Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Plant Engineers and Technicians
• Maintenance and Reliability Engineers
• Process Engineers and Operators
• Utility Engineers and Supervisors
• Energy Managers
• Anyone involved in the operation, maintenance, inspection, or management of boiler and thermal heating systems

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

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

• Understand the principles of heat generation and transfer in boilers and thermal fluid heaters.
• Differentiate between types of boilers and thermal fluid systems.
• Identify the key components and operational characteristics of both systems.
• Apply safe startup, operation, and shutdown procedures.
• Recognize common operational problems and apply troubleshooting techniques.
• Enhance energy efficiency and reduce operating costs.
• Understand maintenance practices for prolonging equipment life and ensuring reliability.

DAY 1

Fundamentals of Heat Generation and Fluid Heating Systems

• Welcome and introduction
• Pre-test
• Introduction to industrial heating systems
• Basics of heat transfer: conduction, convection, and radiation
• Comparison: Boilers vs. Thermal Fluid Heaters
• Applications and industries using each system
• Energy sources: fuels, electricity, waste heat

DAY 2

Boiler Systems – Types, Components, and Operation

• Classification: fire-tube, water-tube, electric, etc.
• Boiler components: burners, feedwater systems, controls
• Combustion principles and fuel types
• Boiler operation cycles: startup, loading, and shutdown
• Steam quality and pressure considerations

DAY 3

Thermal Fluid (Hot Oil) Heaters – Systems and Applications

• Types of thermal fluid heaters
• Characteristics of thermal oils and selection criteria
• System components: heaters, expansion tanks, pumps, piping
• Temperature control and system monitoring
• Comparison to steam systems: pros and cons

DAY 4

Safety, Troubleshooting, and Maintenance

• Common operational issues and root causes
• Safety practices and regulatory standards
• Monitoring and control systems
• Inspection techniques and preventive maintenance
• Troubleshooting case studies (both boilers and heaters)

DAY 5

Energy Efficiency, Optimization, and Case Studies

• Heat recovery and energy-saving techniques
• Boiler efficiency improvement strategies
• Thermal fluid system optimization
• Case studies from various industries
• Interactive group exercise
• Post-test
• Certificate ceremony