COURSE OVERVIEW:

Heat exchangers are the primary vessels for energy management and thermal regulation within refinery and petrochemical complexes. This course provides an advanced technical examination of heat transfer equipment, focusing on the shell and tube configuration as well as specialized plate and air-cooled designs. Participants will explore the fundamental physics of conduction and convection, moving rapidly into the practicalities of maintaining a high thermal efficiency in units that are subject to extreme temperatures, pressures, and corrosive chemical environments.

The scope of this training involves a rigorous analysis of the "fouling" phenomenon, which is the most significant contributor to energy loss and mechanical degradation in heat transfer systems. Attendees will learn to identify the various mechanisms of fouling including crystallization, coking, and biological growth and apply mathematical models to predict the rate of thermal resistance buildup. The course emphasizes the relationship between fluid velocity, metallurgy, and fouling rates, providing engineers with the tools to optimize cleaning cycles and chemical injection programs.

Coverage includes sophisticated troubleshooting techniques for diagnosing internal tube leaks, bypasses, and vibration-induced failures. Participants will examine the use of temperature and pressure drop monitoring as early-warning indicators of performance degradation. By integrating maintenance strategies such as high-pressure water jetting and ultrasonic cleaning with operational best practices, this course equips technical professionals with the expertise to maximize heat exchanger longevity and minimize the carbon footprint of their industrial operations.

COURSE OBJECTIVES:

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

1. Explain the fundamental heat transfer equations and the concept of the Log Mean Temperature Difference.
2. Select the most appropriate heat exchanger type based on process fluid properties and thermal duty.
3. Interpret TEMA standards and mechanical design data sheets for shell and tube exchangers.
4. Quantify the impact of the fouling factor on the overall heat transfer coefficient ($U$).
5. Identify the chemical and physical drivers of scaling, coking, and sedimentation.
6. Design and implement effective chemical cleaning and inhibition programs.
7. Monitor real-time performance using heat duty calculations and pressure drop trends.
8. Diagnose internal tube-to-shell leaks using tracer and temperature analysis.
9. Assess the risk of flow-induced vibration and implement mechanical mitigation.
10. Optimize the operation of air-cooled heat exchangers (fin-fans) during ambient temperature swings.
11. Execute safe procedures for exchanger isolation, blinding, and hydro-testing.
12. Plan maintenance turnarounds based on economic "Clean vs. Dirty" analysis.
13. Troubleshoot complex issues such as temperature crossovers and liquid maldistribution.

TARGET AUDIENCE:

Process Engineers, Reliability Engineers, Maintenance Supervisors, and Operations Managers responsible for thermal equipment performance and energy efficiency.

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.