About the Fired Process Heater Operation, Control & Troubleshooting Course

Time Training Center’s 5-day (30-hour) Fired Process Heater Operation, Control & Troubleshooting course offers in-depth training on operating, controlling, and troubleshooting fired heaters and heat exchangers. It focuses on equipment commonly used in industrial facilities, ensuring participants gain practical skills for safe and efficient process heating operations. This program is designed to equip participants with the fundamental principles of heat transfer, fluid dynamics, and practical knowledge for maximising thermal efficiency and operational reliability.

The course covers the design, function, and maintenance of shell-and-tube, air-cooled, and plate exchangers, plus fired heaters, with a a focus on efficiency, emissions reduction, and equipment life extension. Participants will gain expertise in monitoring critical performance parameters, applying safe operating procedures, and implementing emissions control strategies, particularly for NOx mitigation.

Through a blend of theoretical sessions, interactive workshops, and real-world case studies, our course enhances participants' ability to diagnose performance issues, troubleshoot malfunctions, and optimise the performance of heat transfer systems. It empowers professionals to ensure safe, efficient, and reliable operation of critical heating systems in oil, gas, and petrochemical facilities.

Fired Process Heater Operation, Control & Troubleshooting Course Objectives

​By the end of this Fired Process Heater Operation, Control & Troubleshooting course, participants will be able to:​

• Apply the necessary skills to assess and optimise the performance of equipment used in Understand the principles of heat transfer and combustion in fired heater systems
• Design, operate, and troubleshoot shell and tube heat exchangers
• Operate and evaluate air-cooled and plate-type heat exchangers
• Identify performance issues and apply corrective actions for heat exchanger malfunctions
• Understand the classifications, components, and controls of fired process heaters
• Apply safe operating procedures for heat transfer systems and fired heaters
• Monitor critical performance parameters, including draft, skin temperature, and coking
• Optimise fired heater performance for improved thermal efficiency and reliability
• Implement emissions control strategies, particularly for NOx mitigation

Training Methodology

We employ a comprehensive and applied learning strategy, integrating theory with real-world implementation:

• 30% Conceptual Learning: Expert-led sessions on catalytic theory and engineering principles
• 20% Interactive Workshops: Group exercises, presentations, and technical discussion forums
• 30% Case-Based Learning: Industry-specific examples and troubleshooting scenarios
• 20% Technology Integration: Digital tools, simulations, and catalyst modeling applications

Note: Instructors may adjust the training approach to fit technical requirements or participant engagement levels.

Course Instructor:

Our courses are delivered by highly qualified instructors with extensive experience in both industry and academia. With decades of hands-on expertise across a wide range of technical disciplines, our instructors are dedicated to providing high-quality, impactful training that equips participants with practical knowledge and skills they can immediately apply. Full instructor profiles are available upon request.

Course Fees

The course fee includes the following:

• Course Materials: Comprehensive participant materials, including lecture notes, slides, and case study documents. (Tablet or IPAD)
• Coffee/Tea: Provided on arrival and during morning and afternoon breaks to keep participants refreshed.
• Buffet Lunch: Served daily to ensure participants have an opportunity to network and recharge during lunch breaks.

Who Should Attend Our Fired Process Heater Operation, Control & Troubleshooting Course?

This training course is highly beneficial for professionals responsible for the operation, inspection, and maintenance of fired heaters and heat exchanger systems in process plants, including: 

• Supervisors and Control Room Operators
• Process Plant Shift Leaders
• Environmental and Safety Technicians
• Mechanical Technicians and Inspectors
• Maintenance and Reliability Engineers

Course Outline

Module 1: Fundamentals of Heat Transfer and Combustion

• Pre-test assessment of existing knowledge
• Principles of conduction, convection, and radiation
• Effects of fouling on thermal efficiency
• Combustion chemistry: lean, rich, and stoichiometric combustion
• Excess air control and combustion optimization
• Premixed and diffusion flames
• NOx formation and modern emission reduction strategies

Module 2: Shell and Tube Heat Exchangers

• Overview of common heat exchanger types and applications
• Components and construction features of shell and tube exchangers
• Operational principles and performance limitations
• Troubleshooting techniques for thermal inefficiency and mechanical issues

Module 3: Air-Cooled and Plate Heat Exchangers

• Design and components of air-cooled heat exchangers
• Operating considerations and performance optimization
• Types and configurations of plate heat exchangers
• Diagnosing and rectification of operational problems in compact exchangers

Module 4: Fired Process Heaters – Design and Operation

• Classification of fired heaters and typical applications in industry
• Key components: burners, radiant/convection sections, stacks, dampers
• Instrumentation and control strategies for stable heater performance
• Safe operating procedures and handling of abnormal conditions

Module 5: Monitoring, Troubleshooting, and Performance Optimization

• Factors affecting fired heater performance and efficiency
• Real-time monitoring of key parameters: draft, coking, skin temperature
• Techniques to extend run length and reduce energy consumption
• Troubleshooting procedures and root cause analysis
• Best practices for long-term performance optimization and reliability

Module 6: Capstone and Assessment

• Review of Core Topics and Key Learnings
• Final Group Discussion and Q&A
• Post-Test Evaluation
• Certificate Presentation

Course Completion Certificate

Upon completing your course at Time Training Center, you will be awarded an official Course Completion Certificate, recognizing your achievement and the skills you've gained. This certificate validates your expertise and reflects the high standards of training you've undergone.