COURSE OVERVIEW:

Shell and tube heat exchangers are the workhorses of thermal management in process plants, facilitating the transfer of heat between fluids across a wide range of pressures and temperatures. Their mechanical integrity is vital for process efficiency and safety, as internal leaks or structural failures can lead to product contamination or hazardous releases. This course provides a deep dive into the mechanical architecture of these units, focusing on the codes, standards, and engineering principles that govern their design, operation, and maintenance.

The scope of this course covers the various TEMA (Tubular Exchanger Manufacturers Association) classifications and the ASME Section VIII design criteria. Participants will explore the intricate components of the exchanger, including tube sheets, baffles, tie rods, and expansion joints, and how these parts interact under thermal stress. The Coverage includes a detailed examination of common degradation mechanisms such as vibration-induced tube failure, fouling, and various forms of corrosion, providing engineers with the tools to diagnose performance declines before they lead to unplanned shutdowns.

Furthermore, the training addresses practical troubleshooting and repair strategies. Attendees will learn how to perform non-destructive testing, such as eddy current and ultrasonic thickness gauging, to assess the health of the tube bundle. The course also details the procedures for tube plugging, retubing, and cleaning, ensuring that maintenance teams can restore thermal performance effectively. By the end of this program, participants will be equipped to optimize the lifecycle of heat exchangers through informed design selection and proactive mechanical troubleshooting.

COURSE OBJECTIVES:

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

1. Explain the fundamental heat transfer principles in shell and tube exchangers.
2. Identify TEMA types and select the appropriate design for specific process needs.
3. Understand ASME Section VIII requirements for pressure-retaining components.
4. Analyze the role of baffles and tie rods in fluid flow and structural support.
5. Evaluate the mechanical design of tube-to-tubesheet joints.
6. Identify common failure modes, including flow-induced vibration.
7. Perform visual and non-destructive inspections of exchanger internals.
8. Diagnose fouling and its impact on pressure drop and thermal efficiency.
9. Implement effective cleaning methods: mechanical, chemical, and high-pressure.
10. Execute tube plugging procedures according to industry standards.
11. Manage thermal expansion through the use of expansion joints and floating heads.
12. Interpret inspection reports for corrosion and erosion patterns.
13. Troubleshoot shell-side and tube-side performance issues.
14. Ensure safe hydro-testing and commissioning after repair or maintenance.

TARGET AUDIENCE:

This course is intended for Mechanical Engineers, Plant Inspectors, Maintenance Supervisors, and Process Engineers responsible for the design, operation, and upkeep of heat transfer 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.