Heat Exchangers: Design, Applications, Operations, and Maintenance 28th April – 2nd May, 2025

Course Overview

This 5-day course provides comprehensive training on the design, operation, and maintenance of heat exchangers, focusing on optimizing performance and preventing failures. Participants will gain in-depth knowledge of various heat exchanger types, their applications, thermal and hydraulic design principles, mechanical design considerations, and essential operation and maintenance practices. This course also covers performance enhancement techniques and real-world troubleshooting to ensure the longevity and efficiency of heat exchangers in industrial applications.

Course Objectives

By the end of this course, participants will be able to:

1. Understand the different types and applications of heat exchangers and their components.

2. Apply thermal, hydraulic, and mechanical design principles to various heat exchanger systems.

3. Identify and solve common operation and maintenance challenges in heat exchangers.

4. Implement performance enhancement techniques to increase the efficiency of heat exchangers.

5. Conduct effective inspections and maintenance procedures to prevent failures and extend the service life of heat exchangers.

Target Audience

• Process engineers and design engineers.

• Maintenance supervisors and technicians.

• Plant managers and operators.

• Design and maintenance consultants in thermal systems.

• Technical staff involved in the operation and maintenance of heat exchangers.

Daily Agenda

Day One: Types and Applications of Heat Exchangers

• Overview of heat exchanger types and their applications in industrial processes.

• Selecting the appropriate working fluid for different heat exchanger types.

• Heat transfer fundamentals and how to calculate heat transfer rates.

• Understanding heat exchanger elements: tube bundles, tube sheets, baffles, and nozzles.

• Introduction to TEMA nomenclature of Shell & Tube Heat Exchangers (STHE).

• Air Cooled Heat Exchangers (ACHE) and Plate Heat Exchangers (PHE).

• The role of condensers, evaporators, and reboilers in heat exchanger systems.

Day Two: Thermal and Hydraulic Design of Heat Exchangers

• Analyzing flow vs. temperature difference in Shell & Tube Heat Exchangers (STHE).

• Thermal specification of heat exchangers: sizing and rating techniques.

• Hydraulic design principles for Shell & Tube Heat Exchangers (STHE): fluid velocity and pumping power calculations.

• Aerodynamic design for Air Cooled Heat Exchangers (ACHE): sizing fans and drive systems.

• Sizing and specifying Plate Heat Exchanger (PHE) units: focusing on Compabloc design.

• Workshop: Case studies, examples, and practical solutions on heat exchanger design.

Day Three: Mechanical Design of Heat Exchangers

• Mechanical design principles for heat exchangers: understanding basic calculations.

• Determining piping loads on exchanger nozzles and understanding their impact.

• Material selection and construction techniques for heat exchangers.

• Overview of fabrication technologies used in heat exchanger manufacturing.

• Workshop: Case studies, examples, and practical solutions for mechanical design.

Day Four: Operation and Maintenance of Heat Exchangers

• Addressing fouling and scaling issues in tubes and shells: problem solutions and remedies.

• Inspection techniques for vital heat exchanger elements to ensure safe operation.

• Corrosion and erosion reduction techniques: ensuring longevity and reducing downtime.

• Fitness for Service (FFS) analysis: assessing the integrity of heat exchangers.

• Operational control: dealing with tube vibration and troubleshooting.

• Cleaning, maintenance, and repair techniques: tube plugging and re-tubing.

• Workshop: Case studies, examples, and practical solutions on operation and maintenance challenges.

Day Five: Performance Enhancement and Optimisation of Heat Exchangers

• Performance monitoring and testing techniques to assess heat exchanger efficiency.

• Validating heat exchanger performance and identifying areas for improvement.

• Heat transfer augmentation techniques: using tubes with external and internal fins.

• Basics of heat integration and its impact on performance: understanding pinch technology.

• Workshop: Case studies, examples, and solutions for performance enhancement.

Why Choose this Course?

This course provides a thorough exploration of heat exchanger technology, combining both theoretical concepts and practical applications. By learning how to optimize design, operation, and maintenance processes, participants will be able to improve the efficiency and longevity of heat exchangers in their facilities, preventing costly failures and ensuring high performance in their systems.

Learning Outcomes

By the end of this course, participants will be able to:

1. Select the appropriate type and design of heat exchangers for specific industrial applications.

2. Apply thermal, hydraulic, and mechanical design principles to optimise heat exchanger performance.

3. Identify and mitigate common operational challenges such as fouling, scaling, and vibration.

4. Implement effective maintenance and repair techniques to prolong the life of heat exchangers.

5. Use performance monitoring and enhancement techniques to improve heat exchanger efficiency.