Maintenance and Engineering

Heat Exchanger Design and Maintenance

Heat exchangers are central to energy efficiency in process plants and utilities. This course covers heat exchanger types and design basics, thermal performance, fouling and its costs, cleaning methods, inspection and testing, tube failures and repairs, and monitoring performance to schedule maintenance.

5 days Classroom or live online English

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Take the course details with you.

Download the full standard outline: why attend, methodology, objectives, audience, competencies, the daily outline and current plans.

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Why attend

From knowledge to real-world impact.

Fouled or failing exchangers waste energy and limit production. You will learn to operate and maintain them for best performance.

Workplace challenges

Professional Problems This Course Is Designed to Solve

The programme explores practical approaches to the following challenges. Results depend on how the learning is applied in your organisation.

Difficulty translating subject knowledge into practical workplace decisions.
Inconsistent approaches to the activities covered in the course outline.
Lack of a structured plan for applying and reviewing new skills.

Course methodology

How you will learn.

Performance calculations, failure case studies, cleaning method comparisons and maintenance planning.

Course objectives

What you'll take away.

By the end of this course, participants will be able to:

Explain heat exchanger types and selection
Understand thermal design and performance basics
Assess fouling and its costs
Select cleaning methods
Inspect, test and repair exchangers
Monitor performance to plan maintenance

Target audience

Who should attend.

This course is suitable for:

Process and mechanical engineers
Maintenance engineers
Plant operators
Energy engineers
Inspectors

Target competencies

Capabilities you will build.

Participants will develop competencies in:

Thermal performance analysis
Fouling management
Inspection
Repair techniques
Performance monitoring

Course outline

Your learning journey.

A focused, practical outline with time to explore, apply and reflect.

Day 1Heat Exchanger Types

09:00–10:08Shell and tube
10:08–11:00Plate and air-cooled
11:00–11:30Coffee break
11:30–11:45Plate and air-cooled (continued)
11:45–12:53Selection
12:53–14:00Exercise

Day 2Thermal Performance

09:00–10:08Heat transfer basics
10:08–11:00LMTD and effectiveness
11:00–11:30Coffee break
11:30–11:45LMTD and effectiveness (continued)
11:45–12:53Performance calculations
12:53–14:00Exercise

Day 3Fouling

09:00–10:08Fouling mechanisms
10:08–11:00Costs
11:00–11:30Coffee break
11:30–11:45Costs (continued)
11:45–12:53Mitigation
12:53–14:00Case study

Day 4Maintenance

09:00–10:08Cleaning methods
10:08–11:00Inspection and testing
11:00–11:30Coffee break
11:30–11:45Inspection and testing (continued)
11:45–12:53Tube failures and plugging
12:53–14:00Workshop

Day 5Monitoring

09:00–10:08Performance monitoring
10:08–11:00Maintenance scheduling
11:00–11:30Coffee break
11:30–11:45Maintenance scheduling (continued)
11:45–12:53Improvement
12:53–14:00Action plan

The timings provided are estimates and may vary depending on the number of participants and the discussions taking place during the sessions. They are indicative only and do not constitute a binding commitment.

Dates & venues

Find a session that works for you.

Confirmed dates accept registration requests. Tentative dates are enquiry only.

Good to know

A few things to know.

How is the course delivered?

Our classroom programmes combine facilitated discussion, case studies, exercises and reflection. The precise format will be confirmed before enrolment.

Can you deliver this programme for our team?

Yes, you can enquire about a tailored programme. Share your goals, group size and preferred dates with our learning team.

Will I receive a certificate?

Participants who complete the programme receive a Smart Horizon UK certificate of attendance. Smart Horizon UK programmes are not externally accredited and do not award a professional qualification, licence or designation. Where a course title or outline refers to a professional certification (for example, AACE International's Certified Cost Professional), the programme supports learning and preparation only; the credential itself is awarded solely by the relevant professional body under its own application and examination requirements.

What should I confirm before booking travel?

Please confirm the session, exact venue, accessibility arrangements, fees and any visa requirements with the team before arranging travel. Tentative dates are not confirmed sessions.

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