Heat Exchangers: Types and Application, Design, Operation & Maintenance

Heat Exchangers: Types and Application, Design, Operation & Maintenance

Date/Time: Date(s) - 08/08/2022 - 10/08/2022( 8:00 am - 5:00 pm )
Location: Malaysia, Kuala Lumpur


Heat exchangers are devices designed to transfer heat between two or more fluids—i.e., liquids, vapors, or gases—of different temperatures. Depending on the type of heat exchanger employed, the heat transferring process can be gas-to-gas, liquid-to-gas, or liquid-to-liquid and occur through a solid separator, which prevents mixing of the fluids, or direct fluid contact. Other design characteristics, including construction materials and components, heat transfer mechanisms, and flow configurations, also help to classify and categorize the types of heat exchangers available. Finding application across a wide range of industries, a diverse selection of these heat exchanging devices are designed and manufactured for use in both heating and cooling processes.

This training focuses on heat exchangers, exploring the various designs and types available and explaining their respective functions and mechanisms. Additionally, this training outlines the selection considerations and common applications for each type of heat exchanging device.


At the end of this training you will be able to learn how :

  • To highlight the pivotal function and significance of heat exchangers in cost-effective plant operations.
  • To provide a clear understanding of the fundamentals of heat transfer and hydraulics and fluid flow and their application in the thermal design of heat exchangers.
  • To provide methodologies for the mechanical design of heat exchangers in accordance with industry codes, standards and best practices, specifically ASME BPVC Section VIII, TEMA, and API 660, 661, and 662.
  • To make participants aware of cost-effective technologies and best practices for improving performance of heat exchangers.

Who Should Attend?

Project engineers, process engineers and plant engineers, mechanical engineers involved in design, operations, troubleshooting and maintenance, supervisors, technicians and technologists in the oil, chemical, power, and other industries who require a wider and deeper appreciation of heat exchanger design, performance and operation, coupled with the use of computers. The detailed review of mechanical design is particularly useful to plant and maintenance engineers as well as to those generally knowledgeable in the subject, but who require a refresher or update.


Types and Application of Heat Exchangers

  • Overview and basic fundamentals
    • Significance of heat exchange in the petroleum, petrochemical, and process industries
  • Heat Transfer Fundamentals and Heat Transfer Coefficients
    • Shell and Tube heat exchangers
    • Plate heat exchangers
    • Printed circuit heat exchangers
    • Heat pipes
    • Air-cooled heat exchangers
    • Regenerative heat exchangers
  • Heat Exchanger types and application
  • 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

Thermal and Hydraulic Design of Heat Exchangers

  • Sizing and Specifying the heat exchanger
  • Temperature Difference In STHE
    1. Countercurrent, co-current, and cross-current
    2. TEMA flow arrangements, comparisons
  • Fluid Flow and Pressure Drop
    1. Shell & Tube heat exchangers
    2. Plate heat exchangers
  • Condensers and Recoilless
    1. Types and application
    2. General design considerations

Mechanical Design of Heat Exchangers

  • Design and construction codes and best practices
    1. ASME B&PVC Section VIII
    2. API 660, 661, and 662
    3. TEMA
  • Basic design of heat exchangers – S&THE, PHE, ACHE
  • Special design considerations
    1. Piping loads on exchanger nozzles
  • Materials of construction for heat exchangers
    1. Impact of service conditions on material selection
  • Fabrication of heat exchangers
    1. Shell & tube heat exchangers
    2. Plate heat exchangers

Operation and Maintenance of Heat Exchangers

  • Fouling In Heat Exchangers
    1. Types and mechanisms, economic impact on design and operation
    2. Fouling mitigation by design
    3. Fouling mitigation by operation and maintenance
  • Corrosion and erosion in heat exchangers
  • Heat Exchanger Inspection Methods
  • Operation and Troubleshooting
    1. Performance monitoring and Testing
    2. 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
    1. Cleaning strategies and methods: S&THE, PHE, ACHE
    2. Heat Exchanger Repairs
    3. Removal and Replacement of Heat Exchangers

Performance Enhancement and Optimization of Heat Exchangers

  • Heat transfer augmentation techniques
    1. Finned tubes
    2. In-tube Enhancement – Tube inserts, sintered coatings
  • Tube Bundle Replacement – Alternative enhanced tube bundle designs
    1. rod baffle
    2. heli baffle
    3. twisted tube
  • Heat Integration Basics
    1. Pinch technology
    2. heat exchanger train optimization

Training Methodology

  • Case Studies.
  • Individual and group discussions and exercises.
  • Intensive training by using templates, diagrams, and charts.
  • Planning activities and presentations.
  • Self-assessments.
  • Action plan.

Request Booking

Bookings are closed for this course.

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