About the Training

Steam Methane Reformers are critical assets, and their operation requires a clear understanding of process fundamentals, combustion systems, furnace design intent, and practical operating limits. This training program is developed to strengthen the technical capability of operators and engineers through practical instruction supported by real field case studies, rather than theoretical discussions alone.

The program is typically delivered as an on-site, classroom-based training and customized to reflect the specific design and operating practices of the host facility.

    • SMR Operators

    • Shift Supervisors

    • Process Engineers

    • Maintenance and Inspection Engineers

    • Technical Services and Reliability Personnel

    Applicable Industries:

    • Methanol Plants

    • Hydrogen and Ammonia Plants

    • Refineries and Petrochemical Facilities

  • Common Challenges in SMR Heater Operation:

    • Tube failures, afterburning, overfiring risks

    • Inefficient firing, poor reformer balancing

    • Limited understanding of design intent vs actual operation

    • Inadequate troubleshooting during plant upsets

    • Safety incidents caused by improper startup/shutdown

    This training directly addresses these challenges using real field experience — not textbook theory.

  • The objective of this training is to enable participants to:

    • Understand SMR process fundamentals and operating sensitivities

    • Operate reforming furnaces safely within design limits

    • Identify early warning signs of abnormal operation and tube distress

    • Improve reformer balancing, firing practices, and draft control

    • Apply effective inspection, tuning, and troubleshooting practices

    • Respond confidently to plant upsets, startups, and shutdowns

Course Coverage

SMR Process & Catalysts

  • Feedstocks and operating conditions

  • Steam-to-carbon ratio and reformer outlet temperature

  • Catalyst types, ageing, poisons, and pressure drop

Radiant Section & Catalyst Tubes

  • Firebox and firing arrangements

  • Reformer tube design, metallurgy, and supports

  • Thermal growth and mechanical considerations

Burners, Draft & Refractory

  • Burner design and combustion systems

  • Burner Management Systems (BMS)

  • FD/ID fans, excess air, and draft control

  • Refractory types and heat loss reduction

Convection Section & Heat Recovery

  • Feed preheating and waste heat recovery

  • Steam generation systems

  • Auxiliary firing in convection sections

Operation & Troubleshooting

  • Reformer balancing and tuning

  • Startup and shutdown practices

  • Flame patterns and instrumentation

  • Tube leaks, overfiring, afterburning

  • Case studies based on operating SMR units

Training Format

  1. Delivery: On-site, instructor-led classroom sessions

  2. Duration: Typically 3 days (approximately 18 hours)

  3. Language: Clear, practical English suitable for operators and engineers

  4. Assessments: Pre- and post-training evaluations

  5. Certification: Certificate of Completion issued by FIS

Customization Approach

Where required, the training can be customized using plant-specific information, including:

  • Heater drawings and layouts

  • P&IDs and operating data

  • DCS trends and operating philosophy

  • Site-specific operating and maintenance challenges

This ensures the training remains directly applicable to the facility’s SMR units.

From Our Clients

FIS recently conducted a 3-day, on-site SMR training program at Brunei Fertilizers Industries (BFI). The program was customized to the BFI reforming furnaces and focused on safe operation, reformer balancing, inspection practices, tuning, startup and shutdown philosophy, and troubleshooting based on actual operating scenarios.

Mr. Ashutosh Garg
VP, Furnace Improvements Services

Your Instructor

  • 50+ years of experience in fired heaters & combustion systems

  • IIT Kanpur – Chemical Engineering (1974)

  • Formerly with KTI Corporation & EIL

  • Published author on fired heaters & burners

  • Registered Professional Engineer

  • Member of AIChE, ASME, API Heat Transfer Committee

Has trained operators and engineers across the USA, Europe, and India.

Ready to Improve SMR Heater Safety & Performance?

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