Heat Exchanger Operation and Maintenance

Process plants in the oil, gas and petrochemical industries rely on large numbers of heat exchangers for their efficient operation.

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Level: Intermediate
Type: Classroom

Heat Exchanger Operation and Maintenance

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About Training

Process plants in the oil, gas and petrochemical industries rely on large numbers of heat exchangers for their efficient operation. A single plant may utilise many different heat exchanger types, each with its own specific requirements for operation and maintenance. Site engineers need to be familiar with a wide variety of equipment, processes and techniques in order to ensure safe and reliable operation.

Inefficient operation and unexpected failure of heat exchangers are frequently responsible for significant financial impacts due to lost production, increased energy consumption and costly repair bills. In many cases these losses are exacerbated by failure to identify early indicators of the problem, a lack of understanding of the root causes, and by inappropriate mitigation measures.

This course provides both a broad overview of heat exchanger operation and maintenance in general and a detailed understanding of the critical issues relating to the three main heat exchanger types (shell and tube, air-cooled and plate heat exchangers). The most common problems associated with each type will be presented, and illustrated with case studies drawn from the trainer's own experience. Participants will have the opportunity to work through a range of examples and to discuss their own heat exchanger issues with a highly experienced heat exchanger specialist.

Training Objectives

Broad understanding of heat exchanger technology from an operation and maintenance point of view
Recognition of the most common causes of failure in each heat exchanger type
Awareness of early warning signs of heat exchanger problems
Practice root cause analysis for the investigation of heat exchanger issues
Understanding of specialized inspection, maintenance and repair techniques for heat Exchangers

Audiences

The course is specifically designed for professionals with operational or maintenance responsibility for heat exchangers. While other disciplines will also gain benefits from the course, it is specially designed for:

Maintenance engineers
Plant engineers
Inspectors
Plant operators

Instructor

Ian Gibbard

Ian, CEO of Progressive Thermal Engineering, has more than 25 years of experience in the design, manufacture, operation, maintenance and troubleshooting of heat exchangers worldwide. His company delivers consultancy and training to clients across the process and power generation industries.
He is the former Engineering Business Manager, Technical & Managing Director at Cal Gavin Limited, a heat transfer consultant to new designs of heat exchangers and problematic heat exchangers in the field.
Ian has delivered training courses in over 25 countries for a range of audiences including plant operators, equipment manufacturers and seasoned engineers. His training material draws on his varied experience to provide practical instruction illustrated with insightful case studies.
Currently he is also heat transfer tutor and consultant at HTRI (Heat Transfer Research Incorporated).

Daily Aims

DAY 1

Introduction Exercise

An exercise based on root cause analysis for heat exchangers, designed to encourage participation and to set the scene for the training course.

Introduction to Heat Exchangers

A session intended to build background knowledge of heat exchangers in general, based on an operations and maintenance perspective. The session will provide the opportunity for the participants to highlight the types of heat exchanger of interest, and the most common issues experienced in day-to-day operation
Overview of heat exchanger types - advantages, disadvantages and typical applications
Overview of heat exchanger operation and behavior
Common problems experienced, by heat exchanger type

Case Study

An extended case study based on troubleshooting a shell and tube heat exchanger with a history of tube failures. The case study is designed to illustrate the influence of operations, inspection and maintenance actions on the eventual outcomes

DAY 2 & 3

On the first day of the course it will have been established that the majority of problems with heat exchangers are associated in one way or another with leaks. The core of the training course is therefore concerned with the root causes, detection and resolution of heat exchanger leaks.

Types of Leaks and Methods for Detection:

Tube/plate leaks
Tube-to-tubesheet joint leaks
Flange/gasket leaks
Leak detection and testing
Tube wall thickness surveys

Case Study

An extended case study following a tube leakage issue over the 30 year lifetime of a heat exchanger from commissioning through two refurbishment/repair projects. The case study illustrates a wide range of leak-related issues.

Root Causes of Heat Exchanger Leaks

Corrosion
Erosion
Flow-induced vibration
Flange/gasket issues

Case Study

A case study based on erosion damage to a set of seawater-cooled heat exchangers in a chemical plant.

Resolving Heat Exchanger Leaks

The techniques available to repair and refurbish heat exchangers will be reviewed, including:

Tube plugging
Tube joint re-expansion
Re-tubing
Flange/gasket joint repair and bolt tensioning methods

DAY 4

The final day of the course is dedicated to the issues of fouling and cleaning in heat exchangers. Fouling is a major headache in many heat exchangers, and cleaning is a regular maintenance task.

Case Study

A case study is used to illustrate that, while fouling is commonly blamed for poor heat exchanger performance, the true cause may lie elsewhere.

Causes of Performance Problems

A review of common causes of performance problems in heat exchangers, including:

Fouling
Maldistribution
Bypassing
Venting/draining problems
Fan/air flow issues in air-cooled heat exchangers

Heat Exchanger Fouling

Types of fouling
Effect of fouling on thermal performance
Effect of fouling on hydraulic performance
Preventing fouling

Heat Exchanger Cleaning

Mechanical cleaning
Chemical cleaning
Online cleaning

Case Study

Fouling and cleaning in plate-and-frame heat exchangers (sea water/fresh water heat exchangers)

Training Schedule

Upcoming Trainings Past Trainings

No upcoming session is scheduled yet. Send a quick inquiry and we will let you know the next date.

Why Choose This Training

Credibility

Align with API/ASME standards. Trusted by major operators.

Expert Instructors

Led by industry veterans with real field experience.

Real Case Studies

Practical application of concepts through real world scenarios.

Practical Skills

Hands on calculations and decision making for FFS outcomes.

Trusted by Operators

Delivered to Aramco, ADNOC, SABIC, and other major operators.

Global Training Standard

Recognized across major industries by PetroSync's proven approach.

Professional Training Aligned with Industry Standards

Practical, industry ready training designed for real work environments

Free Consultation

Limited seats available

Frequently Asked Questions

What types of training programs does PetroSync offer?

PetroSync offers various training programs for the oil, gas, petrochemical, and energy industries, such as API, ASME, Reliability, Drilling & Well Engineering.

Are training sessions conducted online or in person?

PetroSync provides both online and in-person training options to accommodate participants' preferences and needs.

How long is the duration of PetroSync's training programs?

The duration of each program varies, typically ranging from 3 to 5 days, depending on the complexity of the topic.

Do these courses include practical sessions?

Yes, most PetroSync courses include practical exercises, case studies, and real-world applications to enhance learning outcomes.

Are there specific courses for beginners or professionals new to the industry?

Yes, PetroSync offers foundational courses designed for beginners, as well as advanced programs for experienced professionals.

How do I register for a training program?

You can register directly through the following link: https://www.petrosync.com/training/ by selecting your desired training program.

What payment methods are accepted?

PetroSync accepts two payment methods:

Direct Transfer

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Is there a discount for group registrations?

Yes, PetroSync offers special discounts for group registrations. Please discuss this with our Sales Team by filling out the form on the designated page first.

Is there a refund policy for cancellations?

Delegates who cancel after the training has been officially confirmed via email are required to pay the full course fee, and no refunds will be granted. However, you may substitute delegates at any time as long as reasonable advance notice is given to PetroSync.
If PetroSync cancels, postpones, changes the trainer, or alters the training location (classroom/virtual) for any reason, and the delegate is unable or unwilling to attend on the rescheduled date, a 100% credit voucher of the paid contract fee will be issued. This credit voucher can be used for another PetroSync training program, subject to mutual agreement, within one year from the postponement date.
PetroSync is not responsible for any loss or damage resulting from the cancellation policy and assumes no liability if the event is canceled, rescheduled, or postponed due to force majeure (e.g., natural disasters, war, government actions, industrial actions).

What happens if the training schedule is changed?

If PetroSync cancels, postpones, changes the trainer, or alters the training location (classroom/virtual) for any reason, and the delegate is unable or unwilling to attend on the rescheduled date, a 100% credit voucher of the paid contract fee will be issued. This credit voucher can be used for another PetroSync training program, subject to mutual agreement, within one year from the postponement date.

Will I receive a certificate upon completing the course?

Yes, participants who complete the training will receive either an attendance certificate or a completion certificate, depending on the course requirements.

Are PetroSync courses internationally recognized?

Yes, PetroSync courses adhere to international standards , with expert instructors in fields such as API, ASME, Reliability, and Drilling & Well Engineering.

Can this certificate be used for professional certification requirements?

Yes, PetroSync certificates are widely recognized and can be used to fulfill professional development and certification requirements across various industries.

Can I customize a training program for my team?

Yes, PetroSync offers customized training programs tailored to your organization's specific needs (In-house Training).

What training materials will I receive during the course?

Participants will receive comprehensive training materials , including slides, handouts, and direct learning from experts with case studies related to the training topic.

Who conducts the training sessions?

PetroSync trainers are industry experts with extensive experience as instructors and consultants in their respective fields, providing professional training with a strong background in the industry.

Can I review the trainer's profile before registering?

Yes, trainer profiles, including their qualifications, experience, and expertise, are available on the website: https://www.petrosync.com/training/.

What platform is used for online training?

Online training sessions are conducted via user-friendly platforms such as Zoom Premium.

What are the technical requirements for online courses?

To access PetroSync Online Training, participants need:

A computer or laptop (tablets or smartphones are not recommended)
A reliable broadband internet connection (minimum 4 Mbps)
A webcam and a headset
Any internet browser (Chrome browser recommended for a better experience)
A reasonably quiet place

Are there Q&A sessions during the course?

Yes, PetroSync provides live Q&A sessions with instructors to address real-world challenges encountered during training.

What is the average number of participants in PetroSync's training programs?

The average number of participants varies depending on the topic and participants’ schedules.

How is my personal information protected when registering for a course?

The information you provide will be safeguarded by PetroSync and may be used to keep you informed of relevant products and services.
As an international group, we may transfer your data globally for the purposes indicated above.
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How can I contact PetroSync for more information?

Please fill out the form on the designated page first. Our team will reach out to you within a maximum of 2x24 hours.

Where can I find the latest training schedule?

The latest training schedule is available on the website: https://www.petrosync.com/training/.