Heat Exchangers and Fired Heaters Design, Repair and Maintenance

The objectives of the course are:
• Gain a comprehensive understanding of the key principles of Heat Exchanger operation and design and how these relate to the efficient and safe use of these types of equipment
• Improve understanding of the operation and maintenance considerations, deliberations of Heat Exchanger equipment with regard to overall process plant integration
• To provide methodologies for the mechanical design of heat exchangers in line with industry codes, standards and best practices, specifically ASME BPVC Section VIII, TEMA, and API 660, 661, and 662
Types and Application of Heat Exchangers
• 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

Methodology
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.

DATE:

1ST BATCH:        14th – 17th Jan, 2025     

2ND BATCH:       9th – 11th June, 2025