PROCESS FIRED HEATERS – OPERATION AND TROUBLESHOOTING COURSE

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