ADVANCED HEAT EXCHANGER

DESIGN, PERFORMANCE,
INSPECTION, MAINTENANCE
AND TROUBLESHOOTING

Conducted by your Expert Course Leader

Your expert course leader, B. Sc., M.Eng., Ph D is a Senior Mechanical & Instrumentation Engineer with over 45 years of industrial
experience in Process Control & Instrumentation, Pumps, Compressors, Turbines and Control Valve Technology. He is currently a
Senior Independent Consultant to various petrochemical industries in the UK, USA, Oman, Kuwait and KSA where he provides
consultancy services on both the application and operational constraints of process equipment in the Oil & Gas industries.
ADVANCED HEAT EXCHANGER DESIGN, PERFORMANCE , INSPECTION,
MAINTENANCE AND TROUBLESHOOTING

About the course

The design, performance and operation of modern heat exchangers requires an understanding of the principles of heat
transfer and fluid flow, coupled with access to numerically based techniques and supporting data. This course will review
heat transfer fundamentals as applied to tubular and plate devices.

Upon completion of this course, delegates will have gained an understanding of the application of basic principles of heat
transfer and fluid flow to the design, operation and maintenance of shell and tube heat exchangers as well as compact and
air-cooled heat exchangers. Participants will gain an understanding of TEMA and ASME codes and learn how to numerically
analyse the different heat exchanger configurations. Attention will be paid to the recognition and solving of a wide variety of
industrial problems, taking existing case studies.

The course will also address the ways in which systematic techniques of inspection and maintenance (including Fouling
Control) can alleviate major problem areas.

Course objectives
Upon the successful completion of this course, each participant will be able to:
• Design, inspect, maintain and operate heat exchangers and analyse their performance in a professional manner
• Employ the concepts of heat transfer coefficients and determine their overall effect on heat exchanger fouling
• Differentiate between the various types of heat exchangers
• Discuss the industrial features and other information that explain distributed types in relation to power cycles,
distillation, re-cuperators and regenerators
• Carry out heat exchanger analysis for counter flow, cross flow and multi-pass heat exchangers and to apply the relevant
correction factors
• Conduct a heat energy balance for different types of heat exchangers
• Choose the correct heat exchanger for a given application and its costing in line with the advantages and disadvantages
of its type and scope of its applications
• Determine the cooling performance of a range of heat exchangers and establish insights on the effectiveness/ NTU
method for heat exchanger analysis in terms of heat capacity ratios
• Interpret TEMA standards and terminologies for present-day shell and tube heat exchangers

Who should attend?

The course is developed for project engineers, process engineers, plant and maintenance engineers and supervisors in the
oil, chemical and other process industries who require a wider and deeper appreciation of heat exchanger design,
performance, inspection, maintenance and operation. It should also prove useful to those generally knowledgeable on the
subject, but who may require a refresher or update. No prior knowledge of heat transfer is required. Participants will be
taken through an intensive primer of heat transfer principles as they apply to shell and tube heat exchangers.

Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to [email protected]. Visit us at www.petroedgeasia.net for more information.
 ADVANCED HEAT EXCHANGER DESIGN, PERFORMANCE , INSPECTION,
MAINTENANCE AND TROUBLESHOOTING

3-DAY COURSE OUTLINE

SESSION 1: Heat Transfer Coefficients SESSION 7: Heat Exchanger Energy Balance

 Conduction  Pre-heat Calculations
 Convection  Energy Moduling
 Overall Heat Transfer
 Logarithmic Temperature Differences SESSION 8: Counter Flow Heat Exchanger
 Correction Factors  Worked Example for Double-Pipe Arrangement
 Fouling
SESSION 9: Heat Exchanger Selection for a Given Process
 Effectiveness
 Course and Fine Filters

SESSION 2: Types of Heat Exchangers  General Points on Material Selection and Pressures
 Double-Pipe  Thermal Effectiveness
 Parallel-Flow and Counter-Flow  Advantages and Disadvantages of Double-Pipe Arrangements
and Scope of Application
 Compact
 Common Materials Used
 Shell and Tube
 Shell and Tube Heat Exchangers
 Plate and Frame
 Plate and Frame Heat Exchangers
 Regenerative
 Advantages and Disadvantages of These Types and Scopes of
 Condensers Application
 Boilers  Air-Cooled Heat Exchangers
 Space Radiators  Plate-fin Heat Exchangers
 Addition of Fins  Printed Circuit Heat Exchangers
 Advantages and Disadvantages of these Types and Scopes of
SESSION 3: Worked Examples Application
 Calculation of Overall Heat Transfer Coefficient for a Heat
Exchanger SESSION 10: Heat Exchanger Costing
 Effect of Fouling on the Overall Heat Transfer Coefficient  Scoping
 Condensation of Steam in a Condenser  Quick-sizing
 Correction Factors
SESSION 4: Industrial Features and Additional Information
 Estimation of the Overall Heat Transfer Coefficient
 Industrial Distribution of Different Types
 Estimating Cost
 Condensation, Evaporation, Heat Recovery, Heat Rejection
 ESDU Data
 Power Cycles, Distillation, Recuperators, Regenerators
 Logarithmic Interpolation

 Worked Example in the Estimation of Cost of a Plate/Frame
SESSION 5: Heat Exchanger Analysis in Detail Heat Exchanger
 The Fluid Mechanics of Heat Exchangers with Laminar and
Turbulent Properties Explained
SESSION 11: Multi-pass Heat Exchanger
 Logarithmic Mean Temperature Difference Method
 Worked Examples in Determining Heat Transfer Rate with and
 Effectiveness - NTU Method without Effects of Fouling

SESSION 6: Counter Flow, Cross Flow and Multi-Pass Heat SESSION 12: Problem Session
Exchangers
 Numerical Exercises on Multi-pass Heat Exchangers
 Application of Correction Factors
 Worked Examples in the Application of Correction Factors SESSION 13: Cooling of an Automotive/Industrial Compact
 Various Arrangements of Split Shells and Their Numerical Radiator
Solution  Determination of Overall Heat Transfer Coefficient

Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to [email protected]. Visit us at www.petroedgeasia.net for more information.
ADVANCED HEAT EXCHANGER DESIGN, PERFORMANCE , INSPECTION,
MAINTENANCE AND TROUBLESHOOTING

SESSION 14: Effectiveness/NTU Method for Heat Exchanger SESSION 21: Worked Example on a Multi-pass Heat Exchanger
Analysis
 Heat Transfer Effectiveness, Capacity Ratios  Determination of Heat Transfer and Outlet Stream
 Worked Examples on a Counter-flow Heat Exchanger Temperatures

SESSION 15: Upper Limit of Heat Transfer in a Heat Exchanger SESSION 22: New Technologies in Heat Exchangers
 Counter Flow Heat Exchanger  Improving Heat Exchanger Design
 Effectiveness as a Function of NTU  Explaining the Factors that Affect Heat Exchanger Design
 Worked Examples on a Counter-flow Heat Exchanger Margins
 Detailing the Proper Application of Design Margins in order to
Reduce Capital Costs and Improve Plant Operation
SESSION 16: Shell and Tube Heat Exchangers
 Advanced Heat Exchangers for Enhanced Air-Side
 Heat Exchanger Inspection
Performance: A Design and Manufacturing Perspective
 Scope
 Construction
 TEMA Standards and Terminologies
 Fluid Allocation
 Design Problems, Design Enhancement Sessions commence at 9am on all days, with short intervals at 10.30am and
3.30pm respectively with light refreshment. Lunch will be provided at
 Examples
12:30pm for 1 hour. Sessions will end at 5pm on all days.

SESSION 17: Heat Exchanger Maintenance

 Planning
 Precautions Required
 Plugging
 Ferruling
 Sleeving
 Shell Side Repairs
 Re-tubing

SESSION 18: Fouling Control of Heat Exchanger

 Uncertainties in Heat Transfer Methods and Fluid Properties
 Fouling and No-fouling fluids

SESSION 19: Heat Exchanger Inspection Techniques

 Visual, NDT
 Common Failures
 Inspection Tools
 Inspection Codes

SESSION 20: Design of Shell and Tube Heat Exchangers

 Achievement of Duty Required
 Developing Design Envelope
 Choosing the Best Design
 Pressure Drop and Tube Vibration Issues

Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to [email protected]. Visit us at www.petroedgeasia.net for more information.
ADVANCED HEAT EXCHANGER DESIGN, PERFORMANCE , INSPECTION,
MAINTENANCE AND TROUBLESHOOTING

About your Expert Course Director:

Your expert course leader (UK, B. Sc., M.Eng., Ph D) is a Senior Mechanical & Instrumentation Engineer with over 45
years of industrial experience in Process Control & Instrumentation, Pumps, Compressors, Turbines and Control Valve
Technology. He is currently a Senior Independent Consultant to various petrochemical industries in the UK, USA,
Oman, Kuwait and KSA where he provides consultancy services on both the application and operational constraints of
process equipment in the oil & gas industries.

During his early career, he held key positions in Rolls Royce (UK) where he was involved in the design of turbine blading
for jet engines, subject to pre-specified distributions of pressure. During this period and since, he has also been closely
involved in various aspects of Turbomachinery, Thermodynamics and Fluid Mechanics where he has become a
recognised authority in these areas.

Later, he joined the academic staff of University of Liverpool in the UK as a Professor in Mechanical Engineering
Courses. A substantial part of his work has been concerned with detailed aspects of Flowmetering – both of single &
multiphase flows. He has supervised doctoral research students in this area in collaboration with various European
flowmeter manufacturers.

He joined Haward Technology Middle East in 2002 and was later appointed as European Manager (a post which has
since lapsed) and has delivered over 150 training courses in Flowmeasurement (single- and multi-phase), Control, Heat
Exchangers, Pumps, Turbines, Compressors, Valve and Valve Selection as well as other topics throughout the UK, USA,
Oman and Kuwait. During the last two years, he has delivered courses with other training companies operating in the
Far and Middle East.

He has published about 150 papers in various Engineering Journals and International Conferences and has contributed
to textbooks on the topics listed above.

Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to [email protected]. Visit us at www.petroedgeasia.net for more information.
 ADVANCED HEAT EXCHANGER DESIGN, PERFORMANCE , INSPECTION,
A D V A N C E D H E A T E XMCAHI N
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MAINTENANCE AND TROUBLESHOOTING
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Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to [email protected]. Visit us at www.petroedgeasia.net for more information.