Course Overview

Heat exchangers are critical components in many Industrial Fields such as Power Plants, Oil, Gas, and Petrochemical Companies. The correct cleaning methods and at the correct intervals will prolong the life of the heat exchanger and operate it close to its maximum design capacity and permissible pressure drop. It will minimize and overcome the problems of fouling, corrosion, and vibrations that are responsible for extensive damage in the Industry. In addition, the proper inspection will increase the lifetime and reduce downtime and thus increase profitability. It is only by determining the condition of equipment by inspection decisions to replace tubes or even bundle replacement that is possible and economical.

The course covers all aspects of the subject of Heat Exchangers from a mechanical and thermal viewpoint using lots of examples from current industrial practice with their associated problems whilst minimizing the use of mathematics. Extensive discussions are included on the numerous types of heat exchangers encountered in industrial plants and the subject is developed through the basic engineering approach by using a wide range of examples of real problems which are typical of those encountered in various industries.

Course ObjectivesThis course is designed to enable participants to:

• Fully understand and identify the different types and designs of shell & tube heat exchangers.
• Demonstrate and apply good working knowledge, installation, upgrading, inspection (visual and by machine), repair, and re-tubing techniques
• Understand the standard principles of TEMA (Tubular Exchanger Manufacturing Ass.) and basic API 660.
• Understand and recognize the selection of materials which has a good thermal conductivity compatible with both shell & tube under normal operating conditions. exchangers.
• Employ correct dismantling, removal, and installation procedures as per working standards.
• Demonstrate various cleaning methods for the heat exchangers.
• Carry out normal procedure (standard) of hydro testing prior to the handover of installation.

Who Should Attend?

• This course is designed for Plant Engineers, Supervisors, Foremen, and Qualified Technicians, who are working related to operating and maintaining Heat Exchanges in different types of industrial and utility plants.

Course ContentModule (01) Types / Classifications

• Double Tube Heat Exchangers
• Shell and Tube Heat Exchangers
• Bundle and Shell Geometries
• Shell Side Flow Paths in a baffled Heat Exchangers
• Breech-lock Technology
• Helixchanger Technology
• Hairpin Heat Exchanger
• Gasket and welded Plate Types Heat Exchangers
• Spiral Heat Exchangers
• Air Coolers
• Condensers

 Module (02) Components and Details of Heat Exchanger

• Shell, Tubes, Tube Sheets, and Baffles
• TEMA classifications of Channels and Shells
• Partitions Plates and number of Passes
• Tube Spacers in Air Coolers

 Module (03) Fouling and the necessity of cleaning

• Indication of Fouling
• Types of Fouling
• Effect of Fouling on Overall Heat Transfer Coefficient
• Cleaning intervals estimate

 Module (04) Off-Line Cleaning Techniques

• Mechanical Cleaning
• Tube brush Cleaning
• Hydro-drilling of Blocked Tubes
• Propelled Tube Cleaners
• Air Driven Tube Cleaners, Special Hand Tools
• Hydro-blasting
• Dry Ice blast cleaning of Heat Exchangers
• Soda Blasting
• Hydrokinetics Process
• Chemical Cleaning
• Advantages and Disadvantages of Chemical Cleaning
• The nature and quantity of the deposit
• The materials of construction of the Equipment
• Solvents and Acids, Choice of Acid
• Choice and handling of Corrosion inhibitors
• Neutralization and Flushing
• Conditions of use of Chemicals
• Hydrokinetics Process
• Cleaning Solutions
• Cleaning Procedures
• Safety Requirement
• Plate Type Heat Exchanger Cleaning
• Mechanical Cleaning Procedures
• Chemical Cleaning Procedures

Module (05) On-Line Cleaning Techniques

• Shell & Tube Heat Exchangers
• Automatic Tube brushing (ATB)
• Solid Particles Cleaning for Vertical Heat Exchangers
• Sponge Rubber balls for Condenser Cleaning
• Air Cooler
• Fire hose, and high-Pressure hand lance
• Automated Cleaning Machine

 Module (06) Inspection of Deterioration Rate

• Planned and forced Outage Inspection
• NDT Techniques for Heat Exchanger Tubing
• Eddy Current Tests: Surface Testing, Tubing Testing
• Bobbin Probes, Multi-Frequency Testing
• Interpretation of ECT, ASME Calibration Tube
• Heat Exchangers: Cracks under Tube-sheet
• Principles of RFECT Techniques
• Magnetic Flux Effect: Type sensor and hall Effect
• Ultrasonic, Ultrasonic IRIS Probe
• Laser Optics

 Module (07) Visual Inspection

• Remote Visual Testing: Borescope and Fiberscope
• Case Studies, Leaking Tube under a baffle Plate, Header Cracking, feed-water heater tube Failure, Ligament Weld, Tube pigging Wear, Scale in tubes
• Liquid Penetrate Examination and limitations
• Magnetic Particle Testing, dry and wet methods

 Module (08) Heat Ex. leak inspection & Repair

• Inspection of Tube leaks in Fixed Tube HE
• Inspection of Tube leaks in U Tube HE
• Inspection of Tube Leaks in Floating Head HE
• Inspection of Tube Leaks in Air Coolers
• Inspection of Tube leaks in plate Type HE
• Hydro Testing according to ASME Standard.

 Module (09) Risk-based Inspection & Re-Tubing Policy

• What is Risk-based Inspection and RBI basics
• Why choose RBI
• Bundle Replacement Strategy
• Online Periodical Service” Ops Code”