Advanced Shell and Tube Industrial Heat Exchanger: Design, Applications and Maintenance
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Advanced Shell and Tube Industrial Heat Exchanger: Design, Applications and Maintenance Course
Introduction:
Modern heat exchangers require knowledge of fluid flow and heat transfer concepts, as well as access to numerically based techniques and accompanying data, for proper design, performance, and operation. The principles of heat transmission as they relate to plate and tubular devices will be reviewed in this course. After completing this course, participants will have a better grasp of how fundamental concepts in fluid flow and heat transfer are applied to the design, operation, and maintenance of compact and air-cooled heat exchangers in addition to shell and tube heat exchangers. Understanding TEMA and ASME codes as well as how to quantitatively assess various heat exchanger setups will be imparted to participants.
Course Objectives:
Upon the successful completion of this course, each participant will be able to:
- Design, inspect, maintain and operate heat exchangers and analyze their performance in a professional manner
- Employ the concepts of heat transfer coefficients and determine their overall effect on heat exchanger fouling
- Differentiate between the various types of heat exchangers
- Discuss the industrial features and other information that explain distributed types in relation to power cycles, distillation, recuperators, economizers and regenerators
- Carry out heat exchanger analysis for counterflow, cross-flow and multi-pass heat exchangers and to apply the relevant correction factors
- Conduct a heat energy balance for different types of heat exchangers
- Choose the correct heat exchanger for a given application and its costing in line with the advantages and disadvantages of its type and scope of its applications
- Determine the cooling performance of a range of heat exchangers and establish insights on the effectiveness/ NTU method for heat exchanger analysis in terms of heat capacity ratios
- Interpret TEMA standards and terminologies for present-day shell and tube heat exchangers
Who Should Attend?
The course is developed for project engineers, process engineers, plant and maintenance engineers and supervisors in the oil, chemical and other process industries who require a wider and deeper appreciation of heat exchanger design, performance, inspection, maintenance and operation. It should also prove useful to those generally knowledgeable on the subject, but who may require a refresher or update. No prior knowledge of heat transfer is required. Participants will be taken through an intensive primer of heat transfer principles as they apply to shell and tube heat exchangers.
Course Outlines:
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
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: Complex 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
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 Optimization 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