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10 - OGE-P - Oil & Gas - Processing Facilities
OG-P 163 - Heat Exchangers: Principles, Operation and Maintenance (10 Days)
| Code | Start Date | Duration | Venue | |
|---|---|---|---|---|
| OG-P 163 | 21 July 2025 | 10 Days | Istanbul | Registration Form Link |
| OG-P 163 | 15 September 2025 | 10 Days | Istanbul | Registration Form Link |
| OG-P 163 | 10 November 2025 | 10 Days | Istanbul | Registration Form Link |
| OG-P 163 | 01 December 2025 | 10 Days | Istanbul | Registration Form Link |
Please contact us for fees
Course Description
Heat exchangers are the workhorses in a refinery and as long the heat exchanger perform its duty, nobody pay’s attention; but in real life it’s different. Process changes, stringent emission regulations might evolve in excessive fouling, high pressure drops and tube vibration which lead to CAPEX intensive replacements.
This course is comprehensive and highly interactive. It combines structured and focused presentations and discussions of topics covered with actual relevant examples. It combines sound engineering principles, methods, and applicable codes & standards and best industry practices with workshops that cover worked examples to enforce the learning. It provides in depth practical understanding of major proven heat exchanger technologies and “state of art” fouling mitigation technologies. This intensive online training course provides a good mix of theory and common practices using highly interactive case studies.
Course Objectives
- Describe shell-and-tube heat exchanger technology – what’s new and how to apply it.
- Discuss the critical aspects of heat exchanger design, operation and Maintenance
- Illustrate the thermal design of shell-and-tube heaters, coolers, column reboilers and condensers.
- Identify methods to quickly and accurately troubleshoot, diagnose and correct operating problems in distillation column reboilers and condensers.
- Gain essential and integrated knowledge about the hydraulic, thermal and mechanical design of heat exchangers
- Predict and identify causes of performance degradation and damage mechanisms that affect heat exchangers fitness for continued service and thereby reduce the risk of potential failures and waste of energy
Who Should Attend?
- Technichians
- Supervisors
- Engineers involved in plant operations, maintenance, technical services and project design
Course Details/Schedule
Day 1
- Overview and basic fundamentals
- Heat transfer fundamental
- Conduction
- Convection
- Radiation
- Heat transfer coefficients
- Heat transfer properties of fluids
- Laminar flow
- Turbulent flow
- Units
- Workshop : Worked examples - heat transfer
Day 2
- Fundamentals of heat exchanger performance
- Energy balance
- Rating methods − F-LMTD−e-NTU
- Pressure drop
- Performance margins −Fouling factors−Cleanliness factors
- Heat exchanger selection criteria
- Cost
- Operating Conditions −Transient
- Maintenance needs−Cleaning schedule
- Material selection −Fluid compatibility
- Mechanical considerations−Temperature and pressure
Day 3
- Significance of heat exchange in the petroleum, petrochemical, and process industries Heat Transfer Fundamentals and Heat Transfer Coefficients
- Heat Exchanger types and application
- Shell and Tube heat exchangers
- Compact heat exchangers
- Plate-frame exchangers
- Printed circuit heat exchangers Heat pipes
- Air-cooled heat exchangers
- Regenerative heat exchangers
- Compact plate-fin exchangers
- Single-phase applications
- Boiling/evaporating
- Condensation
- Pressure drop
- Extended surfaces
- Enhancements
- 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
Day 4
- Boiling applications
- Boiling fundamentals − Pool boiling − Flow boiling
- Two-phase pressure drop
- Typical services −Refrigerant evaporator s−Reboilers - Condensing applications
- Condensing fundamentals −Film condensation −Condensing regimes
- Pressure drop considerations
- Condenser geometries
- Operational problems
- Fouling
- Vibration
- Venting and draining
- Reboiler problems −Instability− Film boiling
- Temperature Pinch
- Troubleshooting
- Use of field data - accuracy of measurements−Accuracy of performance models
- Inspections−Typical mechanical defects/degradation
Day 5
- Operation and Maintenance of Heat Exchangers
- Fouling In Heat Exchangers
- Types and mechanisms, economic impact on design and operation Fouling mitigation by design
- Fouling mitigation by operation and maintenance Corrosion and erosion in heat exchangers
- Heat Exchanger Inspection Methods Operation and Troubleshooting Performance monitoring and Testing
- Flow-induced vibration, mechanisms, vibration prediction, damage numbers, design procedure to avoid vibration including baffle selection, rod baffle exchangers, twisted tube exchangers
- Cleaning strategies and methods: S&THE, PHE, ACHE Heat Exchanger Repairs
- Removal and Replacement of Heat Exchangers
- Cost-effective maintenance and repair of heat exchangers
Day 6
- Performance Enhancement and Optimization of Heat Exchangers
- Heat transfer augmentation techniques Finned tubes
- In-tube Enhancement - Tube inserts, sintered coatings
- Tube Bundle Replacement - Alternative enhanced tube bundle designs rod baffle heli baffle twisted tube
- Pinch technology
- heat exchanger train optimization Heat Integration Basics
- Workshop : Illustrative example: Heat exchanger network optimization
Day 7
- Maintenance, Operation and Troubleshooting
- Tube inspection technique
- Locating leak and repair
- Troubleshooting
- Performance monitoring and cleaning strategies and methods
- 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
Day 8
- Technical field visits to relevant authorities
Day 9
- Technical field visits to relevant authorities
Day 10
- Technical field visits to relevant authorities
