Shell and Tube Heat Exchangers: Comprehensive Mechanical Design, Manufacturing, and Lifecycle Management

This intensive 5-day training program provides a comprehensive exploration of shell and tube heat exchangers, covering every critical aspect from fundamental design principles to advanced maintenance and troubleshooting techniques. Participants will gain in-depth technical knowledge, practical skills, and industry-standard methodologies for managing these critical heat transfer components across various industrial applications.

Audience

Mechanical design engineers
Process plant engineers
Maintenance supervisors
Equipment reliability specialists
Technical sales engineers
Project engineers
Plant operators
Engineering consultants
Equipment procurement specialists

Course objectives

Upon completion of this course, participants will be able to:

Understand comprehensive design principles of shell and tube heat exchangers
Analyze mechanical design considerations and manufacturing processes
Apply advanced thermal and hydraulic performance calculations
Develop effective maintenance and inspection strategies
Identify and resolve common operational issues
Perform detailed failure analysis and prevention techniques
Apply industry standards and best practices

Course contents

Day 1: Fundamentals and Design Principles

Introduction to heat exchanger technologies
Types of shell and tube heat exchangers
Basic heat transfer mechanisms
Thermodynamic principles
TEMA (Tubular Exchangers Manufacturers Association) standards

Mechanical design fundamentals
Materials selection
Thermal stress considerations
Structural integrity analysis
Thermal expansion principles

Tutorial: Basic design calculations
Case Study: Design optimization
Discussion and Quiz

Day 2: Detailed Mechanical Design and Manufacturing

Shell-side and tube-side design considerations
Baffle design and configurations
Tube layout and pitch
Tube bundle mechanical design
Tube support and restraint systems

Manufacturing processes
Fabrication techniques
Quality control methods
Welding and joining technologies
Surface treatment and coating

Session 3 (Late Afternoon):

Tutorial: Design drawing interpretation
Case Study: Manufacturing challenges
Discussion and Quiz

Day 3: Thermal Hydraulic Performance Analysis

Heat transfer coefficient calculations
Pressure drop analysis
Flow distribution modeling
Thermal performance prediction
Fouling factor considerations

Computational fluid dynamics (CFD) applications
Thermal stress modeling
Performance optimization techniques
Simulation and analysis tools
Design verification methods

Tutorial: Performance calculation exercises
Case Study: Thermal performance improvement
Discussion and Quiz

Day 4: Operational Maintenance and Troubleshooting

Operational inspection techniques
Condition monitoring strategies
Vibration analysis
Leak detection methods
Performance degradation indicators

Common failure modes
Root cause analysis
Preventive maintenance strategies
Repair and rehabilitation techniques
Equipment life cycle management

Tutorial: Failure analysis workshop
Case Study: Complex troubleshooting scenario
Discussion and Quiz

Day 5: Advanced Topics and Comprehensive Assessment

Emerging technologies & Advanced materials

Specialized applications
Extreme operating conditions
Retrofit and modification strategies
Economic considerations
Performance optimization

Comprehensive Final Examination
Course Review and Closing Discussion

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