COURSE OVERVIEW:

Fired heaters and boilers are the primary thermal energy sources in refineries and petrochemical plants, operating under extreme conditions that demand rigorous inspection and integrity management. This course provides a comprehensive technical guide to the mechanical design, operational safety, and inspection protocols for these critical assets. Participants will explore the specific degradation mechanisms that affect heater tubes, refractory linings, and combustion systems, ensuring they can identify potential failures before they lead to hazardous incidents.

The scope of this training focuses on the application of industry standards such as API 573 and ASME Section I and IV for the inspection of fired equipment. We will analyze the heat transfer processes within the radiant and convection sections, examining how flame impingement, fuel quality, and burner performance impact the longevity of internal components. The course details the specialized NDT techniques used for tube thickness measurement and weld inspection, as well as the procedures for assessing refractory health and casing integrity.

Coverage includes detailed modules on common failure modes, including creep, oxidation, and sulfidation of heater tubes. Attendees will learn how to conduct thorough internal and external inspections, evaluate the effectiveness of soot blowers, and manage the water chemistry required to prevent boiler scale and corrosion. By mastering these inspection and integrity practices, participants will be able to improve the thermal efficiency of their equipment, extend its service life, and ensure compliance with stringent safety regulations.

COURSE OBJECTIVES:

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

• Identify the major components and design types of fired heaters and boilers.
• Apply API 573 standards for the inspection of refinery-fired equipment.
• Analyze the causes of tube overheating and flame impingement.
• Execute visual inspections of burners, pilots, and combustion air systems.
• Evaluate the condition of refractory linings and insulating firebricks.
• Utilize specialized NDT techniques for tube thickness and creep detection.
• Monitor boiler water chemistry to prevent internal scaling and corrosion.
• Identify signs of external corrosion under insulation (CUI) on heater casings.
• Conduct pressure tests and leak detection for heater and boiler tubes.
• Assess the integrity of soot blowers and air preheaters.
• Determine the remaining life of heater tubes using engineering calculations.
• Troubleshooting combustion issues and flue gas oxygen levels.
• Develop a comprehensive inspection plan for planned turnaround events.
• Implement safety procedures for entering and inspecting fired equipment.

TARGET AUDIENCE:

Inspection Engineers, Refinery Operators, Maintenance Technicians, Boiler Engineers, and Mechanical Integrity Specialists responsible for thermal equipment.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.