Heat Transfer Principles and Equipment

Introduction

This Heat Exchangers and Heat Transfer Equipment training course will provide an overview of technical aspects of heat exchangers and other heat transfer equipment as encountered in various industrial applications. Of special interest will be various designs of evaporators and reboilers as well as condensers associated with cooling towers. The training course will also cover specifics of process heaters and industrial boilers, their operation and control. For all these types of heat transfer equipment, basic elements of the thermal and mechanical design will be presented and explained. The focus will be on potential problems in operation, equipment inspection and maintenance methods. Numerous practical examples related to selection and sizing of these equipment will be solved and discussed to illustrate practical methods as encountered in everyday engineering practice.

The training course will highlight:

• Importance of proper selection of heat exchanger for the given application
• Principles based on Codes for safe operation of thermal process equipment
• Methods of analyzing the thermal efficiency of important equipment
• Equipment Inspection (NDT) and Fitness for Service (FFS) procedures
• Heat Exchangers Design Characteristics
• Understanding of Heat Transfer principles
• International Codes and Standards for fabrication, operation and maintenance
• Problems in operation: Fouling and performance monitoring
• Inspection of corrosion, erosion and structural integrity

Objectives

At the end of training course you will learn to:

• Select and properly use different types of heat exchangers
• Optimize the elements of heat transfer equipment
• Analyze the problems in operation
• Use the root cause analysis in problem solving of process equipment
• Apply the best methods of maintenance and problem troubleshooting
• Understand design guidelines and specifications
• Analyse exchanger thermal and hydraulic operational parameters
• Determine the correct selection criteria for sizing of heat exchangers
• Identify the problems in operation that lead to performance deterioration
• Determine correct troubleshooting techniques

Training Methodology

The course will be conducted along workshop principles with formal lectures and interactive examples, which will result in the active participation of all delegates in discussions and teamwork. Real life examples will be selected to provide physical understanding of the problems of operation and control. There will be ample opportunities for active, open discussions and sharing professional experiences on various industrial applications. All course materials will be provided.

Who Should Attend?

• Engineers and technicians in oil & gas, chemical and process industries
• Process, mechanical and chemical engineers
• Engineers and technicians who deal with reactors and piping systems
• Design engineers, project engineers

Course Outline

Day 1: Overview of Operation of Heat Exchangers

• Shell and Tube Heat Exchangers (STHE)

• Thermal Design & Effectiveness

• Hydraulic Design & Pumping Power Determination

• Control in Operation: Tube Vibration & Troubleshooting

• Fouling and Scaling Problem Solution: Cleaning, and Maintenance

• Inspection of Corrosion & Erosion: Fitness for Service Analysis (FFS)

• Repairs: Tube Plugging and Re-tubing

• Workshop: Examples and problem solutions

Day 2: Evaporators, Reboilers and Condensers

• Surface Condenser Configurations and Major Components

• Vacuum Problems and Air Evacuation

• Fouling Problems and Cleaning Techniques

• Common Evaporator Configurations

• Reboiler Designs and Their Industrial Applications

• Problems in Operation, Maintenance and Repair

• Workshop: Examples and problem solutions

Day 3: Operation and Control of Process Heaters

• Application of Industrial Boilers

• Cooling towers: Efficient Operation and Problem Solving

• Solar Thermal Collectors

• Thermal Insulation Materials and Modern Technologies

• Temperature and Heat Flux Measurement Techniques

• Inspection of Thermal Equipment

Types and Applications of Heat Exchangers

• Heat Exchanger Types and Applications: Choice of Working Fluid

• Heat Transfer Fundamentals and Heat Transfer Rates

• Heat Exchanger Elements: Tube Bundles, Tube Sheets, Baffles and Nozzles

• TEMA Nomenclature of Shell & Tube Heat Exchangers (STHE)

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

• Condensers, Evaporators and Reboilers

Day 4: Thermal and Hydraulic Design of Heat Exchangers

• Flow vs. Temperature Difference in STHE

• Thermal Specification of Heat Exchangers: Sizing and Rating

• Hydraulic Design of STE: Fluid velocity and Pumping Power Calculation

• Aerodynamic Design of ACHE: Sizing of Fans and Drive

• Sizing and Specifying of PHE Units: Compabloc Design     

• Workshop: Case Studies, Examples & Solutions

Mechanical Design of Heat Exchangers

• Mechanical Design of Heat Exchangers

• Calculation of Basic Elements of STHE

• Piping Loads on Exchanger Nozzles

• Material selection and Construction of Heat Exchangers

• Fabrication Technologies of Heat Exchangers

• Workshop: Case Studies, Examples & Solutions  

Day 5: Operation and Maintenance of Heat Exchangers

• Fouling and scaling in tubes and shells: Problem Solutions and Remedies

• Inspection Techniques of Vital Elements of Heat Exchangers

• Corrosion & Erosion Reduction Techniques, Fitness for Service Analysis (FFS)

• Control in Operation: Tube Vibration & Troubleshooting

• Cleaning, Maintenance and Repair Techniques: Tube Plugging and Re-tubing

• Workshop: Case Studies, Examples & Solutions  

Performance Enhancement and Optimisation of Heat Exchangers 

• Performance Monitoring and Testing

• Performance Validation

• Heat Transfer Augmentation Techniques

• Tubes with external and internal fins

• Heat Integration Basics: Pinch Technology

• Workshop: Case Studies, Examples and Solutions