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

What are the Goals?

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 is this Training Course for?

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

Daily Agenda

Day One: Types and Applications of Heat Exchangers

• 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

Day Two: Thermal and Hydraulic Design of Heat Exchangers

• 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

Day Three: Mechanical Design of Heat Exchangers

• 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  

Day Four: Operation and Maintenance of Heat Exchangers

• 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  

 Day Five: Performance Enhancement and Optimisation of Heat Exchangers 

• 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