Heat Exchangers -

Operation & Maintenance

SCOPE OF WORK:

Objectives:

Heat exchangers are one of those critical equipment that are used at our plants. This course is
intended to enable improve our heat exchanger effectiveness and extend our equipment’s life
span by enhancing knowledge on the basic principles of fluid flow and heat transfer. This
course shall enlighten delegates about the design and operation of different types of heat
exchangers; and the causes and preventions of exchanger tube vibration and damage. The
course shall also explain how to use the applicable codes, standards and recommended
practices. It shall discuss factors to consider when deciding between repairs and
refurbishments of aging equipment, focusing on the most cost-effective options.

Learning Outcomes:
On successfully completing the programme, the participants shall achieve the following
learning outcomes:

Select the most suitable heat exchangers for specific application

Use the proper method of sizing of heat exchanger of different designs

Solve practical problems encountered in everyday operation of the system

Choose the right methods of troubleshooting problems by investigating their root
cause

Apply the latest information on reducing corrosion and fouling to maintain
cleanliness of surfaces

Improve the quality and profitability of operation by increasing reliability of heat
transfer process

Types of heat exchangers and TEMA classification of heat exchangers

Cross-Sections at component and equipment level that gives a virtual practical
knowledge on the internals

Different types of Tube sheet construction – Welded, Expanded, seal welded,

Step by step knowledge using sequential activity on the basic procedure involved in
Heat Exchanger Assembly and Dismantling

Various maintenance Methods of cleaning and repair of Heat exchangers

Hydraulic pressure testing of different types of exchangers

Maintenance Methods of specialty heat exchangers –

1. Plate – Frame / Plate Fin Exchangers

2. Floating head exchangers
3. Aluminum Brazed exchangers
4. Fin fan coolers
5. Vacuum Condensers
6. Double pipe exchangers
7. Risks associated with Heat Exchangers maintenance

Recommended practice/ Best Practice guide on specialty heat exchangers

maintenance
Summary of the Scope:

The course content shall include, but not limited to:

Understanding of Heat Transfer principles

Types and Applications of Heat Exchangers

Thermal and Hydraulic Design of Heat Exchangers

Physics behind heat exchanger design, operation, maintenance and troubleshooting

Applicable codes, standards and recommended practices

Mechanical Design of Heat Exchangers

Operation and Maintenance of Heat Exchangers

Procedure for starting up and shutting down the heat exchangers

Troubleshoot, diagnose, and correct operating problems

What is fouling in exchangers and how it can be corrected?

Methods of test and repair of tube leaking

Different performance indicators and early signs of thermal or mechanical problems
and how to resolve them efficiently.

Performance Enhancement and Optimization of Heat Exchangers

General Requirements:
Training Methodology

Delivery shall consist of classroom theory and exercises (at times if require, site
visits)

Instructor-led, systematic approach that shall ensure consistent training within
company’s premises

Certified trainer shall facilitate the course

Training materials should include appropriate interactive audio visual aids according
to industry standards, featuring realistic scenarios filmed in professional settings to
keep participants interested and training relevant

At the end of the course, delegates must successfully complete the written and
practical evaluation

Testing and Certification Methodology:

Written pre-test in the beginning of course

Written/practical evaluation/assessment at end of course

Certificate of successful completion

Training Facilities

The whole training comprising of classroom theory, exercises and the tests shall take
place at company’s premises.

The vendor shall duly inform the company for any other requirement that may be
necessary to facilitate the course.
Batches:

14-15 batches of 18 – 20 participants

Duration of the course:

Shall be 2 days. The timing shall be observed strictly as from 0730 to 1430 Hrs, with
appropriate tea and lunch breaks in between.

Target Audience:

Field Operators (Production)

Maintenance Technicians

Maintenance Supervisors

EVALUATION CRITERIA FOR TRAINING PROVIDER:

The bidders would be evaluated based on their submission – covering their Course
Objectives & hand-outs, Instructor/s Profile, Relevant experience, Method of Execution of
the Training Programme, and commercial offer.

Section - 1 Company Profile:

Company profile and history of delivering similar training courses

Clienteles list where similar training courses have been conducted with their contact
references.

Section - 2: Training Proposal:

Course objective & contents, Training lesson plan

Course presenter CV and testimonials

TERMS & CONDITIONS

Training manual / course materials for the course should be submitted in advance, in
electronic format, for review, suggestions or modifications, within 15 days of
issuing the PO. If found unsatisfactory, company/end user will have the right to
cancel the PO without any penalty thereof.

As soon as the PO is issued/Course Materials reviewed and accepted, a schedule of
running the batches shall be mutually agreed upon.

Since nominated instructor/s for each course has been used as a criterion for
evaluation. Training must, therefore, be delivered by the same instructor identified
in the proposal. If the instructor is found to be not the one who has been evaluated
prior to issuing the PO, our company/end user reserves the right to ask for an
alternate instructor.

Should the course not meeting the course objectives or performance of
instructor is not to the required standard, the training will have to be repeated
at the training provider's cost

Training manuals are to be provided to each of the delegates by the training
provider. Training manual must be structured as a "quick" reference guidebook for
participants to use in the future as well.

End User/our Company will have the right to cancel, terminate or postpone the
Training, if any of the above stated terms & conditions are not adhered to by the
training provider.

In case of confirmation or reschedule of any batch, we will issue prior notification
one week in advance.

Trainers are expected to adhere to all safety regulations as stipulated by our
company.