COURSE OVERVIEW:

Heat exchangers are the thermal lungs of the process plant, and their efficiency directly determines the profitability and energy footprint of the facility. This course provides a comprehensive exploration of heat transfer performance monitoring, specifically focusing on the mechanisms of fouling, the "silent killer" of exchanger efficiency. Participants will analyze the different types of fouling, including crystallization, sedimentation, and biological growth, and how these layers add thermal resistance and increase pressure drops across the system.

The curriculum covers the advanced mathematical models used to calculate the "Heat Transfer Coefficient" (U-value) and "Fouling Factor" in real-time. We will examine how to interpret process data from the DCS to identify the optimal point for cleaning, moving away from "calendar-based" maintenance to "condition-based" interventions. Detailed coverage is provided on the design of exchangers to mitigate fouling, including the use of inserts, specialized coatings, and optimized flow velocities.

A significant portion of the course is dedicated to the technical evaluation of cleaning methodologies. Attendees will compare the effectiveness of mechanical cleaning, such as high-pressure water jetting and pigging, against chemical cleaning (CIP) and thermal methods. By the end of this training, participants will be equipped to develop a proactive fouling management strategy that maximizes the run-length of heat exchangers while minimizing the environmental impact of cleaning chemicals and water usage.

COURSE OBJECTIVES:

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

1.  Calculate the thermal efficiency and heat duty of an exchanger.

2.  Identify the six major types of fouling and their root causes.

3.  Interpret pressure drop data to determine the severity of tube-side fouling.

4.  Utilize "Fouling Resistance" calculations to plan maintenance intervals.

5.  Evaluate the impact of water chemistry on cooling water heat exchangers.

6.  Compare mechanical cleaning methods versus chemical cleaning protocols.

7.  Implement "Clean-In-Place" (CIP) systems for process exchangers.

8.  Assess the risks of "under-deposit corrosion" caused by fouling.

9.  Select specialized tube inserts to enhance turbulence and reduce fouling.

10.  Monitor the performance of "Air-Cooled" heat exchangers (fin-fans).

11.  Develop a cost-benefit analysis for various cleaning technologies.

12.  Manage the environmental disposal of heat exchanger cleaning waste.

13.  Design a comprehensive performance tracking program for the plant.

TARGET AUDIENCE:

Process Engineers, Maintenance Engineers, Operations Supervisors, and Plant Chemists are involved in heat transfer equipment management.

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.