Heat Exchangers - Design, Operation and Performance

Online /
Nov 1 - 4, 2022 /
Course Code: 13-1106-ONL22

  • Overview
  • Syllabus
  • Instructor


Please note, This instructor-led course has specific dates and times:
This course is held online over 4 days on the following schedule (All times in Eastern Time Zone):

9:30 am to 5:30 pm Eastern (Will include the usual breaks)

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

  • Understand the principles of heat transfer in heat exchangers
  • Gain knowledge on heat exchanger design and performance rating
  • Make a proper selection of type of heat exchanger for a given application
  • Perform thermal–hydraulic design of heat exchangers
  • Apply relevant standards, codes and best industry practices
  • Discuss operation and efficiency of condensers and reboilers
  • Analyze in-service performance issues related to fouling and corrosion,
  • Address remedies for vibration and other deteriorations


The course will present the basic principles of heat transfer and fluid flow in heat exchangers. The design and operation of shell and tube heat exchangers (STHE), air-cooled exchangers (ACHE), plate heat exchangers (PHE) will be discussed in detail. This intensive course will provide means to improve the heat exchanger effectiveness and the extension of life of equipment. The course will provide explanations on how to use the standards and codes such as API, TEMA, and ASME and other recommended practices.

Class workshops and discussions will cover the selection of materials, technologies for fabrication. The course will also cover various methods for efficient operation and performance improvement of heat exchangers, including fouling and corrosion mitigation techniques, and control of tube bundle vibration. Presented also will be the best practices for efficient repair of heat exchangers

This course will include several class workshops that will include case studies and selected practical real-world examples to be solved in teamwork.

Course Outline

  • Heat exchanger fundamental 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: tube bundles, baffles and vibration
  • Inspection, Maintenance and Troubleshooting: fouling, corrosion, failures
  • Workshops: Case studies, examples and solutions

Who Should Attend
The course is intended for those involved in selecting, procurement, and operation of heat exchangers in various industries, as well as for those involved in maintenance and troubleshooting:
Project engineers • Process engineers • Mechanical engineers • Plant and Maintenance engineers • Facilities engineers • Engineering technologists, Supervisors, and Managers

More Information

Time: 9:30 AM - 5:30 PM Eastern Time

Please note: You can check other time zones here.


Day-1: Shell and Tube Heat Exchangers (STHE)

  • Principles of Heat Transfer: Efficiency and Choice of Working Fluid
  • Temperature Difference Consideration: Sizing of Heat Exchanger
  • Heat Exchanger Configurations (TEMA) and Major Design Components
  • Construction of Tube Bundle, Tube Sheet, Baffles, Shell and Nozzles
  • Material Selection and Fabrication Technologies
  • Thermal Design Considerations:
  • Effectiveness and ε-NTU method
  • Evaluation of Fluid Pressure Drop and Pumping Power
  • Control in Operation: Tube Vibration & Troubleshooting
  • Workshop: Case Studies, Examples & Solutions

Day-2: Air Cooled (ACHE) and Plate Heat Exchangers (PHE)

  • Specifics of Air Cooling as Applied to ACHE in Process Industry
  • ACHE Configurations & Main Design Components
  • Construction and Fabrication of Tube Bundle with Finned Tubes
  • Aerodynamic Design: Selection and Sizing of Fans and Drives
  • Control in Operation for Various Ambient Conditions
  • Characteristics of PHE and Compabloc Units
  • Flow vs. Temperature Difference in PHE
  • Problems in Operation
  • Workshop: Case Studies, Examples & Solutions

Day-3: Condensers, Reboilers, Cooling Towers

  • Condensation Heat Transfer: Selection of Cooling Medium
  • Surface Condenser Configurations and Main Components
  • Design of Tube Bundle, Water Boxes, Hot Well and Vacuum System
  • Condenser Vacuum Problems and Air Evacuation Techniques
  • Boiling in Boiler Tubes and Pool Boiling
  • Reboilers: Configurations, Design and Applications
  • Cooling Towers: Effect of Fill Media
  • Effect of Wet Bulb Temperature
  • Workshop: Case Studies, Examples & Solutions

Day-4: Performance Monitoring, Validation and Maintenance

  • Performance Testing and Validation
  • Monitoring of Operating Parameters
  • Efficiency Improvement Methods
  • Typical problems in Operation
  • Fouling and Scaling Removal and Cleaning
  • Inspection of Corrosion and Erosion of Vital Elements
  • Fitness for Service Analysis (FFS, API579)
  • Maintenance, Repairs and Replacements
  • Summary and Conclusions


Mike Ivanovic, Ph.D.

Dr. Mike Ivanovic is President of UBAMIP Consulting, and also a former Adjunct Associate Professor at U of Toronto.

After working in the consulting group of ANSYS Canada Ltd., he now runs the private consulting company UBAMIP Consulting in Waterloo.

Mike has been very active in providing training courses of various levels of complexity for professionals in industry in Canada, USA and overseas.

His area of professional expertise has been the analysis and problem solving in operation of pressure systems, specifically of stationary components such as pressure vessels, storage tanks and piping systems, together with rotating machinery, such as pumps, compressors and turbines, in the process and petrochemical industry.

Technical consulting projects also included design, operation and maintenance of various thermal engineering components, such as heat exchangers and industrial heaters.

The focus in most of the projects has been on the equipment optimization, combined with the risk assessment and failure prevention technologies based on fitness for service studies and remaining life analysis.


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Course Rating
4.4 out of 5

Overall rating of this course by its previous attendees!

Fee & Credits

$2595 + taxes

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

Group Training
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