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Fired Process Heater Operator Course

Introduction

Fired Process Heater Operator Course

Course Objectives

• Explain how fired heaters function and the role that each part plays
• Describe key operating parameters and standard protocols to follow
• Appraise the performance of heat transfer equipment and identify any gaps
• Recognise the best practice operation procedures of heat exchangers and implement them in different environments
• Detect the problems of heat exchangers and discuss the feasibility of the recommended solutions in various circumstances
• Classify safe operation procedures for fired heaters and discuss how they can be implemented
• Distinguish and list the applicable codes and guidelines for fired heaters and plan to benchmark them in your organisation
• Recognise typical problems in the equipment or its utilisation and identify possible causes and resolutions
• Discuss key inspection and turnaround items, assess potential risks and develop a risk management and business continuity plan

Who Should Attend?

This Certified Fired Process Heater Operator Course would be suitable for:

• Process Engineers/Designers
• Mechanical Engineers/Designers
• Heat Transfer Engineers/Designers
• Supervisors and Operators
• Process Plant Shift Leaders
• Environmental and Safety Technicians
• Mechanical Technicians
• Maintenance Engineers
• Project Engineers/Managers
• Maintenance Personnel
• Machine and Technical Operators
• Individuals interested or involved in the design, specification, and retrofitting of fired heaters

Course Outline

Module 1: Fundamentals of Heat Transfer and Combustion Protocols

• Introduction to Conduction, Convection, and Radiation
• Fouling and Heat Transfer
• Combustion Reactions
• Lean, Rich, and Stoichiometric Combustion
• Excess Air and Combustion Efficiency
• Premixed and Diffusion Combustion
• Techniques for NOx Control

Module 2: Shell and Tube Heat Exchangers

• Different Types of Heat Exchangers
• Shell and Tube Heat Exchangers: Performance
• Shell and Tube Heat Exchangers: Operation
• Monitoring and Solving Issues in Shell and Tube Heat Exchangers

Module 3: Compact Heat Exchangers

• Main Components of Air-Cooled Heat Exchangers
• Operation of Air-Cooled Heat Exchangers
• Troubleshooting of Air-Cooled Heat Exchangers
• Types of Plate Heat Exchangers
• Main Components of Plate Heat Exchangers
• Compact Heat Exchangers: Performance
• Operation of Plate Heat Exchangers
• Troubleshooting of Plate Heat Exchangers

Module 4: Components and Their Role In The Operation of Fired Heaters

• Taxonomy of Fired Heaters
• Application of Fired Heaters
• Parts of Fired Heaters
• Control of a Fired Heater
• Operating a Fired Heater
• Responding to Abnormal Operating Conditions

Module 5: Monitoring and Troubleshooting of Fired Heaters  

• Aspects Affecting the Performance of Fired Heaters
• Optimizing Fired Heater Operation
• Performance Monitoring
• Draft, Coking, and Skin Temperature
• Troubleshooting of Fired Heaters

Module 6: Deterioration Mechanisms

• Deterioration of Fired Heaters
• Deterioration of Boiler Tubes
• Deterioration Mechanisms of Other Components

Module 7: Frequency and Timing of Inspections

• Fired Heaters Inspection Frequency
• Inspector Qualifications
• General Preparatory Work