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Heat exchangers are important & expensive items of equipment that are used in a wide variety of industries. A better understanding of the basic principles of fluid flow & heat transfer and their application to the design & operation of shell & tube heat

Course Outline
After participating in this course, you will be able to:
€¢ Explain the principles of heat transfer and fluid flow in shell and tube heat exchangers
€¢ Apply good industry practices and a substantial amount of supporting data needed for design, performance and operation of modern heat exchangers
€¢ Benefit from your insight gained at the course into the cause, effect and mitigation of fouling
€¢ Classify the various types of heat exchangers including the air-cooled exchangers, their application, and recent advance in heat exchanger technologies
€¢ Develop thermal and mechanical design and determine rating considering the practical aspects and tips on shell and tube heat exchangers and the applicable API, TEMA and ASME recommended practices, standards and codes that you learn at the course
€¢ Prevent future problems and damage with your insight into vibration forcing mechanisms
€¢ Determine the causes of failure and correct performance of your heat exchangers
€¢ Achieve cost savings from the newly gained knowledge of fabrication, materials of construction and costs of tubular units, condensers  and reboilers

Heat exchangers are important and expensive items of equipment that are used in a wide variety of industries. A better understanding of the basic principles of fluid flow and heat transfer and their application to the design and operation of shell and tube heat exchangers as well as compact and air cooled exchangers that you gain from this course will enable you to improve their effectiveness and extend their life. You will better understand how to use the applicable API, TEMA and ASME codes, standards and recommended practices. Discussions cover fabrication, materials of construction and costs of tubular units; condensers and reboilers; effect and mitigation of fouling; and causes and prevention of exchanger tubes vibration and damage.

The workshops include practical worked examples to reinforce the key learnings.

€¢ To understand the significance of heat exchange in the refining and process industries and how to optimize heat recovery.
€¢ To review design features and standards for heat exchangers with emphasis on shell-and-tube heat exchangers.
€¢ To discuss techniques of failure prevention and appropriate maintenance procedures.
€¢ To provide information that will enable decisions to be made on the repair and refurbishment of aging equipment.
€¢ To delineate the factors that lead to overall economically advantageous decisions.

Who Should Attend
Project engineers, process engineers and plant engineers, facilities engineers, mechanical engineers involved in design, operations, troubleshooting and maintenance, supervisors, technicians and technologists in the oil, chemical, power, and other industries who require a wider and deeper appreciation of heat exchanger design, performance and operation, coupled with the use of computers. The detailed review of mechanical design is particularly useful to plant and maintenance engineers as well as to those generally knowledgeable in the subject, but who 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 applicable to shell and tube heat exchangers.

Special Feature
This is an intensive and interactive course in which participants are drawn into discussions to facilitate learning.

Program Outline

Faculty: Nabil Al-Khirdaji, President, Kappa Associates International

Day I - Types and Application of Heat Exchangers

Registration and Coffee

Welcome, Introduction, Workshop Preview, Learning Outcomes and the 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 Application
€¢ 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 & tube heat exchangers
   o Shells, channels and heads, tubesheets, bundles,
   o 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
   o 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 procedure to avoid vibration including 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 to Participants on Achievement of Learning Outcomes

Daily Schedule:
8:00 Registration and Coffee (Day I only)
8:30 Session begins
12:00 Lunch
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.


Nabil Al-Khirdaji
Nabil Al-Khirdaji, M. Eng., P. Eng. is president of Kappa Associates International, which provides engineering and project services to the petroleum, process, energy, and related industries. Nabil has taught many professional development courses, and he specializes in the areas of plant integrity and petroleum refinery and process plant equipment design and operation. Mr. Al-Khirdaji holds B.Eng. (Mechanical) degree from the American University of Beirut and M. Eng. degree from the University of Toronto. He is a registered professional engineer with the Association of Professional Engineers of Ontario, Canada.  

Nabil has over 35 years of professional experience mainly in the petroleum, petrochemical and related industries, both in Canada and the Middle East, including 24 years with Shell Canada Limited.  He assumed a number of project, engineering specialist, and engineering management positions with responsibilities covering design & construction; pressure equipment & piping; combustion & heat transfer equipment; mechanical equipment & drives; materials, corrosion & inspection; utilities & energy systems; and engineered safety. He also assumed the position of mechanical program director with EPIC, a primary provider of professional development training in Canada, and a senior project management position with an oil and gas engineering company in Milan, Italy. Mr. Al-Khirdaji served for several years on the API Committee on Refinery Equipment which oversees the development of engineering practices for the design, fabrication, installation, inspection, and use of materials and equipment in refineries and related processing facilities.

Nabil has developed and delivered well over a hundred technical professional development courses covering design, operation and maintenance of process plant equipment and piping systems. He has taught in Canada, USA, Saudi Arabia, Kuwait, Sudan, Yemen, Oman, Abu Dhabi, Dubai and Malaysia, on topics including API 579 Fitness-For-Service, Mechanical integrity in refineries and petrochemical plants, and Layout design of equipment and piping systems.

Prerequisites & Certificates

Certificates offered

2.4 CEUs / 24 PDHs

Cancellation Policy
To withdraw from a course, you must send a request, in writing, with the official receipt to our office. Fifteen or more business days in advance: full refund less $50.00 administration charge. Five to fifteen business days in advance: non-refundable credit of equal value for any future EPIC seminar within one year. Credits are transferable within your organization. In case of an unexpected event occurring after this time, you may send someone else to take your place without any additional cost.
Map & Reviews
EPIC Educational Program Innovations Center
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Would have liked more interactive problem solving.
Reviewed by 2011

This course currently does not have any dates scheduled. Please call 1-877-313-8881 to enquire about future dates or scheduling a private, in house course for your team.

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