Heat Exchangers and Fired Heaters Design, Repair and Maintenance

• Overview and basic fundamentals
• Significance and importance 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
• Worked examples – heat transfer
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
• First Principles: Velocity Triangles and Performance Derivation
• Pump performance curves: head-capacity, power, efficiency
• System curve: static, friction, pressure head components
• Fluid Flow and Pressure Drop
o Shell & Tube heat exchangers
o Plate heat exchangers
• Condensers and Re-boilers
o Types and application
o General design considerations
• Worked examples: Tube heat exchangers, Thermal design and rating shell
Mechanical Design of Heat Exchangers
• Design and construction codes and best practices
o ASME B&PVC Section VIII
o API 660, 661, and 662
o TEMA
• S&THE, PHE, ACHE – Basic design of heat exchangers
• Special design considerations
o Piping loads on exchanger nozzles
• Materials of construction for heat exchangers
o Impact of service conditions on material selection
• Fabrication of heat exchangers
o Shell & tube heat exchangers
o Plate heat exchangers
• Worked examples: Mechanical design of STHE
Operation and Maintenance of Heat Exchangers
• Fouling in Heat Exchangers
o Types and mechanisms, economic impact on design and operation
o Fouling mitigation by design
o Fouling mitigation by operation and maintenance
• Corrosion and erosion in heat exchangers
• Heat Exchanger Inspection Methods
• Operation and Troubleshooting
o Performance monitoring and Testing
o Flow-induced vibration, mechanisms, vibration prediction, damage numbers, design procedure to avoid vibration including baffle selection, rod baffle exchangers, twisted tube exchangers
• Cost-effective maintenance and repair of heat exchangers
o Cleaning strategies and methods: S&THE, PHE, ACHE
o Heat Exchanger Repairs
o Removal and Replacement of Heat Exchangers
Performance Enhancement and Optimization of Heat Exchangers
• Heat transfer augmentation techniques
o Finned tubes
o In-tube Enhancement – Tube inserts, sintered coatings
• Tube Bundle Replacement – Alternative enhanced tube bundle designs
o Rod baffle
o Heli baffle
o Twisted tube
• Heat Integration Basics
o Pinch technology
o heat exchanger train optimization
• Illustrative example: Heat exchanger network optimization

1ST BATCH: Tuesday, January 13, 2026 — Friday, January 16, 2026.

2ND BATCH: Tuesday, May 5, 2026 — Friday, May 8, 2026.

3RD BATCH: Tuesday, September 1, 2026 — Friday, September 4, 2026.

The training methodology integrates lectures, interactive discussions, collaborative group exercises, and
illustrative examples. Participants will acquire a blend of theoretical insights and hands-on practical
experience, emphasizing the application of learned techniques. This approach ensures that attendees return
to their professional environments equipped with both the competence and self-assurance to effectively
implement the acquired skills in their responsibilities.