Course Details

Objective

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

• Understand the basic principles of process heater operation.
• Identify the different types of process heaters and their applications.
• Learn how to select the appropriate process heater for specific industrial processes.
• Understand safety measures and operational guidelines for process heaters.
• Troubleshoot and maintain process heaters to ensure efficient and reliable performance.

Content

COURSE PROGRAM:

Day 1: Introduction to Process Heaters

• Overview of process heaters and their role in industrial processes
• Basic principles of heat transfer and the heating process
• Types of process heaters (direct-fired, indirect-fired, electrical, steam)
• Applications of process heaters in various industries (chemical, petrochemical, power, food processing)

Day 2: Components and Types of Process Heaters

• Key components of process heaters (burners, heat exchangers, controllers, valves)
• Differences between direct and indirect fired heaters
• Electric heaters vs. combustion-based heaters
• Heat transfer methods (conduction, convection, radiation)

Day 3: Selection and Sizing of Process Heaters

• Criteria for selecting process heaters based on application and fluid properties
• Calculating heating capacity and sizing process heaters
• Temperature and pressure requirements in the selection process
• Evaluating fuel types and energy efficiency considerations

Day 4: Operation, Control, and Safety of Process Heaters

• Operating principles of process heaters
• Control systems and temperature regulation
• Safety protocols and standards for operating process heaters
• Common safety issues (overheating, pressure relief, fire hazards)
• Best practices for ensuring safe and efficient heater operation

Day 5: Troubleshooting and Maintenance of Process Heaters

• Common issues in process heaters (flame failure, pressure loss, overheating)
• Diagnostic tools and techniques for troubleshooting
• Routine maintenance tasks for process heaters
• Preventive maintenance strategies to extend heater life and improve efficiency
• Optimizing heater performance and energy consumption

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

………………………………………………………….

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions