Certified Fired Process Heater Operator

Why Select this Training Course?

Certified Fired Process Heater Operators are responsible for the smooth and highly efficient working conditions in industrial facilities. They start, shut down, monitor, and change burner settings, fuel, and airflow to ensure the heaters work efficiently. They are also responsible for routine maintenance and inspections to maintain equipment reliability and comply with all environmental regulations.

The Rcademy Certified Fired Process Heater Operators training program is designed to provide you with a comprehensive understanding of the design parameters and limitations of thermal/hydraulic heaters that are fired by oil and/or gas. The course covers a wide range of topics, including furnace design, process factors, field inspection of fired heaters, troubleshooting everyday complications with heaters, heater operation, instrumentation, inspection and turnaround procedures, emission, and new heater designs. Through theoretical training, practical exercises, and hands-on training, participants will gain the knowledge and experience necessary to excel in furnace operation and achieve on-the-job field excellence.

What is the process of a fired heater?

Fired heaters harness all three heat transfer mechanisms: conduction, convection, and radiation. Radiation involves the transmission of energy from a heat source to objects through space. In fired heaters, this occurs as tubes exposed to flames in the radiant section absorb heat energy. Convection entails heat transfer through fluid movement, such as gases flowing over process tubes in the convection section. Lastly, conduction transfers heat through direct contact between materials or within an object. In fired heaters, conduction happens as heat moves from the tube walls to the fluid flowing inside.

What is the difference between a fired heater and a reformer?

A fired heater functions as a heat exchanger, facilitating heat exchange from the flame generated by burning fuel with the process fluid circulated within tube(s).

On the other hand, a reformer operates as an endothermic reactor. Heat is needed to initiate a reaction, and this heat comes from a flame outside the tubes. Typically, the reaction occurs within tube(s) packed with a solid catalyst to facilitate the reaction.

Despite their differing purposes, both pieces of equipment often share a similar external appearance due to their configuration and construction.

Who Should Attend?

The Rcademy Certified Fired Process Heater Operator Course is ideal for:

• Process engineers/designers who design and optimise fired process heaters.
• Mechanical engineers/designers who contribute to the mechanical aspects of fired process heater design and operation.
• Process plant shift leaders responsible for overseeing the operation of fired process heaters within industrial plants.
• Mechanical technicians and maintenance personnel who perform maintenance and troubleshooting tasks on fired process heaters.
• Environmental and safety technicians who ensure compliance with environmental and safety regulations during fired process heater operation.
• Maintenance engineers who develop maintenance strategies and plans for fired process heaters.
• Project engineers/managers who oversee the installation and commissioning of fired process heaters.
• Machine and technical operators who operate and monitor fired process heaters during normal operation.
• Individuals interested or involved in the design, specification, and retrofitting of fired heaters.

What are the Course Objectives?

After successful completion of the Rcademy Certified Fired Process Heater Operator course, participants will be able to:

• Explain the operational principles of fired heaters and elucidate the function of each component.
• Describe critical operating parameters and adhere to established protocols.
• Evaluate the performance of heat transfer equipment, identifying areas for improvement.
• Apply best practices in heat exchanger operation across various settings.
• Identify issues with heat exchangers and evaluate proposed solutions within diverse contexts.
• Implement safe operating procedures for fired heaters, emphasising practical application.
• Identify relevant codes and guidelines governing fired heaters and devise strategies for compliance within organisational frameworks.
• Recognise common equipment problems and their root causes, proposing effective resolutions.
• Analyse key inspection and turnaround considerations, assess associated risks and formulate risk management and business continuity strategies.

How will this Course be Presented?

This participant-centred course is designed to meet the expectations of attendees and enhance their knowledge and skills. Various practical methodologies are incorporated to ensure continuous and engaged learning. Industry-leading professionals with extensive experience deliver the course content, rooted in thorough research on the subject matter.

The Rcademy Certified Fired Process Heater Operator Course offers a blend of theoretical insights and hands-on learning opportunities. Participants gain access to a range of resources, including slides, lecture notes, case studies, video presentations, and real-life scenarios. Interactive quizzes, seminars, and mock sessions enrich the learning experience. Moreover, a feedback platform is established to gather input from participants, ensuring their utmost satisfaction with the course.

What are the Topics Covered in this Course? 

Module 1: Combustion Fundamentals

• Principles of combustion
• Types of fuels and their characteristics
• Stoichiometry and air-fuel ratio
• Combustion efficiency and emissions control

Module 2: Heater Components and Equipment

• Overview of fired heater components
• Burners, fuel systems, combustion controls, and instrumentation
• Heat transfer mechanisms in fired heaters
• Auxiliary systems: air preheaters, draft systems, and fuel handling systems

Module 3: 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 4: 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 5: 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 6: 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 7: Monitoring and Troubleshooting of Fired Heaters

• Aspects affecting the performance of Fired Heaters
• Optimising Fired Heater operation
• Performance monitoring
• Draft, Coking, and Skin Temperature
• Troubleshooting of Fired Heaters

Module 8: Deterioration Mechanisms

• Deterioration of Fired Heaters
• Deterioration of Boiler Tubes
• Deterioration mechanisms of other components

Module 9: Safety in Fired Heater Operations

• Hazard identification and risk assessment
• Personal protective equipment (PPE) requirements
• Fire safety measures and emergency procedures
• Permit-to-work systems and hot work procedures

Module 10: Maintenance and Inspection

• Routine maintenance tasks and schedules
• Inspection procedures for burner assemblies, refractory linings, and heat exchangers
• Lubrication, alignment, and vibration analysis
• Predictive maintenance techniques

Module 11: Frequency and Timing of Inspections

• Fired Heaters inspection frequency
• Inspector qualifications
• General preparatory work

Module 12: Environmental Regulations and Compliance

• Overview of environmental regulations applicable to fired process heaters
• Emissions monitoring and control measures
• Compliance reporting and documentation requirements
• Best practices for environmental stewardship

Module 13: Emerging Technologies

• Advanced combustion control systems
• Low-NOx burners and emissions reduction technologies
• Continuous Emissions Monitoring Systems (CEMS)
• Remote Monitoring and Control Systems
• Energy Management Systems (EMS)
• AI and IoT

Module 14: Emerging Considerations and Trends

• Health and wellness considerations
• E-commerce rise in the fired process heating market
• Eco-friendly and sustainability considerations