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

This Heat Exchangers 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 Heat Exchangers training course will familiarize 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.

Audience

This course is designed for:

Process & Operations Engineers
Maintenance Professionals
Inspection Personnel
Process Supervisors
Plant Operators
Plant/Technical Managers

Course objectives

The course objectives are:

Understand essential design guidelines and specifications
Analyze heat 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

Course contents

Day-1

Pretest
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-2

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-3

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-4

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-5

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
Posttest

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