COURSE OVERVIEW:

Cooling and utility heat exchangers are essential components within industrial facilities, responsible for managing thermal energy and ensuring process fluids remain within safe operational limits. This course explores the mechanical integrity and thermal efficiency of these units, focusing on the various designs used for utility services such as cooling water, steam, and chilled media. Participants will gain a comprehensive understanding of how material selection and fluid dynamics influence the long-term reliability of heat transfer equipment.

The scope of this training covers the complete lifecycle of utility heat exchangers, from initial inspection protocols to advanced maintenance strategies. We will examine the specific degradation mechanisms that affect these units, including various forms of corrosion, fouling, and mechanical fatigue. By understanding the root causes of efficiency loss, technical personnel can implement more effective cleaning and repair procedures that minimize downtime and extend the service life of the assets.

Furthermore, the course provides detailed guidance on regulatory compliance and industry best practices for pressure vessel maintenance. Attendees will learn how to interpret inspection data, perform tube bundle repairs, and manage gasket integrity to prevent leaks. This coverage ensures that maintenance teams are equipped with the practical skills needed to maintain peak performance in utility systems while adhering to stringent safety and environmental standards.

COURSE OBJECTIVES:

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

1. Distinguish between different types of utility heat exchangers and their specific applications.
2. Identify common types of corrosion and erosion found in cooling water systems.
3. Perform detailed visual inspections of tube bundles, shells, and channels.
4. Evaluate the impact of fouling on heat transfer coefficients and pressure drops.
5. Apply appropriate non-destructive testing (NDT) methods for tube integrity assessment.
6. Execute professional tube plugging and sleeving techniques according to standards.
7. Select the correct gasket materials and bolting procedures to ensure leak-free joints.
8. Develop effective chemical and mechanical cleaning programs for exchangers.
9. Analyze the causes of vibration-induced tube failures and implement fixes.
10. Interpret hydro-testing results and safety requirements for pressure equipment.
11. Implement a structured preventive maintenance schedule for utility exchangers.
12. Assess the remaining life of equipment based on wall thickness measurements.
13. Coordinate maintenance activities during major plant shutdowns and turnarounds.

TARGET AUDIENCE:

This course is intended for Mechanical Maintenance Engineers, Inspection Engineers, Plant Operators, Maintenance Technicians, and Reliability Engineers working in refineries, power plants, and manufacturing facilities.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.