Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Operation and Maintenance Engineers
• Mechanical and Process Engineers
• Plant Technicians and Supervisors
• Instrumentation and Control Personnel
• Reliability and Energy Efficiency Specialists
• Anyone involved in operating or maintaining fired heaters and combustion systems

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand combustion principles and fuel characteristics
• Identify components and operations of various fired heater types
• Analyze heat transfer and combustion efficiency
• Apply proper start-up, shutdown, and burner management procedures
• Diagnose and troubleshoot combustion and heater performance problems
• Implement safe operating and maintenance practices

DAY 1

Introduction to Combustion and Fired Heaters

• Welcome and Introduction
• Pre-Test
• Fundamentals of Combustion
• Fuels, Air Requirements, and Stoichiometry
• Types and Configurations of Fired Heaters
• Heat Transfer Mechanisms: Radiation, Convection, Conduction
• Overview of Burner Design and Operation
• Safety Considerations in Combustion Systems

DAY 2

Combustion Equipment and Controls

• Main Components of Fired Heaters

• Burners, Air Registers, Dampers, and Fuel Trains

• Combustion Air and Draft Systems
• Flame Detection and Ignition Systems
• Burner Management Systems (BMS)
• Instrumentation and Control Loops
• Heater Efficiency and Air-Fuel Ratio Control

DAY 3

Operation and Performance Optimization

• Heater Start-up and Shutdown Procedures
• Normal Operating Conditions and Monitoring
• Temperature and Pressure Profiles
• Factors Affecting Heater Efficiency
• Heat Distribution and Flame Pattern Control
• Emissions Reduction and Environmental Compliance
• Performance Evaluation and Data Analysis

DAY 4

Maintenance and Inspection Practices

• Routine Maintenance Procedures
• Tube Cleaning and Inspection
• Refractory and Insulation Maintenance
• Burner Overhaul and Calibration
• Inspection of Air and Flue Gas Paths
• Preventive and Predictive Maintenance Techniques
• Safety Interlocks and Emergency Shutdown Systems

DAY 5

Troubleshooting and Reliability Improvement

• Common Operational and Maintenance Problems
• Troubleshooting Combustion Instability and Flame Failures
• Identifying Efficiency Losses and Mechanical Issues
• Heater Reliability and Performance Improvement Strategies
• Post-Test
• Certificate Ceremony