Heat Exchanger Design, Operation, Performance, Inspection, Maintenance & Repair

The course concentrates on heat exchanger hardware, performance requirements, inspection, maintenance and repair, and life extension. The material applies to tubular exchangers used in chemical and petrochemical plants, oil refineries, power stations and industrial facilities. Thermal design is not discussed except where it affects the structure. The TEMA system which is, internationally used explained for describing size and type. TEMA nomenclature and terminology are illustrated. The ASME code and TEMA standards are observed. Design point setting which affects the structure of the operating deviations, transients and upsets are examined. An overview of tube vibration includes descriptions and illustrations of damage caused by tube vibration, vibration forcing mechanisms and information required for vibration analysis.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

• Gain understanding of the nomenclature and terminology used for shell and tube heat exchangers,
• Determine how the tube side and shell side of tubular heat exchangers are constructed, Determine how heat exchangers are structured and assembled, manufactured, preparation for installation and joined to tube sheets
• Learn how to write and interpret specifications, some of the exchanger codes and standards, inspections, maintenance, repair and inspection techniques and determination of failure causes

Who Should Attend?

The course is aimed at personnel, who are involved with procurement, construction, installation, inspection and troubleshooting, also with maintenance, repair, mechanics, operation and life expectancy of shell and tube heat exchangers. The program will also be of special value to individuals who specify or buy heat exchangers or who are in charge of evaluating the condition of existing equipment.

Course Outline

Day 1
Types and Applications of Heat Exchangers

• Overview and Basic Fundamentals
• Heat Transfer Fundamentals and Heat Transfer Coefficients
• Heat Exchanger Types and Application
• Geometry Of Shell & Tube Heat Exchangers (STHE)
• Double Pipes TEMA Nomenclature, Front End Head Types, Shell Types
• Rear End Types, Double Pipe Units, Selection Guidelines

Day 2
Thermal and Hydraulic Design of Heat Exchangers

• Sizing and Specifying the Heat Exchanger
• Flow vs. Temperature Difference in STHE
• Temperature Difference in STHE
• Condensers and Reboilers

Day 3
Mechanical Design of Heat Exchangers

• Mechanical Design Of Heat Exchangers
• Basic Design Of Heat Exchangers
• Special Design Considerations
• Piping Loads on Exchanger Nozzles
• Materials of Construction On Heat Exchangers
• Fabrication of Heat Exchangers

Day 4
Operation and Maintenance of Heat Exchangers

• Fouling in Heat Exchangers
• Corrosion and Erosion in Heat Exchangers
• Heat Exchanger Inspection Methods
• Operation and Troubleshooting
• Performance Monitoring and Testing
• Cost-Effective Maintenance and Repair of Heat Exchangers

Day 5
Performance Enhancement and Optimization of Heat Exchangers

• Heat Transfer Augmentation Techniques
• Finned Tubes
• Heat Integration Basics
• Pinch Technology
• Heat Exchanger Train Optimization
• Tube Bundle Replacement - Alternative Enhanced Tube Bundle Designs

Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation

Course Fees

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings

Daily Course Timings
08:00 - 08:20 Morning Coffee / Tea
08:20 - 10:00 First Session
10:00 - 10:20 Coffee / Tea / Snacks
10:20 - 12:20 Second Session
12:20 - 13:30 Lunch Break & Prayer Break
13:30 - 15:00 Last Session