COURSE OVERVIEW:

The purpose of this course focuses on the complex technical management of fired process heaters, which are essential but high-hazard assets in refineries and petrochemical plants. Fired heaters transfer massive amounts of thermal energy into process fluids, requiring precise control of combustion, draft, and fuel systems to ensure both efficiency and safety. This program provides the foundational and advanced knowledge needed to operate these units within their design limits while optimizing fuel consumption.

The scope of this training encompasses the mechanical design of heaters, the principles of efficient combustion, and the implementation of advanced control strategies. Participants will explore the role of the Burner Management System (BMS) in preventing furnace explosions and the use of oxygen trim to improve thermal efficiency. The curriculum is designed to provide a detailed understanding of how process variables such as coil outlet temperature and excess air impact the integrity of heater tubes and overall plant productivity.

Coverage includes systematic troubleshooting techniques for common operational issues like flame impingement, tube coking, and draft instability. Attendees will learn how to conduct burner inspections, manage "hot spots" through infrared thermography, and execute safe startup and shutdown sequences. By focusing on the intersection of thermodynamics, mechanical integrity, and automation, the course ensures that participants can maintain fired heaters at peak performance while adhering to rigorous safety and environmental standards.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Analyze the heat transfer mechanisms within the radiant and convective sections.
• Optimize combustion efficiency through excess air and oxygen control.
• Manage furnace draft and damper positions to ensure stable firing.
• Implement Burner Management System (BMS) logic and safety interlocks.
• Monitor heater tube integrity and identify signs of coking or oxidation.
• Interpret infrared thermography data to locate tube hot spots.
• Execute safe startup, purging, and shutdown procedures for heaters.
• Troubleshoot burner flame instability, lifting, and flashback issues.
• Calculate the heater's thermal efficiency and identify sources of heat loss.
• Manage NOx and CO emissions through combustion tuning.
• Coordinate the response to process tube leaks and emergency trips.
• Evaluate the impact of fuel gas composition changes on heater performance.

TARGET AUDIENCE:

This course is intended for Plant Operators, Process Engineers, Maintenance Technicians, and Combustion Specialists responsible for the operation and upkeep of fired process heaters and furnaces.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.