 FL102

Th 9/27/12 FL102

F 9/28/12 FL102

M 10/1/12 PB107 PB171

Tu 10/2/12 PB107 PB171

W 10/3/12 PB108

Th 10/4/12 PB108

F 10/5/12 PB134 PB134

M 10/15/12 KG178

Tu 10/16/12 KG178

W 10/17/12 KG178

Th 10/18/12 KG178

F 10/19/12 KG178

Online Course PB155 Process Burner Theory

On Demand Courses PB116 Process Burners Custom PB135 Cracking Furnaces - Reaction and Combustion Fundamentals PB136 Fundamentals of Steam Methane Reforming Furnaces PB150 Process Burners: Luxembourg: German PB159 Process Burners: Luxembourg: French PB161 Process Burners: Luxembourg: English PB175 Process Troubleshooting, the SL+1L2M Method PB177 Burner Management Systems BB174 High-Pressure Boiler Fundamentals CO113 CFD Modeling CO137 Combustion Dynamics CO149 Industrial Combustion Pollution and Control EQ173 Troubleshooting Vibration of Industrial Machinery SA176 OSHA 10-Hour General Industry Outreach Training VC103 Vapor Combustion Systems

On-Site Courses PB156 Process Burner Operations FL119 Process Flare Operations TO126 Thermal Oxidizer Operations

1Enroll online today at johnzinkinstitute.com

WELCOME TO THE JOHN ZINK INSTITUTE

If you’re an engineer or operator looking to optimize your plant or maximize your career, the JOHN ZINK INSTITUTE’S year-round accredited combustion and process courses are specifically designed to meet your needs. The JOHN ZINK INSTITUTE is John Zink Company’s educational organization.

Choose from a variety of courses where you’ll learn how to optimize fired equipment and industrial application for safe, efficient and cost-effective operation with minimum pollution emissions.

The JOHN ZINK INSTITUTE also offers on-site courses that can be customized for your facility. Our instructors, in collaboration with your staff, will tailor the curriculum to your plant’s actual equipment, providing focused study for practical implementation.

At the JOHN ZINK INSTITUTE, our goal is to help expand your knowledge of today’s challenging process technologies and industrial applications —– so you can start working smarter.

For more information on what courses are available, or to enroll online, visit www.johnzinkinstitute.com. Classes fill up quickly — reserve your place today! RECEIVE A CERTIFICATE IN PROCESS COMBUSTION TECHNOLOGYStudents may earn a certificate in Process Combustion Technology if they successfully complete the following courses within a five-year time span:

PB107 Process Burner FundamentalsPB108 Advanced Process BurnersFL102 Process FlaresElective Any other IACET-accredited John Zink Institute course

Most INSTITUTE courses are IACET-accredited. However, PB155 is an online prerequisite course for PB107 and is not currently IACET-accredited. Therefore it would not meet the requirements for the elective.

Students do not need to apply or register for the certificate as the Institute Registrar automatically checks on a regular basis for students meeting the necessary requirements. No additional fees are required for the certificate, which is automatically sent to students meeting the requirements.

This program was originally developed to recognize students typically working in refineries and chemical plants, taking consecutive courses to receive training in the combustion equipment in their plants. The certificate does not certify students for a particular position or task —– it merely recognizes they have met the requirements for the courses in the certificate program.

ONLINE COURSESThe JOHN ZINK INSTITUTE began offering online courses in 2006. Online courses are a simple and cost-effective learning tool. For more information visit www.johnzinkinstitute.com.

TUITION Each participant will receive a hardcopy of a color training manual of the course presentation and a certificate of completion.

The JOHN ZINK INSTITUTE takes pride in hosting classes with southern hospitality. Each registrant for a Tulsa class will receive a continental breakfast, complete lunch, morning and afternoon snacks and all-day complimentary beverages. IACET ACCREDITED COURSESThe JOHN ZINK INSTITUTE is an Authorized Member of the International Association for Continuing Education and Training (IACET). Continuing Education Units (CEUs) are used internationally to maintain records of completion of organized post-secondary education. To receive a certificate and Continuing Education Units, participants must attend at least 80% of the class, take a pretest, score at least 80% on the post test, complete a course evaluation form and complete all prerequisites, if any.

The JOHN ZINK INSTITUTE, sponsored by John Zink Company, LLC, has been approved as an Authorized Provider by the International Association for Continuing Education and Training (IACET), 1760 Old Meadow Road, Suite 500,

McLean, VA, 22102. In obtaining this approval, the JOHN ZINK INSTITUTE has demonstrated that it complies with the ANSI/IACET Standards, which are widely recognized as standards of good practice internationally. As a result of their Authorized Provider membership status, John Zink Company is authorized to offer IACET CEUs for its programs that qualify under the ANSI/IACET standards. John Zink Company has awarded more than 5,000 CEUs to participants who have successfully completed courses at the JOHN ZINK INSTITUTE. For more information on IACET CEUs, please visit www.iacet.org or call 703-506-3275. The JOHN ZINK INSTITUTE has earned certification of multiple courses from the American Petroleum Institute. We are the only company to offer combustion courses certified under API’s Training Provider Certification Program.

PB107 TPCP-0058PB108 TPCP-0117PB118/PB156 TPCP-0071FL102 TPCP-01 16

API1220 L Street, NWWashington, D.C. 20005-4070 USAPhone 202-682-8000www.api.org

Provide current and high-quality continuing education combining both theory and practice to improve the knowledge, performance and efficiency of our customers, partners and employees.

JOHN ZINK INSTITUTE’S MISSION STATEMENT

2 Call the John Zink Institute today at 918.234.5710

WHAT SETS US APART

Students at the JOHN ZINK INSTITUTE will learn from a team of professionals

who are proven leaders in their fields. Many instructors hold doctorate degrees

and have pioneered the industry with patents and authorships which keep them

on the cutting-edge of technology. Many have also contributed to The John

Zink Combustion Handbook which is the text used in many of the courses.

Participants can also observe equipment tests under actual and simulated

industrial-scale conditions using the many configurations of test furnaces, flare

systems, thermal oxidation systems and extensive utility supplies at John Zink’s

state-of-the-art facility.

Contact the JOHN ZINK INSTITUTE today to schedule your next training course at

918-234-5710 or enroll online at www.johnzinkinstitute.com.

Whether you’re a novice or a seasoned professional, you’ll gain invaluable intelligence from some of the world’s most recognized engineers and educators in the science of combustion – all in a classroom that’s truly on an industrial scale.

Some courses have demonstrations at John Zink’s Research and

Development Test Center located on the campus of the company’s world

headquarters in Tulsa, Oklahoma.

Disclaimer:

This document was prepared for promotional purposes only. Class dates and locations are

subject to change without notice. Check the John Zink Institute website for the most up-to-

date information. John Zink Company, LLC is not responsible for any costs associated with

cancellations. The information in this brochure is neither a guarantee nor a statement of

warranty, either expressed or implied.

2


TESTIMONIALS

John Zink operates the largest and most comprehensive research, development and test center of its kind. JOHN ZINK INSTITUTE students will observe equipment tests under actual and simulated industrial-scale conditions. • Test furnaces• Flare systems• Thermal oxidation systems• Cold flow scale models

To visit our playground, register for a JOHN ZINK INSTITUTE course today.

johnzinkinstitute.com918.234.5710

VISIT OUR PLAYGROUND.

3

“ My thanks to all at the John Zink Institute for a class that was far and above what was expected. The information and understanding I walked away with was priceless to me. You could have charged twice as much and I would still recommend this course to anyone working in the landfill gas extraction industry.” – Engineering Technician

“ This was the best heater training I have attended. The information was very practical and relates to day-to-day operations.”

– Refinery Operator

“ My instructors were great at involving the whole class and added just enough humor to keep it fresh and not boring.”


“Excellent instruction and activities. Had a lot of fun. Thank you!” – JOHN ZINK INSTITUTE Student

“ I enjoyed the group session. Overall the class was excellent. I would definitely recommend attending more JOHN ZINK INSTITUTE classes.”

– Engineer

“ The combination of theory and hands-on training and teaching is excellent.”

– Engineer

“ My instructors were seasoned professionals who knew exactly what they were talking about.”


“ Until I attended this course my knowledge about burners was limited. After this course, I can safely say that I look forward to working with burners in my next rotation.”

– JOHN ZINK INSTITUTE Student

4 Call the John Zink Institute today at 918.234.57104 Call the John Zink Institute today at 918.234.5710

PROCESS BURNER FUNDAMENTALS PB107Prerequisite: PB155

2-DAY COURSE

1.4 CEUs

AUTHORIZED IACET PROVIDER

DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel from hydrocarbon and chemical processing plants around the world.

COURSE OVERVIEW: Process Burner Fundamentals provides introductory instruction related to the essential theory and practical application of process burners. In this two-day course, a broad range of skills will be covered.

• Review the basics of combustion, heat transfer and fluid flow, with instruction on how they impact burner and heater performance

• Operate a heater safely and more efficiently• Distinguish a good flame from a poor flame• Understand different types of typical burners, their operation maintenance

and troubleshooting• Diagnose problems with heaters and burners to determine necessary actions

to correct the problems• Maximize the thermal efficiency of your heating equipment• Install burners in accordance with manufacturer’s drawings• Maintain burners to obtain optimal performance• Witness live demonstrations that illustrate principles covered in the course

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Fluid flow• Combustion fundamentals and safety• Burner installation and maintenance• Heat transfer• Burner fundamentals• Heater operations• Fuels• Burner demonstrations• Troubleshooting/service• Pollution emission basics

LOCATIONS, DATES AND PRICES:Tulsa, OK September 19 – 20, 2011 $1,595Tulsa, OK April 23 – 24, 2012 $1,595Tulsa, OK October 1 – 2, 2012 $1,595

TPCP-0058

2-DAY COURSE

1.4 CEUs


ADVANCED PROCESS BURNERS PB108Prerequisite: PB107


COURSE OVERVIEW: Two-day course designed as a follow-up course to Process Burner Fundamentals (PB107). Participants will be shown the basics of some of the latest diagnostic techniques including:

• Techniques for assessing burner and heater performance• Determine what causes burner flames to interact • The effect of having burners placed too close to each other and/or too close

to furnace walls/tubes• What is involved in performing a computational fluid dynamics (CFD) analysis

and the difficulties and benefits of conducting such an analysis• How CFD can be used to solve advanced burner-burner/burner-furnace interactions• The basics of heater design

The important factors that impact pollution emissions (especially NOx and noise) are discussed, including the techniques for minimizing them. Alternate fuels and oil firing are discussed. Participants will see the key parameters in burner testing in a safe and environmentally acceptable manner, as well as how to identify problems with and methods for firing waste fuels. Some live demonstrations will be used to illustrate concepts covered in the course.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Advanced process diagnostics• Oil firing• Special fuels• General pollutant emissions• NOx emissions• Noise• CFD modeling• Burner testing• Live demonstrations



PROCESS BURNERS CUSTOM PB116Prerequisite: None

UP TO 3-DAY COURSE

UP TO 2.1 CEUs


COURSE OVERVIEW: Process Burners Custom presents introductory information related to the essential theory and practical application of process burners. This is a customized course where the client selects the topics to be covered. It typically ranges from one to three days in length depending on the topics selected.

TYPICAL COURSE OBJECTIVES: • Discuss the basics of combustion• Describe the importance of fuel consumption• List the 3 burner types and 6 Ms of combustion• Discuss where to measure draft and excess O2

• Discuss blowoff and liftoff• Describe proper burner operation• Identify common burner problems and possible causes and solutions

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Combustion fundamentals• Combustion safety• Burner installation and maintenance• Heat transfer • Heater fundamentals• Burner fundamentals• Heater operations • Fuels• Troubleshooting and service• Noise• Cfd modeling

LOCATIONS, DATES AND PRICES:Offered as demanded.

1-DAY COURSE

0.7 CEUs


FIRED HEATER RELIABILITY MANAGEMENT: ADVANCED OPERATION AND RISK ASSESSMENT PB134 - Prerequisite: None

DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel working with or responsible for fired heaters.

COURSE OVERVIEW: Fired Heater Reliability Management allows students to experience the science of optimizing reliability and performance in the life cycle of a fired heater. This course also demonstrates the essential theory provided in American Petroleum Institute (API) recommended practices, as well as practical approaches to performance monitoring, advanced operation, tube inspection, root cause failure analysis, reliability monitoring, risk assessment and safety.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Heater performance monitoring• Tube condition inspection and assessment systems• Tube temperature measurements• API 579 fitness for service• API 580 risk assessment• Root cause failure analysis• Performance and reliability strategies

LOCATIONS, DATES AND PRICES:Tulsa, OK September 23, 2011 $695Tulsa, OK April 27, 2012 $695Tulsa, OK October 5, 2012 $695

ON-

DEMAND

COURSE

5


2.5-DAY COURSE

1.8 CEUs


CRACKING FURNACES – REACTION AND COMBUSTION FUNDAMENTALS PB135 Prerequisite: None

DESIGNED FOR: Engineers, operators, maintenance and training personnel responsible for issues associated with cracking furnaces.

COURSE OVERVIEW: The first part of the course provides introductory knowledge of the fundamental theory of cracking (pyrolysis), coking and decoking, combustion and heat transfer inside the firebox. In the second part of the course, this knowledge will be used to examine the impact burners have on each of these elements and how their design can be optimized to reach production and emission targets.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Pyrolysis reactions• Radiant coil design• Coking and decoking fundamentals• Combustion and heat transfer• Firebox/burner design and operation• Burner solutions for flux control and emissions• Maintenance and inspection• Troubleshooting

LOCATION AND PRICE:As requested. Tulsa, OK $1,995

2-DAY COURSE

1.4 CEUs


FUNDAMENTALS OF STEAM METHANE REFORMING FURNACES PB136 Prerequisite: None

DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel responsible for issues associated with steam methane reforming furnaces.

COURSE OVERVIEW: Fundamentals of Reforming Furnaces provides introductory material of the essential theory and practical application of the reforming process, its design and operation. This course is taught by industry experts who have the latest and most practical knowledge of the reforming process. Attendees are invited to bring specific operating problems for discussion with an institute instructor or for discussion with a group of peers who have experienced similar situations at their facilities.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Reforming process fundamentals• Reforming furnace designs• Reforming combustion fundamentals and safety• Burner fundamentals• Burner operation and maintenance• Reforming furnace operation and maintenance• Troubleshooting/service

LOCATION AND PRICE:As requested. Tulsa, OK $1,795

ON-

DEMAND

COURSE

ON-

DEMAND

COURSE

Can’t get away? Visit www.johnzinkinstitute.com to register for our online Process Burner (PB155) Course today.

www.johnzinkinstitute.com

GET AN EDUCATION RIGHTFROM YOUR DESKTOP.

2-DAY COURSES3-DAY COURSES

1.4 CEUs2.1 CEUs


PROCESS BURNERS PB150–German, PB159–French, PB161–EnglishPrerequisite: None

DESIGNED FOR: German, English and French-speaking engineers, operators, maintenance, safety and training personnel from hydrocarbon and chemical processing plants around the world.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • The basics of combustion and how they impact burner and heater performance• Operate a heater safely and more efficiently• Distinguish a good flame from a poor flame• Understand different types of typical burners, their operation, maintenance

and troubleshooting• Diagnose problems with heaters and burners to determine what action to take

to correct the problems• How to maximize the thermal efficiency of your heating equipment• Install burners in accordance with manufacturer’s drawings• Maintain burners to obtain optimal performance• Witness live demonstrations that illustrate principles covered in the course

LOCATIONS, DATES AND PRICES:PB161 Luxembourg - English September 26 - 28, 2011 3-DayPB150 Luxembourg - German 2012 2-DayPB159 Luxembourg - French April 16 - 18, 2012 2-Day PB161 Luxembourg - English September 24 - 26, 2012 3-Day

Check website for exact dates and prices.

PROCESS BURNER THEORY PB155Prerequisite: None

ONLINE COURSE


COURSE OVERVIEW: Process Burner Theory in an online course designed to provide basic fundamentals of combustion, fluid flow and heat transfer as they pertain to burners used in process heaters and furnaces. This course is designed to provide students some of the basic information required to take Process Burner Fundamentals (PB107). The course consists of 16 modules, which each take approximately 15 minutes to complete via the Internet.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Combustion fundamentals• Fuels• Combustion safety• Irregular flame patterns• Furnace draft• Flow-through nozzles• Conduction• Convection• Radiation• Heat transfer in furnaces

ONLINE COURSE ONLY: 2011 $3392012 $339

ON-

DEMAND

COURSE


1-DAY COURSE

0.7 CEUs


PROCESS BURNER OPERATIONS PB156Prerequisite: None

DESIGNED FOR: Operators, engineers, maintenance, safety and training personnel from hydrocarbon, chemical and petrochemical processing, and refining plants around the world.

COURSE OVERVIEW: Process Burner Operations teaches students the science of safe operation and the art of troubleshooting fired equipment. Students are invited to bring specific operating problems for one-on-one discussion with an institute instructor or for discussion with a group of peers who have experienced similar situations at their facilities.

Participants will be present for an in-depth explanation of the latest combustion technologies and techniques to improve efficiency, insight into how air and fuel variability affect burner performance and emissions and the instruction to accurately evaluate the economics of replacements and retrofits.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Burner safety• Burner design• Burner installation• Burner maintenance• Heater/burner operation• Troubleshooting• Inspection information• Combustion survey• Turnaround support

LOCATIONS, DATES AND PRICES:Currently scheduled and open for registration.Salt Lake City, University of Utah October, 11, 2011 $795

TPCP-0071

ON-SITE

COURSE

1-DAY COURSE

0.7 CEUs


FURNACE REFRACTORY FUNDAMENTALS PB158Prerequisite: None

DESIGNED FOR: Engineers, operators, maintenance and training personnel responsible for refractory specification, reliability and maintenance in high-temperature fired process heaters.

COURSE OVERVIEW: Furnace Refractory Fundamentals provides introductory knowledge of high-temperature furnace refractory lining principles and refractory used for burner tiles. Discussion includes furnaces similar to ethylene, hydrogen reformers, ammonia reformers, steam superheaters and EDC/VCM cracking furnaces. This one-day course examines the basics of selection, design, installation and maintenance of a broad range of refractory materials. Current best practices for brick, ceramic fiber, cast and gunned materials will be discussed.

Students will be introduced to the Three Keys to Reliability for refractory installations. Examples of best practices will be shown, as well as examples of failures observed in a variety of service conditions. Participants are encouraged to bring specific examples and questions based on their own operations for group and one-on-one discussions.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Plant performance• Industry standards• Refractory material selection criteria• Hard refractory materials: brick, castable and gunite• Comparison of various ceramic fiber systems• Hot-face coating and rigidizer• Bullnoses and transitions• Peephole tiles and door plugs• Burner tiles• Penetration seals• Maintenance considerations

LOCATIONS, DATES AND PRICES:Tulsa, OK September 23, 2011 $695Tulsa, OK April 27, 2012 $695Tulsa, OK October 5, 2012 $695



2-DAY COURSE

1.4 CEUs


2-DAY COURSE

1.4 CEUs


PROCESS BURNER OPERATOR TRAINING PB171 Prerequisite: None

PROCESS TROUBLESHOOTING, THE SL+1L2M METHOD PB175 Prerequisite: None

DESIGNED FOR: Operators using process burners.

COURSE OVERVIEW: Students will be shown safe process burner operation. This course includes one day in the classroom learning the basics of process burners and one day in John Zink’s world-class test facility with hands-on burner operation in a process heater. Students will also get to troubleshoot typical problems and experience routine burner maintenance.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Combustion fundamentals• Combustion safety• Burner fundamentals• Heater operations• Test procedures• Hands-on burner operation• Troubleshooting • Maintenance


DESIGNED FOR: Engineers, operators, safety and training personnel from hydrocarbon, chemical and petrochemical processing and refining plants around the world.

COURSE OVERVIEW: Has your plant become more complex? Has your equipment become more unreliable? Is your unit lasting less time between scheduled turnarounds? Have you ever made a problem worse by having the wrong answer to a problem? Have you ever felt overwhelmed by all the DCS data while searching for the root cause of your problem?

If you answered yes to any or all of these questions, we can help. We will demonstrate methods that rapidly sort through hundreds of data points and narrow the focus of your search for the root causes of your problem.

Since the key to becoming proficient with any new skill is application, 75% of class time is devoted to practice problems. This is intended to anchor the technique in your long-term memory and greatly increase your confidence.

LOCATION AND PRICE:As requested. Tulsa, OK

ON-

DEMAND

COURSE


2-DAY COURSE1.4 CEUs

BURNER MANAGEMENT SYSTEMS PB177Prerequisite: None

FIRED PROCESS HEATERS PB181Prerequisite: None

4-DAY COURSE

2.8 CEUs


DESIGNED FOR: Engineers, operators, maintenance and safety personnel and other professionals involved with design and operation of fired process heaters.

COURSE OVERVIEW: This course will introduce the basics of thermal and mechanical design and safe, efficient operation of fired heaters. Emphasis will be on common design methods, considerations of fuel type, combustion air supply and control, combustion chemistry and control and safe heater operation. Attendees are encouraged to bring the details of current problems for discussion with an instructor or general discussion with other attendees.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Description of heater types and factors governing choice of design• Combustion calculations and sampling• Radiant zone design• Convection zone design• Application of burners• Combustion air supply and control• Instrumentation and safety devices• Improving efficiency• Design of tubes, including flow regime issues• Operation, testing, tune-up and troubleshooting of heaters• Emissions control• Refractories• Corrosion and fouling• Fuel considerations• Maintenance planning

LOCATIONS, DATES AND PRICES:Tulsa, OK June 5 – 8, 2012 $2,995

DESIGNED FOR: Personnel interested in understanding and applying burner management technology for fired heaters, boilers, sulfur plants and other industrial combustion equipment. It provides operators and engineers a solid foundation for determining BMS requirements and understanding its operation.

COURSE OVERVIEW: Burner Management Systems is a two-day course that gives students an overview of the methods used to achieve safe and reliable automatic startup, monitoring and shutdown of burner systems. The course begins with an overview of prescriptive (NFPA 86/86/87, CSA B149.3, API 556) and performance-based (IEC 61508/11) codes and standards. Risk, safety and reliability requirements for fired equipment are introduced. A detailed review of current and future BMS technology is provided including safety PLCs, redundant processors, instrument voting methods, on-line maintenance and testing, automatic fault detection and trip avoidance.

Basic operation, selection and maintenance of burner control components are discussed, including fuel safety valves, regulators, control valves, dampers, flame detection and ignition systems.

Solutions to common startup problems are provided, including purging of natural draft furnaces, turndown control during refractory dryouts, multiple burner pressure control, reliable ignition systems, valve proving systems, reliable flame detection, fuel oil and gas combination systems.

System operation is presented, including monitoring functions, alarming, on-line maintenance and on-line trip testing. Shutdown conditions and techniques are provided, including typical trip settings, emergency shutdowns and quick recover trips.

The course includes numerous applications to fired heaters, boilers, sulfur plants and other combustion equipment.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • BMS codes and standards• Pre-startup permissives• Measurement and time purging systems• Valve proving techniques and fuel header management• Flame detection technologies• Ignition system technologies• Safety PLC systems


ON-

DEMAND

COURSE NEW!

2-DAY COURSE1.4 CEUs

CFD MODELING CO113 Prerequisite: None

DESIGNED FOR: Engineers who use CFD to solve combustion-related issues.

COURSE OVERVIEW: CFD Modeling teaches students to apply CFD to solve real-life problems by making judicial determinations of meshing strategies, physical models, convergence parameters and discretization schemes. The two-day course will feature case studies highlighting the power of CFD in delivering real benefits to your business. There are two labs associated with the course: 1.) A virtual engineering demonstration of practical industrial processes using immersive stereo visualization technology; 2.) Hands-on experience with predefined exercises to solidify the various techniques and methods learned in the classroom.

ON-

DEMAND

COURSE

INDUSTRIAL COMBUSTION POLLUTION AND CONTROL CO149 – Prerequisite: None

COMBUSTION DYNAMICS CO137Prerequisite: None

2-DAY COURSE 2-DAY COURSE1.4 CEUs

1.4 CEUs


DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel responsible for environmental issues associated with combustion in fired equipment.

COURSE OVERVIEW: Industrial Combustion Pollution and Control provides the essential theory and practical knowledge needed to work with and control pollution from combustion processes and equipment. This two-day course will help students understand the fundamentals of industrial combustion, how to control pollution and the applications associated with industrial combustion pollution. Attendees are invited to bring specific pollution and control issues for discussion with the Institute instructor or for discussion with a group of peers who have experienced similar situations at their facilities.

DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel responsible for issues associated with combustion in fired equipment.

COURSE OVERVIEW: Combustion Dynamics is taught by professor Ben Zinn from Georgia Institute of Technology and John Zink personnel. This course demonstrates the essential theory and practical knowledge needed to work with, diagnose and treat combustion-related instability problems in fired equipment applications.

Attendees are invited to bring specific operating problems for discussion with the instructor or for discussion with a group of peers who have experienced similar situation at their facilities.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Combustion instabilities• Types and causes of instabilities• Flame response to flow perturbations• Approaches to preventing combustions instabilities• Instabilities in industrial applications

LOCATION AND PRICE:Tulsa, OK $1,795

Each student will receive a copy of the book Industrial Combustion Pollution and Control by C.E. Baukal.

STAY THERE. WE’LL BRING THE CLASSROOM TO YOU.

The JOHN ZINK INSTITUTE offers on-site courses that can be customized for your facility. Almost any John Zink course can be delivered on-site. Contact us today to schedule a course for a time that’s convenient for you.

www.johnzinkinstitute.com

918.234.5710

ON-

DEMAND

COURSE

ON-

DEMAND

COURSE


DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel from hydrocarbon and chemical processing plants.

COURSE OVERVIEW: Process Flares provides an introduction to the selection, operation and maintenance of offshore and onshore flare systems. It outlines the many different flare technologies available and the type of application each is most suited for. It will demonstrate to attendees how to control smoke, noise, radiation and flame luminosity. Attendees will also be shown how to accurately evaluate the economics of replacements and retrofits. Students are invited to bring specific operating problems for one-on-one discussion with an Institute instructor or for discussion with a group of peers who have experienced similar situations at their facilities. Students will see flare demonstrations in a world-class flare test facility.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Types of flares• Flare safety• Noise• Emissions • Stack design• Flare selection• Flare upgrades• Flare pilots • Thermal radiation• Efficiency• Smoke control• Flare demonstrations

LOCATIONS, DATES AND PRICES:Tulsa, OK September 26 – 28, 2011 $2,195Tulsa, OK September 26 – 28, 2012 $2,195 TPCP-0116

DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel from hydrocarbon and chemical processing plants.

COURSE OVERVIEW: This one-day course provides an introduction to the operation and maintenance of offshore and onshore flare systems. It will demonstrate to students how to control smoke, noise, radiation and flame luminosity. Attendees will also be shown how to accurately evaluate the economics of replacements and retrofits. Students are invited to bring specific operating problems for one-on-one discussion with an Institute instructor or for discussion with a group of peers who have experienced similar situations at their facilities.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • History and purpose of flares• Flashback prevention• Radiation• Gas/liquid separation• Noise and smoke control• Utility and steam flares• Air-assisted and multi-point flares• Ignition systems• Pilots• API 521/537

LOCATIONS, DATES AND PRICES:As requested.


1-DAY COURSE

0.7 CEUs


3-DAY COURSE

2.1 CEUs


PROCESS FLARES FL102Prerequisite: None

PROCESS FLARE OPERATIONS FL119Prerequisite: None ON-SITE

COURSE


1 TO 2-DAY COURSE

1.4 CEUs


2-DAY COURSE

1.4 CEUs


THERMAL OXIDIZERS TO110Prerequisite: None

THERMAL OXIDIZER OPERATIONS TO126Prerequisite: None

DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel from hydrocarbon and chemical processing plants and production operations that handle hazardous and non-hazardous organic waste disposal in their daily operations.

COURSE OVERVIEW: This course focuses on gaseous and liquid waste thermal oxidizers and covers a broad range of thermal oxidation topics. Course begins with thermal oxidation and combustion basics and advancing through the fundamental system types – sulfur, low NOx, chlorinated and down-fired/salt. The course addresses CFD modeling, pre- and post-treatment, alternative technologies and control systems. Maintenance and service are also discussed. Thermal oxidizer tests and demonstrations will be conducted at John Zink’s new state-of-the-art thermal oxidation test facility.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Combustion fundamentals• Design guidelines• Instrumentation and controls• Waste types• Pollution emissions• Equipment components• Fume and vent systems• Sulfur plant equipment• Chlorinated systems• Down-fired systems• Low-NOx systems• Ultra low-NOx systems• NOx and N2–bearing wastes• Oxidizer maintenance and service

LOCATIONS, DATES AND PRICES:Tulsa, OK September 29 – 30, 2011 $1,595Tulsa, OK September 24 – 25, 2012 $1,595

DESIGNED FOR: Engineers, operators, maintenance, safety and training personnel from hydrocarbon and chemical processing plants and production operations who handle hazardous and non-hazardous organic waste disposal in their daily operations.

COURSE OVERVIEW: This course is usually one or two days and covers the basics of combustion and thermal oxidizers. It can also be customized to fit your specific needs. This course can also be used to train operators and may include a simulator of the actual control system that will be used in the plant.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Combustion basics• Thermal oxidizer basics• Fume incineration• Down-fired systems• Chlorinated systems• Sulfur plant systems• NOxidizer® and NOx reduction• Furnace refractory• CFD as a design tool• Hazardous waste disposal• Controls• Operation and maintenance


ON-SITE

COURSE


5-DAY COURSE

3.5 CEUs


3-DAY COURSE

2.1 CEUs


VAPOR CONTROL SYSTEMS VC106Prerequisite: None

MASS TRANSFER KG178Prerequisite: None

DESIGNED FOR: Engineers, operators, technicians and regulatory personnel who deal with vapor recovery or vapor combustion equipment for petroleum distribution facilities in their daily operation.

COURSE OVERVIEW: Vapor Control Systems is taught by our engineering and service personnel who work full time on vapor control equipment. This course is well-balanced between classroom and hands-on training. The course includes in-depth discussions, demonstrations and visits to see actual systems in operation.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Vapor control background• Recovery/combustion theory• System description• Operating description• Vapor recover unit/vapor control unit demonstration• Mechanical components• Electrical components• Maintenance and troubleshooting

LOCATIONS, DATES AND PRICES:Tulsa, OK October 11 – 13, 2011 $1,095Tulsa, OK March 27 – 29, 2012 $1,095Tulsa, OK September 18 – 20, 2012 $1,095

DESIGNED FOR: Engineers in the refining, petrochemical, chemical and EPC industries.

COURSE OVERVIEW: This is a five-day course taught by engineering professionals with extensive mass transfer experience. The course includes classroom training, design exercises and hands-on sessions in a world-class pilot plant. The lectures include classwork examples, videos, demonstrations, viewing product samples and the use of detailed notes. During the course of each session, attendees will participate in several pilot-plant experiments that will demonstrate the equipment discussed in the classroom.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Fundamentals of different types of mass transfer devices• Operation of trays, packing and distributors• Basic mass transfer equipment calculations• Applicability of different mass transfer devices• Equipment design and selection

LOCATIONS, DATES AND PRICES:Wichita, KS October 24 - 28, 2011 SOLDOUTWichita, KS April 16 – 20, 2012 $2,300Wichita, KS October 15 – 19, 2012 $2,300

2-DAY COURSE

1.4 CEUs


VAPOR COMBUSTION SYSTEMS VC103Prerequisite: None

DESIGNED FOR: Engineers, operators, technicians and regulatory personnel who deal with vapor combustion for petroleum and ethanol distribution facilities in their daily operation.

COURSE OVERVIEW: Vapor Combustion Systems is taught by John Zink engineering and service personnel who work full-time on vapor control equipment. This course is well-balanced between classroom and hands-on training. Course includes in-depth discussion and hands-on demonstrations.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Vapor control background• Combustion theory• System description• Operating description• Vapor control unit demonstration• Mechanical components• Electrical components• Maintenance and troubleshooting


2-DAY COURSE

1.4 CEUs


LANDFILL FLARES LF105Prerequisite: None

DESIGNED FOR: Engineers, operators, technicians and regulatory personnel from landfill facilities, waste management facilities and governments around the world.

COURSE OVERVIEW: Landfill Flares is taught by our engineering and service personnel who workfull-time on landfill flare equipment. It is well-balanced between classroom and hands-on training. The course includes in-depth discussion, demonstrations and viewing an actual system check-out in our manufacturing facility.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Combustion principles• System design and selection• Mechanical and electrical components• Emissions• Troubleshooting • Operation and maintenance• New technologies• Condensate injection

LOCATIONS, DATES AND PRICES:Tulsa, OK April 11 – 12, 2012 $1,095

ON-

DEMAND

COURSE

15Enroll online today at johnzinkinstitute.com 15Enroll online today at johnzinkinstitute.com

1-DAY COURSE 5-DAY COURSETROUBLESHOOTING VIBRATION OF INDUSTRIAL MACHINERY EQ173 – Prerequisite: None

HIGH-PRESSURE BOILER FUNDAMENTALS BB174 – Prerequisite: None

DESIGNED FOR: Beneficial for all persons involved with the reliability, maintenance and operation of equipment susceptible to destructive vibration.

COURSE OVERVIEW: Troubleshooting Vibration of Industrial Machinery provides practical vibration information with actual case histories used by the course presenter on general-purpose equipment during his more than 40 years in the industry.

At the end of the accelerated one-day seminar, participants will have received an overview on the type of vibration problems that occur in industry. The seminar identifies causes that can result in expensive downtimes and how to avoid them.

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Steps in troubleshooting a vibration problem• Basics of vibration• Problems vibration forces cause and how to solve them• Causes of and solution for vibration• Structural and pressure vessel vibration• Torsional vibration

DESIGNED FOR: Engineers, operators, safety and training personnel from hydrocarbon, chemical and petrochemical processing and refining plants around the world.

COURSE OVERVIEW: Steam has many and varied uses in today’s world. In the modern power plant it is used to turn generators that produce electricity. In many industrial plants, steam powers turbines that are connected to pumps, compressors or fans. Steam is also injected into many processes. The device that produces this steam is a boiler.

This course is designed to give students a strong foundation of basic boiler operating and safety principles. Through the use of multi-media and a variety of interactive instructional techniques, the subject matter is brought to life.

Participants will discover the many uses, designs, systems and controls for safely operating high-pressure boilers. Boiler theory, equipment, fitting and accessories are also covered. Boiler operating techniques, start-up and shutdown will be demonstrated with the use of a dynamic simulator.

Each student will receive a copy of the book An Analytical Troubleshooting of Process Machinery and Pressure Vessel by Anthony Sofronas.

2-DAY COURSEOSHA 10-HOUR GENERAL INDUSTRY OUTREACH TRAINING SA176 – Prerequisite: None

DESIGNED FOR: Safety personnel, instructors, managers, supervisors or anyone having responsibility for OSHA compliance in an industrial setting.

COURSE OVERVIEW: Two-day course which familiarizes participants with OSHA General Industry standards and requirements. This course provides an overview of compliance programs and procedures required for the workplace. Training course explains how to read and use the Code of Federal Regulations (CFRs).

SOME TOPICS COVERED DURING THE COURSE INCLUDE: • Introduction to OSHA/OSHA standards• Walking and working surfaces• Means of egress and fire protection• Hazardous materials • Electrical standards• Industrial hygiene • Personal protective equipment• Machine guarding

ON-

DEMAND

COURSE

ON-

DEMAND

COURSE

ON-

DEMAND

COURSE


ONLINE FURNACE SIMULATOR

BOOKS WRITTEN BY JOHN ZINK EMPLOYEES

THE JOHN ZINK INSTITUTE offers an online

process heater simulator that enables users to

alter the following factors:

Fuel compositions

Ambient air conditions

Firing rates

Position of the stack damper

Position of the burner damper

Outputs such as excess oxygen, temperatures,

heat transfer rates, furnace efficiencies and

pollution emissions such as NOx can be studied.

The online process heater simulator is free

of charge for anyone that attends or has

attended a course at the JOHN ZINK INSTITUTE.

To register for access to the simulator, alumni

should visit: www.johnzinkinstitute.com.

1. The John Zink Combustion Handbook

1. 2.

5.

3.

6.

4.

7.

2. Oxygen-Enhanced Combustion

3. Computational Fluid Dynamics in Industrial Combustion

4. Industrial Burners Handbook

5. Industrial Combustion Testing

6. Industrial Combustion Pollution and Control

7. Heat Transfer in Industrial Combustion

17

LOGISTICSHOTEL RESERVATIONS The JOHN ZINK INSTITUTE has arranged for preferred rates at the DoubleTree Hotel Warren Place, Courtyard Marriott and Embassy Suites Hotel. Please mention the JOHN ZINK INSTITUTE for the special rate.

DOUBLETREE HOTEL WARREN PLACE6100 South Yale AvenueTulsa, OK 74136Phone: 1-918-495-1000(Ask for the JOHN ZINK INSTITUTE rate)

The DoubleTree Hotel Warren Place offers a unique location in Tulsa. Within walking distance you’ll find numerous eateries, shopping and entertainment. DoubleTree offers a free breakfast buffet in the Warren Duck Club, free high-speed Internet access, as well as free airport transportation.

COURTYARD MARRIOTT9041 East 71st StreetTulsa, OK 74133Phone: 1-918-992-4500(Ask for the JOHN ZINK INSTITUTE rate)

Courtyard Woodland Hills hotel features a state-of-the-art lobby with comfortable spaces to work or socialize, along with free Wi-Fi to help you stay connected with the latest news, weather, airport conditions and more. The Courtyard Marriott offers complimentary shuttle service to and from the Tulsa International Airport, as well as to John Zink.

EMBASSY SUITES HOTEL3332 South 79th East AvenueTulsa, OK 74145Phone: 1-918-622-4000(Ask for the JOHN ZINK INSTITUTE rate)

Centrally located in the heart of midtown Tulsa, nine miles away from The John Zink Institute. Embassy Suites Hotel is located right off Interstate-44, allowing for easy access to all business and shopping districts within minutes. Embassy Suites Hotel offers complimentary shuttle service to and from Tulsa International Airport, as well as to John Zink.

CANCELLATIONS If a minimum number of students are not registered seven days prior to the course, the administrator may elect to reschedule the class. Students will be contacted via e-mail or phone and rescheduled for the next available course. All paid students will have re-registration priority.

Students canceling more than five business days before the course begins may be refunded 100% of the course cost. Students canceling five or fewer business days before the course begins may apply all of the course fees to another John Zink Institute course within one year of the cancellation date, or elect a refund of 65% of the fees (a 35% cancellation fee is assessed if the course is not rescheduled).

If your plans change, please call the INSTITUTE administrator early. Substitutions of attendees within the same company may be made any time prior to the start of the course. DISCOUNTS Discounts are available for parties of three or more from one company, for early enrollment at least 30 days prior to start of class, for taking multiple classes and for JOHN ZINK INSTITUTE alumni.

POLICY STATEMENT It is the policy of John Zink Company, LLC that 100% of the tuition must be paid by the student’s employer or an affiliate of the employer. Admission of employees of companies that John Zink deems to be a competitor is prohibited. John Zink reserves the right to deny admissions for any reason permitted by law. All decisions regarding admissions are made without regard to color, race, religion, gender, sexual orientation, national origin, ethnicity, age, disability, pregnancy, veteran status or other legally protected factors.

Enroll online today at johnzinkinstitute.com

For more information on what courses are available or to enroll online, visit www.johnzinkinstitute.com. Classes fill up quickly –– reserve your place today!

Discounts are available for groups of three of more, early enrollment, taking multiple courses and for JOHN ZINK INSTITUTE alumni.

® Registered trademarks of John Zink Company, LLC in the U.S. & various foreign countries. ™ Trademarks of John Zink Company, LLC© 2011 John Zink Company, LLCJZI – 11050

John Zink Company, LLC11920 East Apache, Tulsa, OK 74116 United States of America800-421-9242

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PROCESS TECHNOLOGY TRAINING GUIDE - John Zink Hamworthy Combustion

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