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ONL 125 - Process Fired Heaters/Furnaces: Safe Operation and Troubleshooting

Code Start Date Duration Venue
ONL 125 08 December 2020 1 Days Online Registration Form Link
ONL 125 05 January 2021 1 Days Online Registration Form Link


Course Description

Fired process heaters are critical equipment and the major consumer of energy in process plants, and their proper operation is integral to their safety, reliability, production capacity, and profitability. 

This 1 day on-line course provides the theoretical knowledge and practical skills required to improve the operation, profitability, and safety of a plant’s fired heaters.

Course Objectives

  • Analyse and troubleshoot fired heater performance
  • Apply techniques for safe operation, to improve efficiency, and to minimize emissions, corrosion and fouling
  • Gain practical means to increase heater duty, process flow and efficiency

Who Should Attend?

  • Operation Engineers/Team Leaders/Supervisors & Operators
  • Process Engineers/Designers
  • Mechanical Engineers/ Project Engineers
  • Maintenance Personnel
  • Inspection, Materials, Environmental and Safety Engineers


Session 1: 

  • Refinery and Petrochemicals Process Heaters 
  • Furnace Main Components
  • Process Coils and Tube Skin Thermocouples
  • Control strategy SIS and Emergency shutdown system (ESD)
  • Fired Heaters Operation Variables

Session 2: 

  • Fuels, Emissions and Combustion Reactions
  • Fired Heaters Combustion fundamentals
  • Combustion Reactions, Stoichiometry and Excess Air
  • Fired Heaters Fuel and Flow Variables control
  • Burner Management System Logic, and Interlock 

Session 3: 

  • Proactive Heater Operational Assessment 
  • Heater Operation Control and Safe Practices
  • Heater Performance Assessment
  • Periodic Heater Inspections (Burners, Flame Patterns, Coils, Refractories)
  • Draft and Excess Air Continuous Control


  • Heater Performance & Efficiency Evaluation and Troubleshooting 
  • Operational Monitoring Trends and Adjustments
  • Troubleshooting Typical fired heater problems and root causes
  • Heater run length factors  
  • Coke Formation and Anti-Coking 
  • Safety and Operational Practices