Name: Heat Exchangers: Design, Operation and Maintenance
Price: 4500.00 EUR
Availability: InStock

Heat exchangers are among the most common items of equipment in oil, gas, petrochemical, power, desalination and utility plants, and among the most common causes of lost performance. Units are selected with fouling allowances that hide real problems. Operating conditions drift away from design. Performance is not monitored until throughput falls. Cleaning is scheduled by habit rather than data, and tube failures are repaired without understanding the damage mechanism behind them.

This programme follows the exchanger through its life cycle. It moves through five stages: thermal fundamentals and exchanger types, the basics of thermal and mechanical design, operation and performance monitoring, fouling and damage mechanisms, and inspection, maintenance and repair.

Built on recognised practice. The programme references the TEMA Standards for shell and tube exchangers, API 660 for shell and tube heat exchangers, API 661 for air-cooled heat exchangers, ASME Boiler and Pressure Vessel Code Section VIII Division 1, API 510 for pressure vessel inspection, API RP 571 on damage mechanisms and ASME PCC-1 for bolted flange joint assembly. They are used as working references, not as a substitute for the full documents.

Decisions this programme improves. Which exchanger type suits a service; whether a design specification and fouling allowance are sensible; when declining performance justifies cleaning; which cleaning method to use; what inspection scope a turnaround needs; and whether to plug, repair, retube or replace.

How it is delivered. Twenty hours across five sessions, built around one running case: a crude preheat train with falling outlet temperature and a history of tube leaks. Participants calculate duty and overall heat transfer coefficient from plant data, estimate the cost of fouling, choose a cleaning strategy and plan an inspection and repair scope using simple spreadsheet tools.

In-house option. For organisations, the programme can be tailored to your own exchanger types, services, datasheets, inspection records and maintenance procedures, and delivered for process, mechanical, inspection and operations staff together.

Who Should Attend

Process engineers: process, operations and energy engineers responsible for exchanger performance

Mechanical and maintenance engineers: static equipment, maintenance and reliability engineers

Inspection staff: inspection engineers and technicians responsible for pressure equipment

Operations supervisors: shift supervisors and senior operators in process and utility plants

Technical staff: planners, technicians and project engineers involved in exchanger specification or turnarounds

Objectives

Explain the heat transfer principles behind exchanger performance, including LMTD and effectiveness methods

Select suitable exchanger types for different services and operating conditions

Read TEMA designations, datasheets and key mechanical design features of shell and tube exchangers

Calculate duty and overall heat transfer coefficient from plant data and compare them with design

Monitor performance and estimate the energy and throughput cost of fouling

Identify common fouling and damage mechanisms and their operating causes

Choose appropriate cleaning methods and plan cleaning based on performance data

Define inspection scope and methods for shell and tube, plate and air-cooled exchangers

Plan safe maintenance activities, including bundle removal, testing and bolted joint assembly

Decide between plugging, repair, retubing and replacement on technical and economic grounds

Course Outline

Heat Transfer Fundamentals and Exchanger Types

Conduction, convection and overall heat transfer coefficient
LMTD, correction factors and the effectiveness-NTU method
Shell and tube exchangers and TEMA front, shell and rear head types
Plate, plate-fin, double pipe and spiral exchangers
Air-cooled exchangers, condensers, reboilers and feedwater heaters
Selecting the right type for pressure, temperature, fouling and maintenance needs

Thermal and Mechanical Design Essentials

Reading a heat exchanger datasheet
Fluid allocation, velocities, pressure drop and baffle arrangements
Fouling resistance and design margins: benefits and risks
Materials selection and corrosion allowance
Mechanical design under ASME Section VIII and API 660 and API 661 requirements
Vibration, thermal expansion and design for maintainability

Operation and Performance Monitoring

Start-up, shutdown and safe operating limits
Monitoring duty, approach temperatures and pressure drop
Calculating and trending the overall heat transfer coefficient
Energy and throughput cost of fouling
Operating practices that reduce fouling and damage
Digital monitoring, online data and predictive analytics for exchanger networks

Fouling, Corrosion and Damage Mechanisms

Types of fouling: particulate, scaling, biological, chemical reaction and corrosion
Cooling water treatment and seawater service
Damage mechanisms under API RP 571: corrosion, erosion, vibration and cracking
Tube-to-tubesheet joint failures and leak causes
Root cause analysis of repeated failures
Mitigation through design changes, operating limits and chemical treatment

Inspection, Cleaning, Maintenance and Repair

Inspection planning and risk-based inspection principles
Inspection methods: visual, eddy current, IRIS and pressure testing
Mechanical, hydro-jetting and chemical cleaning methods and their safety
Bundle pulling, handling, testing and reassembly
Bolted flange joint assembly and gasket practice under ASME PCC-1
Plugging, retubing and replacement decisions and life cycle cost
Action plan: improving exchanger reliability in your plant

Competencies

Heat transfer and exchanger performance fundamentals

Heat exchanger type selection

Datasheet and TEMA designation interpretation

Performance monitoring and fouling cost analysis

Fouling and damage mechanism identification

Cleaning method selection and planning

Heat exchanger inspection planning

Bundle handling and bolted joint assembly

Repair and replacement decision-making

Dubai

Elite Academy can deliver its complete portfolio of professional training programs in Dubai. With a global business, aviation and services hub with excellent international accessibility, the destination suits both scheduled learning and tailored arrangements for organizations or individual professionals. As an Elite Academy training destination, Dubai provides access to our full portfolio rather than a city-specific set of specializations. The city is a global business, aviation and services hub with excellent international accessibility, creating a suitable environment for organizations developing their teams and for professionals attending independently. Upcoming scheduled courses are listed on this page, while any other Elite Academy program can also be requested for delivery in Dubai, subject to scheduling and delivery requirements. Explore the schedule or browse our training areas to find the right option.

Heat Exchangers: Design, Operation and Maintenance