Heat Exchangers: Types, Applications, Design, Operation & Maintenance

Category: Heat Exchangers: Types, Applications, Design, Operation & Maintenance

Course Description

This training course will present the technical and operational features of Heat Exchangers of various designs (shell-and tube (STHE), air-cooled (ACHE), plate (PHE) that play a vital role in thermal power plants and petrochemical and process industries. It has been realized that Engineers of diverse backgrounds and expertise need to develop a sound understanding of fundamental principles and interrelationship between various parameters that govern the well designed and operated heat exchangers.

This course will familiarise engineers and technicians with various codes and standards and best practices used for design, manufacture, operation and maintenance of heat exchangers. The emphasis in course will be on the best practices for efficient operation, inspection, maintenance and repair of widely used types of heat exchangers: shell and tube, air-cooled, plate compact types. Several workshops will be included with case studies and real examples from engineering practice that will enable the analysis of the root causes as a prerequisite for effective troubleshooting process.

This training course will feature:

  • Heat Exchangers Design Characteristics
  • Understanding of Heat Transfer principles
  • International Codes and Standards for fabrication, operation and maintenance
  • Problems in operation: Fouling and performance monitoring
  • Inspection of corrosion, erosion and structural integrity

Benefit of Attending

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

  • Understand design guidelines and specifications
  • Analyse exchanger thermal and hydraulic operational parameters
  • Determine the correct selection criteria for sizing of heat exchangers
  • Identify the problems in operation that lead to performance deterioration
  • Determine correct troubleshooting techniques

Who Should Attend

This training course is suitable to a wide range of technical professionals but will greatly benefit:

  • Maintenance Professionals
  • Inspection Personnel
  • Process Supervisors
  • Plant Operators
  • Plant/Technical Managers

Course Design

This training course will be conducted along the workshop principles, with formal lectures, case studies and interactive worked examples. Relevant case studies and practical exercises will be provided to illustrate the application of main learning points presented in the lectures. There will be ample opportunities for discussion and sharing experience to ensure maximum understanding of material. The goals of each participant will be discussed to ensure fulfilling of their needs and fining the solutions to their specific problems.

Course Outline

  • Heat Exchanger Types and Applications: Choice of Working Fluid
  • Heat Transfer Fundamentals and Heat Transfer Rates
  • Heat Exchanger Elements: Tube Bundles, Tube Sheets, Baffles and Nozzles
  • TEMA Nomenclature of Shell & Tube Heat Exchangers (STHE)
  • Air Cooled Heat Exchangers (ACHE) and Plate Heat Exchangers (PHE)
  • Condensers, Evaporators and Reboilers
  • Flow vs. Temperature Difference in STHE
  • Thermal Specification of Heat Exchangers: Sizing and Rating
  • Hydraulic Design of STE: Fluid velocity and Pumping Power Calculation
  • Aerodynamic Design of ACHE: Sizing of Fans and Drive
  • Sizing and Specifying of PHE Units: Compabloc Design     
  • Workshop: Case Studies, Examples & Solutions
  • Mechanical Design of Heat Exchangers
  • Calculation of Basic Elements of STHE
  • Piping Loads on Exchanger Nozzles
  • Material selection and Construction of Heat Exchangers
  • Fabrication Technologies of Heat Exchangers
  • Workshop: Case Studies, Examples & Solutions
  • Fouling and scaling in tubes and shells: Problem Solutions and Remedies
  • Inspection Techniques of Vital Elements of Heat Exchangers
  • Corrosion & Erosion Reduction Techniques, Fitness for Service Analysis (FFS)
  • Control in Operation: Tube Vibration & Troubleshooting
  • Cleaning, Maintenance and Repair Techniques: Tube Plugging and Re-tubing
  • Workshop: Case Studies, Examples & Solutions
  • Performance Monitoring and Testing
  • Performance Validation
  • Heat Transfer Augmentation Techniques
  • Tubes with external and internal fins
  • Heat Integration Basics: Pinch Technology
  • Workshop: Case Studies, Examples and Solutions