COURSE OVERVIEW:

The efficient operation of a process plant depends on the seamless interaction between pumps, valves, and heat exchangers. This course provides a comprehensive overview of these three critical components, focusing on how they function together as a system to move, control, and thermally manage process fluids. Participants will gain practical insights into the mechanical design and operational characteristics of each asset class, learning how to optimize their performance while ensuring safety and reliability.

The scope of this training addresses the common operational challenges found in fluid circuits, such as pressure drops, thermal stresses, and flow instabilities. We will examine the various types of pumps used for fluid transport, the valves required for precise flow control and isolation, and the heat exchangers utilized for energy recovery and temperature regulation. The course emphasizes a practical troubleshooting approach, teaching participants how to identify the root cause of system-wide issues that may originate in any of these three components.

Coverage includes detailed modules on failure modes such as cavitation in pumps, seat leakage in valves, and fouling in heat exchangers. Attendees will learn how to interpret process data to detect performance degradation and implement effective maintenance interventions. By the end of this course, participants will be equipped with a holistic understanding of process equipment, enabling them to improve system efficiency, reduce downtime, and enhance the overall productivity of their plant operations.

COURSE OBJECTIVES:

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

• Describe the functional relationship between pumps, valves, and heat exchangers.
• Select the appropriate pump type for specific process fluid requirements.
• Identify the design features and applications of various industrial valves.
• Analyze the heat transfer mechanisms in shell-and-tube and plate exchangers.
• Troubleshoot pump performance issues using head and flow data.
• Diagnose valve malfunctions including sticking, cavitation, and leakage.
• Implement effective cleaning and maintenance strategies for heat exchangers.
• Monitor system parameters to detect fouling and internal scaling.
• Execute safe startup and shutdown procedures for integrated fluid loops.
• Evaluate the impact of valve throttling on pump reliability and energy use.
• Identify common failure modes and root causes for each asset class.
• Apply condition monitoring techniques to assess equipment health.
• Coordinate maintenance activities to minimize system downtime.
• Optimize the efficiency of fluid circuits through better equipment integration.

TARGET AUDIENCE:

Plant Operators, Maintenance Technicians, Process Engineers, Production Supervisors, and Junior Mechanical Engineers involved in process plant operations.

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.