ANNEXURE - A

Karachi Institute of Power Engineering

Heat Exchangers Maintenance Training: Training Need/Tasks Identification

Course Name: Maintenance of Heat Exchanger

Field: Mechanical Maintenance

Training Media: Class room, Audio Visual, Hands on

Credit hours: Total 24 (16 for Class room and Audio Visual and 8 hours for Hands on)

Target Audience: Fresh Maintenance Engineers and Technicians

Objectives of the Maintenance Training on a Centrifugal Pump

 Explain the basic philosophy, types of heat exchangers and terminologies involved.
 Explain and understand the purpose of the basic parts and components of a heat
exchanger in order to be able to disassemble different components
 Basic operation & characteristics of heat exchanger in order to understand the
operation related troubleshooting and problems
 Explain and understand the issues and problems related to trouble shooting and
fault analysis of a heat exchanger
 Describe safety precautions that should be taken as part of preparing to work on a
heat exchanger and its removal from the system
 Understand and explain the ‘basic-steps’ for a correct pump disassembly
 Understand and carry out the Inspection of the heat exchanger components and to
assess the condition of the components
 Explain the causes of heat exchanger components damage and possible solutions
of the problem like replacement or refurbishment
Training Needs/Tasks for the Maintenance Training on Heat exchangers

Following needs/tasks have been identified for the training of maintenance personnel
performing maintenance job on a heat exchanger. The detailed material will be made
available for the topics/tasks below during the development phase of the SAT based
training.

1. Introduction to Heat Exchangers

2. Considerations Used to Determine Appropriate Inspection Frequencies for
Heat Exchangers

3. Periodic Inspection of Heat Exchangers

a. Safety
b. Operational Continuity
c. Efficiency

4. Primary Causes of Heat Exchanger Deterioration

a. Metallurgical Deterioration
b. Mechanical Deterioration
c. Faulty Materials and Fabrication

5. General Considerations in Determining Inspection Frequency and Scheduling

a. Occasion and Frequency for External Inspection
b. Occasion and Frequency for Internal Inspection
c. Scope of External Inspection and Problems Indicated
d. Scope of Internal Inspection

6. Maintenance Procedures
a. Locating Leaking Tubes
b. Hydrostatic Test
c. Air Leak Bubble-Test
d. Halogen or Helium Leak Test
e. Locating Tube-to-Tubesheet Joint Leaks
f. Re-Expanding Tubes

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 g. Re-Expansion Requirements
h. Methods for Re-Expanding Tubes
i. Repairing Tube-to-Tubesheet Joint Welds
j. Seal Welding Expanded Tube-to-Tubesheet Joints
k. Repairing Damaged Ligaments
l. Plugging Tube Leaks
m. Friction Plugs
n. Welded Plugs
o. Installing Tube Ferrules, Sleeves, and Liners
p. Retubing
q. Individual Tube Replacement
r. Partial Retubing
s. Complete Retubing
t. Remedying Leaking Girth Flanges

7. Types and Causes of Heat Exchanger Vibration Problems and Potential

Solutions to These Problems
a. Causes of Vibration
b. Vortex Shedding
c. Turbulent Buffeting
d. Fluid-Elastic Whirling
e. Acoustical Resonance
f. Possible Types of Damage
g. Interspan-Collision Tube Damage
h. Wear Damage
i. Fatigue Failure of Tubes
j. Tube-to-Tubesheet Joint Leaks
k. Tubesheet Ligament Cracking
l. Weld Bead Cracking in Tube-to-Tubesheet Welds
m. Intensified Stress Corrosion
n. High Operating Noise

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 o. Increased Shell side Pressure Drop
p. Design and Operating Parameters Affecting Vibration
q. Tube Natural Frequency
r. Effect of Tube End Fixity on Natural Frequency
s. Effect of Baffle Spacing on Tube Natural Frequencies
t. Effect of Axial Load on Tube Natural Frequency
u. Effective Tube Weight.
v. Damping
w. Shell Side Velocity
x. Acoustic Resonance
y. Potential Solutions

8. PRIMARY METHODS OF CLEANING HEAT EXCHANGERS

a. Mechanical Cleaning
b. Hydraulic Cleaning
c. Chemical Cleaning

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