Heat Exchangers

Day 1: Types and Application of Heat Exchangers

• Overview and basic fundamentals

  • Significance of heat exchange in the petroleum, petrochemical, and process industries

• Heat Transfer Fundamentals and Heat Transfer Coefficients

• Heat Exchanger types and application

• Shell and Tube heat exchangers

• Compact heat exchangers

  • Plate heat exchangers

  • Printed circuit heat exchangers

  • Heat pipes

• Air-cooled heat exchangers

• Regenerative heat exchangers

• Geometry of Shell & Tube Heat Exchangers (STHE) and Double Pipes - TEMA nomenclature, front end head types, shell types, rear-end types, double pipe units, selection guidelines

• Workshop 1: Worked examples – heat transfer

Day 2: Thermal and Hydraulic Design of Heat Exchangers

• Sizing and Specifying the heat exchanger

• Temperature Difference In STHE

  • Countercurrent, co-current, and cross-current

  • TEMA flow arrangements, comparisons

  • worked example

    • Velocity Triangles and Performance Derivation from First Principles

    • Pump performance curves: head-capacity, power, efficiency

    • System curve: static, friction, pressure head components

• Fluid Flow and Pressure Drop

• Shell & Tube heat exchangers

• Plate heat exchangers

• Types and application

• General design considerations

• Condensers and Reboilers

• Workshop 2:Worked examples: Thermal design and rating shell & tube heat exchangers

Day 3: Mechanical Design of Heat Exchangers

• Design and construction codes and best practices

  • ASME B&PVC Section VIII

  • API 660, 661, and 662

  • TEMA

• Basic design of heat exchangers - S&THE, PHE, ACHE

• Special design considerations

• Piping loads on exchanger nozzles

• Impact of service conditions on material selection

• Shell & tube heat exchangers

• Plate heat exchangers

• Materials of construction for heat exchangers

• Fabrication of heat exchangers

• Workshop 3: Worked examples: Mechanical design of STHE

Day 4: Operation and Maintenance of Heat Exchangers

• Fouling In Heat Exchangers

  • Types and mechanisms, economic impact on design and operation

  • Fouling mitigation by design

  • Fouling mitigation by operation and maintenance

• Corrosion and erosion in heat exchangers

• Heat Exchanger Inspection Methods

• Operation and Troubleshooting

• Performance monitoring and Testing

• Flow-induced vibration, mechanisms, vibration prediction, damage numbers, design procedure to avoid vibration including baffle selection, rod baffle exchangers, twisted tube exchangers

• Cleaning strategies and methods: S&THE, PHE, ACHE

• Heat Exchanger Repairs

• Removal and Replacement of Heat Exchangers

• Cost-effective maintenance and repair of heat exchangers

Day 5: Performance Enhancement and Optimization of Heat Exchangers

• Heat transfer augmentation techniques

  • Finned tubes

  • In-tube Enhancement - Tube inserts, sintered coatings

• Tube Bundle Replacement - Alternative enhanced tube bundle designs

• rod baffle

• heli baffle

• twisted tube

• Pinch technology

• heat exchanger train optimization

• Heat Integration Basics

• Workshop 4: Illustrative example: Heat exchanger network optimization