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11 - OGE-P - Oil & Gas - Processing Facilities

OG-P 162 - Heat Exchanger Re‐tubing (10 Days)

Code Start Date Duration Venue
OG-P 162 12 June 2023 10 Days Istanbul Registration Form Link
OG-P 162 07 August 2023 10 Days Istanbul Registration Form Link
OG-P 162 02 October 2023 10 Days Istanbul Registration Form Link
OG-P 162 27 November 2023 10 Days Istanbul Registration Form Link
OG-P 162 11 December 2023 10 Days Istanbul Registration Form Link
Please contact us for fees


Course Description

This training course will feature the importance and relevance of the significant and expensive items of equipment known as heat exchangers that are used in a wide variety of industries. It will familiarize engineers and technicians with the various standards and practices used for design, manufacture, operation and maintenance of heat exchangers.

To all these engineers with diverse backgrounds and expertise, the principle of heat exchangers design and codes will allow them to understand the recommended practices. This training course will cover all these aspects with respect to engineering design in general and shell and tube exchangers in particular.

Course Objectives

  • Understand heat transfer fundamentals 
  • Analyse exchanger operational parameters 
  • Determine correct troubleshooting techniques 
  • Determine the correct selection criteria for heat exchangers 
  • Troubleshoot exchange problems 

Who Should Attend?

  • Maintenance Professionals 
  • Inspection Personnel 
  • Process Supervisors 
  • Plant Operators and Technicians
  • Plant and maintenance Engineers


Course Details/Schedule

Day 1

  • Types and Applications of Heat Exchangers
  • Overview and Basic Fundamentals
  • Materials of Construction & Fabrication
  • Heat Transfer Fundamentals and Heat Transfer Coefficients
  • Geometry of Shell & Tube Heat Exchangers (STHE)
  • 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
  • Flow vs. Temperature Difference in STHE
  • Temperature Difference in STHE
  • Condensers and Reboilers

Day 2

  • Design of Heat Exchangers
  • Materials of Construction of Heat Exchangers
  • Operation of Heat Exchangers
  • Fouling in Heat Exchangers
  • Corrosion and Erosion in Heat Exchangers
  • Heat Exchanger Inspection Methods
  • Operation and Troubleshooting
  • Performance Monitoring and Testing
  • Heat Transfer Improvement Techniques
  • Finned Tubes
  • Heat Integration Basics
  • Pinch Technology
  • Heat Exchanger Train Optimization

Day 3

  • Vibration Considerations
  • Causes of vibration
  • Possible types of damage
  • Design and operating parameters affecting vibration
  • Potential solutions to vibration problems
  • Maintenance and Repair
  • Evaluating the suitability of corroded components
  • Typical maintenance and inspection procedures
  • Locating leaks
  • Leak repairs
  • Retubing considerations
  • Typical cleaning methods
  • Tube inspection techniques
  • Rerating exchangers

Day 4

  • Heat Exchanger Tube Side Maintenance
  • Repair vs. Replace ‐ Factors to Consider
  • Heat Exchanger maintenance Options
  • Heat exchanger Bundel (Hydraulic/mechanics/lifting plan)
  • Repair option
  • Plug
  • Sleeving
  • Tube Expansion
  • Replacement option
  • Re-bundling
  • Complete replacement
  • Retubing
  • Chiller Retubing
  • Condenser Retubing
  • Absorbers Retubing
  • Lube Oil cooler retubing
  • Boiler Retubing
  • Heat Exchanger Retubing
  • U-tube bundle retubing-replacement

Day 5

  • Troubleshooting and Heat exchangers’ problems
  • Tube Bundle Replacement ‐ Alternative Enhanced Tube Bundle Designs
  • Tube bundle extraction and transporting
  • The Aerial Bundle Extractor / Hydraulic Tube Bundle Extractor
  • Heat Exchangers maintenance procedure phases:
  • tube bundle extraction: with aerial bundle extractor /with truck mounted
  • tube bundle transport
  • bundle cleaning
  • Tube bundle Insertion
  • Heat exchanger retubing by tube sheet cutting method/without tube sheet cutting method
  • Documents required for retubing
  • Method statement (Repair procedure) 
  • Inspection Test plan (ITP) 
  • Welding Procedure Specification (WPS) &Procedure Qualification Record (PQR) 
  • Welder Qualification Test Record (WQTR) 
  • Tube Expansion Procedure (TEP) 
  • NDT Procedures 
  • Hydro Test Procedures & Pneumatic Test Procedures
  • A Case Study on Procedure Standardization of Heat Exchanger Retubing in Oil and Gas Industries

Day 6

  • Cost‐ Effective Maintenance and Repair of Heat Exchangers
  • Tube Cleaning Projectiles
  • Metal tube cleaners
  • Water blasting with high pressure
  • Chemical cleaning
  • Mechanical cleaning with water propulsion and metal tube cleaners
  • Benefits of cleaning with metal tube cleaners
  • Safety Considerations 
  • Quality of cleaning
  • Misconceptions about metal tube cleaners

Day 7

  • Abrasive projectiles
  • Tube projectiles
  • Grinding projectiles
  • Ultra clean projectiles bulk
  • Tube projectiles bulk
  • Product recovery projectiles
  • Tube Cutting and Preparation
  • Pipe Reamers
  • Pipe Cutters
  • Power Pipe Cutting
  • Copper / Stainless Cut & Prep
  • Tubing Cutters
  • Plastic and Multilayer Cutters
  • Reamers, Deburring Tools
  • Pipe Cutter Selection
  • Heavy‐ Duty Pipe Cutters
  • Wheel Pipe Cutters
  • Wide‐ Roll Pipe Cutter
  • Hinged Pipe Cutters

Day 8

  • Power Pipe Cutters
  • Copper & Stainless-Steel Cutting Prep Machine
  • Midget Cutters for Close Quarters Tubing
  • Plastic & Multilayer Pipe Cutters
  • Tube Stubs Removal
  • Traditional Stub Removal
  • Induction Heat Stub Extraction
  • Induction Heating Tube Shrinking
  • Cooling
  • Extraction
  • Induction Heat‐ and‐ Pull
  • Advantages of pulling stubs

Day 9

  • Tube facing equipment
  • Facing pressure
  • Securing the pipe
  • Adjust, align and secure
  • Cleaning
  • Pipe ends extending through the jaw clamps to permit complete facing
  • Finishing the facing the of the pipe
  • Tube Leaks Elimination
  • Solving heat exchanger problems
  • Excessive load
  • Gradual fouling buildup, harming heat transfer
  • Excessive stream pressure loss
  • Failing heat exchanger equipment
  • Inadequate heat transfer
  • Inadequate pressure or temperature rating
  • Instrumentation
  • Detection of leaks in a liquid‐ liquid heat exchanger using passive acoustic noise

Day 10

  • Practical session and site visit