COURSE OVERVIEW:

Heat exchangers are vital components in process plants, and their failure can lead to significant production losses, environmental hazards, and safety risks. This course provides a detailed technical analysis of the integrity challenges faced by shell-and-tube heat exchangers, with a specific focus on the vulnerability of the tube bundle. Participants will learn to identify the various degradation mechanisms that affect heat transfer efficiency and structural soundness, ranging from vibration-induced wear to complex corrosion phenomena.

The scope of this training addresses the full lifecycle of heat exchanger integrity, from initial material selection to advanced in-service inspection and repair strategies. We will examine the specific NDT techniques used for tube inspection, such as Eddy Current Testing (ECT), Internal Rotary Inspection Systems (IRIS), and Remote Field Electromagnetic Technique (RFET). The curriculum emphasizes the root cause analysis of common tube failures, including inlet erosion, stress corrosion cracking, and flow-induced vibration, providing attendees with a framework for effective troubleshooting.

Coverage includes the development of robust inspection plans and the application of Risk-Based Inspection (RBI) to heat exchanger fleets. Attendees will investigate mitigation strategies such as chemical treatment, cathodic protection, and the use of protective inserts or coatings. By the end of this course, participants will be equipped to manage heat exchanger integrity programs effectively, ensuring high availability and minimizing the frequency of unplanned bundle replacements.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Identify the primary mechanical and thermal components of shell-and-tube heat exchangers.
• Analyze common tube failure mechanisms including erosion, pitting, and galvanic corrosion.
• Explain the phenomenon of flow-induced vibration and its impact on tube-to-baffle wear.
• Differentiate between various tube inspection technologies (ECT, IRIS, RFT, and NFT).
• Select the most appropriate NDT method based on tube material and expected damage.
• Evaluate the integrity of tube-to-tubesheet joints and seal welds.
• Interpret tube inspection reports to determine the percentage of wall loss and remaining life.
• Apply plugging criteria and calculate the maximum allowable number of plugged tubes.
• Implement chemical cleaning and mechanical descaling procedures safely.
• Recommend material upgrades and liners to mitigate recurring corrosion issues.
• Develop a Risk-Based Inspection strategy for heat exchanger bundles.
• Assess the effectiveness of cathodic protection systems in exchanger water boxes.

TARGET AUDIENCE:

This training is intended for Integrity Engineers, Maintenance Engineers, Heat Exchanger Specialists, Inspection Technicians, Reliability Engineers, and Asset Managers responsible for the performance of thermal equipment.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.