Course Details
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Course Description
Fired process heaters are essential tools in petroleum refineries and plants, chemical plants, and other industrial facilities. Also known as process heaters, they are significantly used in refineries and petrochemical plants because they heat and vaporize the hydrocarbon fluids to create valuable biproducts like diesel, gasoline, and jet fuel. They are a major consumer of energy in such locations, and their correct function is essential for the safety, production capacity, and profitability of the premises.
The Training Course Will Highlight ?
What does BTS’s “Fired Heater Operation and Safety Course” involve? This training program will provide you with detailed insight into the design parameters and limitations of thermal/hydraulic fired process heaters. It will include topics like furnace design, process factors, field appraisal of fired heaters, troubleshooting common heater problems, burner operation, instrumentation, inspection and turnaround items, emissions, and new heater designs.
Training Objective
What does BTS’s “Fired Heater Operation and Safety Course” involve? This training program will provide you with detailed insight into the design parameters and limitations of thermal/hydraulic fired process heaters. It will include topics like furnace design, process factors, field appraisal of fired heaters, troubleshooting common heater problems, burner operation, instrumentation, inspection and turnaround items, emissions, and new heater designs.
Target Audience
Unit contact engineers, design engineers, unit supervisors, and unit operators who must understand how to operate a fired heater safely and/or respond to fired heater operating problems.
Training Methods
This interactive Training will be highly interactive, with opportunities to advance your opinions and ideas and will include:
- Lectures
- Workshop & Work Presentation
- Case Studies and Practical Exercise
- Videos and General Discussions
Daily Agenda
This course is divided into four sections.
Section 1 - Troubleshooting Fired Heater Operations
- Air leaks
- Flame impingement
- Irregular flames
- Burner problems
- Hot spots
- Coke buildup
- Loss in flow
- Flameout
- Feed valve failure
- Fuel gas valve failure
- Tube problems
- Tube support problems
- Instrumentation problems
Section 2 - Safe Operation of a Fired Heater
- Major fired heater components
- Radiant section
- Convection section
- Stack
- Tubes
- Burners
- Fired heater safety hazards
- Emergency shutdown (ESD) systems
- Startup/shutdown procedures
- High tube metal temperatures (TMTs)
- Loss of flow
- Flame out protection
- Other fired heater safety concerns
Section 3 - Optimizing Fired Heater Operation
- Define and describe the term "fired heater efficiency"
- Control of excess oxygen
- Control of fired heater draft
- Monitoring fired heater parameters (e.g., draft, excess air, inlet and outlet temperatures, pass flows, fuel gas pressures)
- Performing visual surveillance of the firebox
- Responding to abnormal operating conditions
- Operation in a turndown mode
- Flow balancing in a multi-pass fired heater
Section 4 - Operating a Fired Heater
- Inspecting the heater
- Proper purging of the heater
- Properly lighting off the pilot
- Properly lighting off the main gas burners
- Making natural draft O2 and draft adjustments
Accreditation
BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.
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