PROCESS FIRED HEATERS – OPERATION AND TROUBLESHOOTING COURSE
Course Description
DURATION
21 hours (Three (3) days)
TARGET GROUP
The course would be valuable to professionals working with fired process heaters in the petroleum refining, petrochemical, chemical and related industries, such as: –
- Process Engineers/Designers
- Mechanical Engineers/Designers
- Heat Transfer Engineers/Designers
- Project Engineers/Managers
- Maintenance Personnel
- Operators
TARGETED INDUSTRY/INDUSTRIES
Oil & Gas, Petrochemicals, Power Plant, Renewal Energy Plant, Co-Generation Plant, Refineries and others related industries that using process fired heaters.
CERTIFICATION
This course can be certified for the Continuing Professional Development (CPD) Program by the Board of Engineers, Malaysia (BEM).
COURSE OBJECTIVE
This course provides the theoretical knowledge and practical skills required to improve the operation, profitability, and safety of a plant’s fired heaters. Classroom lectures cover furnace design, process considerations, and field evaluation of fired heaters.
Topics such as troubleshooting common heater problems, burner operation, inspection and turnaround items, emissions, instrumentation, and preparation of new heater specifications are also covered.
COURSE OUTCOMES
Upon completion of this course, participant will be able to: –
- Describe the component parts of common refinery heaters
- Analyse and troubleshoot fired heater performance
- Understand the criteria for selecting the appropriate type of heater for a new duty
- Perform calculation for excess air and efficiency
- Apply techniques for safe operation, to improve efficiency, and to minimize emissions, corrosion and fouling
- Explain the structural and mechanical aspects and limitations of fired heaters and ancillary equipment
- Evaluate air pre-heater revamp economics
COURSE CONTENTS
Learning objectives
Fired heater fundamentals
Fired heater types
- Vertical cylinder fired heater
- Cabin type fired heater
- U-tube platforming fired heater
Heat transfer
Radian section
-
- Heat flux
- Mass velocity (in-tube)
- Heat distribution in heater
- Flux distribution around tubes
- Maximum average radiant heat flux
- Radiant heat balance
- Tube wall temperature (TWT)
- Estimated tube wall temperature
- Bridge wall temperature (BWT)
Convection section
-
- Convection section calculations
Efficiency
- Excess air calculation
- Stack loss based on flue gas
- Fuel efficiency exercise
- Efficiency from observation temperatures
Air pre-heating systems
General design consideration
- Codes and Standards
- Design conditions
- Phase conditions
- Orientation
- Pressure drop and tube velocity
- Typical heater design factors
- Design vs normal duty
- Type of fuel
- Sulphur dew point
- Skin thermocouples
Air and Flue Gas Hydraulics:
- Fired Heater Draft Profile
- Natural Draft
- Stack
- Forced and Induced Draft
Tube Design
- Elastic and Creep/Rupture Design
- Determination of Tube Metal Temperature
- Calculation of Tube Thickness
- Tube and Fitting Material/Selection
Refractory/Internal Insulation
- Types
- Thermal Design / Heat Loss
- Mechanical Design
- Selection Criteria
Operations
- Start-up
- Troubleshooting
- Routine Checks/Monitoring
- Mitigation of Fouling and Corrosion