COURSE OVERVIEW:

The meaning of thermal performance and efficiency management in heat exchangers refers to the systematic optimization of heat transfer processes to minimize energy loss and maximize thermal recovery in industrial systems. This course focuses on the critical role of heat exchangers as the primary energy "recyclers" within refineries, power plants, and chemical facilities. By mastering the engineering of temperature gradients and flow regimes, participants can prevent the massive energy waste associated with fouling, improper design, and sub-optimal fluid dynamics.

The scope of this training encompasses the technicalities of Shell and Tube, Plate and Frame, and Air-Cooled heat exchangers, alongside advanced compact heat exchanger technologies. It examines the impact of fluid properties, Reynolds numbers, and "Log Mean Temperature Difference" (LMTD) on the overall heat transfer coefficient. The course provides a deep dive into the utilization of "Pinch Technology" to design integrated Heat Exchanger Networks (HEN) that minimize the need for external heating and cooling utilities.

Coverage includes the analysis of "Fouling Factors" and their direct impact on fuel consumption, the implementation of automated cleaning systems, and the reduction of pressure drops across exchanger bundles. The course addresses the critical role of material selection in preventing corrosion and ensuring long-term thermal integrity. Participants will gain practical expertise in conducting heat exchanger performance tests, utilizing simulation software for "What-If" efficiency scenarios, and formulating maintenance strategies that prioritize thermodynamic recovery.

COURSE OBJECTIVES:

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

1.  Define the fundamental laws of thermodynamics governing heat exchange.

2.  Calculate the "Overall Heat Transfer Coefficient" for various geometries.

3.  Utilize the "LMTD" and "$\epsilon$-NTU" methods for performance analysis.

4.  Identify the energy impact of "Fouling" and calculate fouling resistance.

5.  Optimize fluid flow rates to balance heat transfer and pressure drop (kW)

1.  Design and analyze Heat Exchanger Networks (HEN) using Pinch Analysis.

2.  Evaluate the efficiency of Plate vs. Shell-and-Tube for specific fluids.

3.  Manage "Air-Cooled" exchanger performance under varying ambient conditions.

4.  Diagnose "Vibration" and "Erosion" issues that lead to efficiency loss.

5.  Utilize "Enhancement Technologies" (inserts/fins) to boost performance.

6.  Conduct systematic thermal audits of industrial heat exchange systems.

7.  Formulate a technical business case for high-efficiency exchanger retrofits.

TARGET AUDIENCE:

This course is designed for Mechanical Engineers, Process Engineers, Maintenance Supervisors, Energy Auditors, and Plant Operators in thermal-intensive industries.

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.