Heat Exchangers - Design, Operation and Performance

Edmonton, Alberta /
Sep 9 - 12, 2019 /
Course Code: 10-0915-2370

  • Overview
  • Syllabus
  • Instructor
  • Location


After participating in this course, you will be able to:

  • understand the principles of heat transfer and fluid flow in heat exchangers and the basics of heat exchanger design and performance rating
  • apply a systematic treatment of the proper selection, thermal–hydraulic design, and rating of the various types of heat exchangers including condensers and reboilers
  • apply relevant codes, standards and best industry practices and supporting data
  • optimize heat exchanger design and network configuration
  • analyze in-service performance issues and address cause, effect and appropriate corrective actions including vibration, fouling and other deteriorations

This intensive course will enable you to improve heat exchanger effectiveness and extend the equipment’s life span by teaching the basic principles of fluid flow and heat transfer. You will also learn about the design and operation of shell and tube heat exchangers, as well as compact and air-cooled exchangers.

The problem of heat exchanger design is complex and multidisciplinary. The major design considerations for a new heat exchanger include: process/design specifications, thermal and hydraulic design, mechanical design, manufacturing and cost considerations, and trade-offs and system-based optimization

The course will explain how to use the applicable API, TEMA, and ASME codes, standards, and recommended practices. Class discussions will cover fabrication; materials of construction; the effect and mitigation of fouling; and, causes and preventions of exchanger tube vibration and damage. You will study factors to consider when deciding between repairs and refurbishments of aging equipment.

This course includes workshops that reinforce principles with practical worked examples.

Course Outline

  • Thermodynamics and Heat Transfer Fundamentals and calculations
  • Types and Application of Heat Exchangers
  • Thermal and Hydraulic Design of Heat Exchangers
  • Sizing and Specifying Shell-and-Tube Heat Exchangers (STHE)
  • Mechanical Design Parameters, Codes, Standards and Recommended Practices
  • Basic Mechanical Design of Heat Exchangers: STHE, PHE, ACHE
  • Materials, Construction Features, and Fabrication of Heat Exchangers
  • Heat Exchanger Performance Enhancement – specialty tubes and tube bundles, tube inserts
  • Troubleshooting and Maintenance of heat exchangers – corrosion, fouling, vibration, tube failures
  • Workshop 1 - Worked examples: Heat Transfer
  • Workshop 2 - Worked examples: Thermal Design and Rating of Heat Exchangers
  • Workshop 3 - Worked examples: Mechanical Design of Heat Exchangers
  • Workshop 4 – Illustrative Examples: Heat Exchanger Network Optimization

Who Should Attend
This course is targeted at the oil and gas and refining, petrochemical, process and other industries such as power, pulp and paper, and manufacturing industry, as well as military and other facilities.

The course is intended for project engineers • process engineers • mechanical engineers • plant and maintenance engineers • facilities engineers • engineering technologists, supervisors, and managers, involved in specifying, design, procurement, operations, troubleshooting, and maintenance of heat exchangers. Engineers in Training will benefit greatly from this course.

More Information


Daily Schedule
8:00 Registration and Coffee (1st Day only)
8:30 Session begins
12:00 Lunch (provided)
4:30 Adjournment

There will be a one-hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session.

Day I - Types and Application of Heat Exchangers

Registration and Coffee

Welcome, Introduction, Course Preview, Learning Outcomes, and Assessment Methods

1.1 Significance of Energy Use and Heat Exchange in the Petroleum, Petrochemical, Process, and Power Plants, and Other Facilities

1.2 Thermodynamics and Heat Transfer Fundamentals

  • Laws of thermodynamics
  • Heat transfer fundamentals: thermal properties of fluids, heat capacity rate ratio, conduction, forced convection
  • Critical and economic insulation thickness

1.3 Heat Transfer Coefficients

  • Resistances to heat transfer
  • Local and overall heat transfer coefficients
  • Heat transfer coefficients inside tubes, cross and baffled flow, annuli, and coils

1.4 Types of Heat Exchangers and Their Application

  • Shell-and-tube heat exchangers, air-cooled heat exchangers, gasketed plate, welded plate, spiral tube, spiral plate, printed circuit exchangers, and other specialty exchangers
  • Construction, applications, range and limitations, sizes, heat transfer coefficients

1.5 Geometry of Shell and Tube Heat Exchangers (STHE) and Double Pipes

  • TEMA nomenclature, front end head types, shell types, rear end types, double pipe units
  • Thermal and mechanical design features and relative costs of common STHE configurations

1.6 Workshop 1 - Worked examples: Heat Transfer


Day II - Thermal and Hydraulic Design of Heat Exchangers

2.1 Temperature Difference in STHE

  • Countercurrent, cocurrent, and cross flow: comparisons
  • Worked example

2.2 Fluid Flow and Pressure Drop

  • Single-phase, two-phase, friction losses, kinetic losses, tubeside, shellside, nozzles, coils, pipes
  • worked example

2.3 Thermal Design and Rating of STHE

  • Strategy, design algorithm
  • Wall temperature
  • Overall heat transfer coefficients
  • TEMA flow arrangements

2.4 Condensers and Reboilers

  • Types and applications
  • General design considerations

2.5 Sizing and Specifying STHE

  • General guidelines and best industry practices
  • Operability and maintainability considerations

2.6 Workshop 2 - Worked examples: Thermal Design and Rating of Heat Exchangers


Day III - Mechanical Design of Heat Exchangers

3.1 Design Parameters, Design Codes, Standards and Recommended Practices

  • ASME B&PVC Section VIII,
  • American Petroleum Institute (API) API 660, 661, and 662
  • Tubular Exchanger Manufacturers Association (TEMA)
  • Heat Exchange Institute (HEI)

3.2 Basic Design of Heat Exchangers: STHE, PHE, ACHE

  • Regulations and codes requirements
  • Best industry practices, special design considerations
  • Piping loads on exchanger nozzles
  • Operability and maintainability considerations

3.3 Materials of construction for heat exchangers

  • Impact of service conditions on material selection
  • Common materials of construction for heat exchangers

3.4 Fabrication of Heat Exchangers

  • Shell and tube heat exchangers
  • Shells, channels and heads, tubesheets, bundles
  • Tubes: tubesheet attachment, bolt tightening
  • Plate heat exchangers
  • Air-cooled heat exchangers (fin fans)
  • Non-destructive testing, hydraulic testing

3.5 Workshop 3 - Worked examples


Day IV – Operation, Optimization, and Performance Enhancement of Heat Exchangers

4.1 Fouling in Heat Exchangers

  • Types and mechanisms, economic impact on design and operation
  • Fouling mitigation by design
  • Fouling mitigation by operation and maintenance

4.2 Degradation Mechanisms and Inspection Methods

  • Corrosion and erosion
  • Tube inspection methods
  • Repair strategies and methods
  • Heat exchanger failures: case studies

4.3 Performance Enhancement

  • Heat transfer augmentation techniques: extended surface, tube inserts
  • Alternative enhanced bundle replacements: rod baffle, heli-baffle, twisted tubes

4.4 Heat Exchanger Optimization

  • Heat integration basics
  • Pinch technology
  • Heat exchanger networks

4.5 Operation and Troubleshooting

  • Performance monitoring and cleaning strategies and methods
  • Flow-induced vibration, mechanisms, vibration prediction, damage numbers, design procedures to avoid vibration (baffle selection, rod baffle exchangers, twisted tube exchangers)
  • Cost-effective maintenance and repair of heat exchangers

4.6 Workshop 4 – Illustrative Examples: Heat Exchanger Network Optimization

Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes

Concluding Remarks and Final Adjournment


Nabil Al-Khirdaji, M.Eng., P.Eng.

Nabil is president of Kappa Associates International, which provides engineering and project services to the petroleum, process, energy, and related industries.

Mr. Al-Khirdaji has taught well over 200 technical professional development courses in Canada and internationally. He has over 40 years of experience in the petroleum, petrochemical, and related industries both in Canada and the Middle East, including 24 years with Shell Canada Limited, where he assumed a number of project, engineering specialist, and engineering management positions. He also held the position of mechanical program director with EPIC and a number of senior international positions including project management with an oil and gas engineering company in Milan, Italy. Mr. Al-Khirdaji served for several years on the API committee on refinery equipment.


Radisson Hotel Edmonton South
4440 Gateway Blvd.
Edmonton, AB T6H 5C2
(780) 437-6010

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Fee & Credits

$2995 + taxes

  • 2.8 Continuing Education Units (CEUs)
  • 28 Professional Development Hours (PDHs)
  • ECAA Annual Professional Development Points

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