Operations and Troubleshooting of Heat Exchangers and Fired Heaters

Start Date End Date Venue Fees (US $)
16 Nov 2025 Dubai, UAE $ 3,900 Register

Operations and Troubleshooting of Heat Exchangers and Fired Heaters

Introduction

This course is designed to provide the participants with a detailed and up-to-date overview on the operation and troubleshooting of heat exchangers and fired heater problems that may occur during operation. The course will also cover the principles of heat transfer and the factors affecting heat transfer, the flow arrangements of fluids inside heat exchangers and the various types and its major components.

During this course, participants will learn to apply the proper procedure in taking out of services and putting in service of heat exchangers, identify the various types of furnaces and the major parts of a horizontal and vertical furnace, recognize the types of gas burner and its properties, apply combustion process, employ furnace start-up, shutdown and troubleshooting, identify the thin tube, hot spot, tube fireside heater, furnace explosion, flame temperature, flame stability and combustion.

Objectives

    Upon the successful completion of this course, each participant will be able to:-

    • Operate and troubleshoot heat exchangers and fired heaters in a professional manner.
    • Discuss the principles of heat transfer and the factors affecting heat transfer
    • Illustrate flow arrangements of fluids inside heat exchangers and identify the types and its major components.
    • Apply proper procedure in taking out of service and putting in service of heat exchangers.
    • List the various types of furnaces and identify the major parts of a horizontal and vertical furnace.
    • Enumerate the types of the gas burner and describe its properties as well as the combustion process.
    • Employ furnace start-up, shutdown and troubleshooting.
    • Identify thin tube, hot spot, tube fire side heater, furnace explosion, flame temperature, flame stability and combustion.
    • Evaluate the performance of heat transfer equipment
    • Identify the best practice operation procedures of heat exchangers
    • Identify the problems of heat exchangers and recommended solutions
    • Identify the safe operation procedures for fired heaters
    • Identify the problems of fired heaters and recommended solutions

Training Methodology

This is a highly interactive training course with opportunities to advance your opinions and ideas. Participation is encouraged in a supportive environment. To ensure the concepts introduced during the program are understood, they will be reinforced through a mix of learning methods, including lecture-style presentation, open discussion, case studies, simulations and group work.

Who Should Attend?

This course provides an overview of all significant aspects and considerations of heat exchangers and fired heaters operation for process engineers, section heads, shift controllers, shift supervisors, operators and for those who are interested in heat exchangers and furnaces.

  • Supervisors and Operators
  • Process Plant Shift Leaders
  • Environmental and Safety Technicians
  • Mechanical Technicians
  • Maintenance Engineers

Course Outline

DAY 1: Basics of Heat Transfer and Combustion

  • Conduction, Convection and Radiation
  • Fouling and Heat Transfer
  • Combustion Reactions
  • Lean, Rich and Stoichiometric Combustion
  • Excess Air and Combustion Efficiency
  • Premixed and Diffusion Combustion
  • Techniques for NOx Control

DAY 2: Shell and Tube Heat Exchangers

  • Types of Heat Exchangers
  • Main Components of Shell and Tube Heat Exchangers
  • Operation of Shell and Tube Heat Exchangers
  • Factors Affecting the Performance of Shell and Tube Heat Exchangers
  • Troubleshooting of Shell and Tube Heat Exchangers

DAY 3: Compact Heat Exchangers

  • Main Components of Air Cooled Heat Exchangers
  • Operation of Air Cooled Heat Exchangers
  • Troubleshooting of Air Cooled Heat Exchangers
  • Types of Plate Heat Exchangers
  • Main Components of Plate Heat Exchangers
  • Factors Affecting the Performance of Compact Heat Exchangers
  • Operation of Plate Heat Exchangers
  • Troubleshooting of Plate Heat Exchangers

DAY 4: Components and Operation of Fired Heaters

  • Classification of Fired Heaters
  • Application of Fired Heaters
  • Parts of Fired Heaters
  • Control of a Fired Heater
  • Operating a Fired Heater
  • Responding to Abnormal Operating Conditions
  • Case Studies

DAY 5: Monitoring and Troubleshooting of Fired Heaters  

  • Factors Affecting the Performance of Fired Heaters
  • Optimizing Fired Heater Operation
  • Performance Monitoring
  • Draft, Coking and Skin Temperature
  • Troubleshooting of Fired Heaters
  • Case Studies

Accreditation

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