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Process Engineering in Fired Heater

Fired heaters are simply the heart of those process plants which have it. Through them massive energy is provided to the process and reactions like cracking [Ethylene Plants] or reforming [Ammonia, Methanol and Hydrogen Plants]. Both fired heaters design and operation requires a great deal of knowledge and experience and it takes years for one to master it.

Don’t worry, we make it easy for you, we start from beginning and finish it with you becoming professional.

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Process Engineering in Fired Heater

Who should take this course?

1.Process engineers

2.Control room operators

3.Chemical engineers

4.Mechanical engineers

Who should take this course?

1.Process engineers

2.Control room operators

3.Chemical engineers

4.Mechanical engineers

Process Description

Session 1: Introduction

In this section, the trainer provides an amazing introduction on components and sections of a process fired heater with an easy approach. At the end of this course, you will get how important this session was! In this session you will learn about:

– Process Fluid Heating Section

– Fuel Supply and Burner Control Section

– Combustion Air Supply Section, where forced air supply or air preheater (APH) is installed

Session 2: PFD description

In this part the instructor describes the complex process happening in fired heaters so clearly and simply even if you are a non-process or non-chemical engineer, you get the whole story. Since the fired heater in ammonia, methanol and hydrogen-related plants are the most complex among other plants and more importantly, recently these plants are in trend, the instructor spends his time talking about catalyst tubes, burners and convection section.

P&ID Development

Session 3: P&ID development

In this session, he instructs how P&ID for a typical fired heater could be developed and which design notes should be included or shown when preparing P&ID. In this regard, he develops a page for process fluid heating section, a page for fuel section, a page for combustion air and flue gas, and a page for additional connections and information.

Control System

In this part, the instructor starts from basic of control system for fuel, combustion air and convection sections and goes deep in each in three sessions.

Session 4: Combustion air control system

He presents which equations are used for combustion air adjustment in industrial fired heaters and how those equations and statements are converted to logic diagram form, which should be delivered by licensor or vendor to instrument department to implement it in DCS during project phase.

Session 5: Fuel control system

In this session, he elaborates on the followings:

1. Typical control philosophy

2. Complex loop and calculators

Advanced control (Split-range + feedforward and feedback control loop)

ESD for Fired Heaters

Session 6: causes of fired heater trips

In this session numerous trip causes prevalent in all fired heater designs are stated which should be taken into account for interlock and logic diagram.

Session 7: Interlock diagram

In this session you are taught how to convert trip causes into interlock diagram.


Session 8: Unloading and loading of catalysts

The following subjects are discussed:

1. Catalyst unloading notes

2. Inspection of tubes and cleaning

3. Pressure drop measurement across empty tubes

4. Pressure drop measuring device

5. Cleaning and Screening of Catalyst

6. Loading of the Catalyst

7. Box-up

8. Refractory dry-out preparation

9. Refractory dry-out procedure


Session 9: Purge and Leak test

The speaker presents the following about purge and leak test:

1. Objectives

2. Procedure

3. Design notes

4. Logic

Session 10: Fired heater start-up

The followings are discussed throughout the session:

1. Loop warm-up and operational notes

2. Burner sequence and operational notes

3. Natural Gas injection and operational notes

4. Normal Operation

Our Mistakes

Session 11: Design mistakes

Session 12: Operational mistakes

1. Can you prepare a purge and leak test logic for a new fired heater?

2. Can you start-up a fired heater?

3. How much do you know about dry-out procedure?

4. How much do you know about advanced control and complex loops used for fuel control?

5. Do you know why and when APH and draft dampers are installed?

6. Can you develop P&ID for a typical fired heater?


Be honest with yourself and for each question give yourself a score out of 10. If the sum is less than 30, then take the course; if the score is between 30 to 50, consult with us. If it is more than 50, we think you don’t need to take it.

1.The Process Engineering in Fired Heaters course will be available in both online and offline modes to enthusiasts. By online mode, the enthusiasts can participate in online classes while by offline mode, the enthusiast can only watch offline videos after purchasing the package.

2.Notice that the enthusiasts who choose online mode will also receive offline package so that they can review what they have learned in online classes.

3.It is obvious that in both modes, the whole package including videos, documents, excelsheets will be provided.

Mode : Offline Videos

After registration you will receive offline and recorded videos for lifetime access.

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