COURSE OVERVIEW:

Heat exchangers are fundamental process units that facilitate the efficient transfer of thermal energy between fluids without direct contact. This course provides a comprehensive engineering perspective on the design principles of shell and tube, plate and frame, and air-cooled exchangers. Participants will explore the mechanical architecture of these units, focusing on the selection of configurations—such as fixed tubesheet, U-tube, or floating head to accommodate thermal expansion and high-pressure differentials.

The operational segment of the training emphasizes the practical management of heat transfer duty and the prevention of mechanical failure. We will detail the physics of fluid flow, focusing on the prevention of vibration-induced tube damage and the management of "temperature cross" scenarios.

Coverage includes the critical role of baffles and tie rods in directing flow and supporting the bundle, as well as the importance of proper venting and draining to maintain the integrity of the heat transfer surfaces.

The maintenance and repair curriculum provides a deep technical dive into the restoration of exchanger performance. Participants will study the latest techniques for tube plugging, bundle pulling, and the repair of tubesheet-to-shell joints. By analyzing common degradation mechanisms like impingement erosion and galvanic corrosion, attendees will learn how to execute precision repairs that meet ASME Section VIII and TEMA standards, ensuring the long-term reliability of the plant’s thermal assets.

COURSE OBJECTIVES:

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

1.  Distinguish between various TEMA types and their industrial applications.

2.  Apply ASME Section VIII Division 1 codes for heat exchanger design.

3.  Interpret heat exchanger data sheets and mechanical drawings.

4.  Manage startup and shutdown thermal ramping to prevent tubesheet stress.

5.  Identify the root causes of flow-induced vibration in tube bundles.

6.  Execute precision tube plugging according to industry-accepted procedures.

7.  Perform bundle pulling and re-insertion without damaging the shell.

8.  Evaluate the integrity of gasket seating surfaces on exchanger flanges.

9.  Diagnose internal bypass and fluid leaking between stages.

10.  Monitor and calculate the Overall Heat Transfer Coefficient (U-value).

11.  Implement effective cathodic protection for exchanger water boxes.

12.  Conduct hydrotesting and pneumatic testing of the shell and tube sides.

13.  Select appropriate materials for corrosive and high-temperature service.

TARGET AUDIENCE:

Mechanical Maintenance Engineers, Process Operators, Static Equipment Specialists, and Technical Managers responsible for the design and upkeep of thermal equipment.

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.