Heat Exchangers - Design, Operation and Performance
Edmonton, AB
(Mar 24 - 26, 2010)
Course Code: 00-0318-2055
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
Description
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 heat transfer and fluid flow 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.
Objectives
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 engineer, 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 interactive course in which participants are drawn into discussions to facilitate learning.
Program Outline
Faculty: Nabil Al-Khirdaji, President, Kappa Associates International
Day I
Registration and Coffee
Welcome, Introduction, Workshop Preview, Learning Outcomes and the Assessment Methods
Overview – Significance of Heat Exchange in the Oil Refining and Process Industries
1.1 Heat Transfer Fundamentals and Heat Transfer Coefficients Mechanisms, types of fluid flow, heat capacity rate ratio, conduction,
forced convection, resistances and fouling, critical and economic insulation thickness, heat transfer coefficients inside tubes, cross
and baffled flow, annuli, and coils
1.2 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, construction, applications, range and limitations, sizes, heat transfer coefficients
1.3 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 design features, relative costs
1.4 Temperature Difference in STHE
Countercurrent, cocurrent, TEMA flow arrangements, comparisons, worked example
1.5 Fluid Flow and Pressure Drop
Single phase, two-phase, friction losses, kinetic losses, tubeside, shellside, nozzles, coils, pipes, worked example
1.6 Workshop 1 Worked examples – heat transfer and fluid flow
Adjournment
Day II
2.1 Thermal Design and Rating of STHE
Strategy, design algorithm, wall temperature, overall heat transfer coefficients, TEMA flow arrangements
2.2 Fouling in Heat Exchangers • Types and mechanisms, economic impact on design and operation
• Fouling mitigation by design
• Fouling mitigation by operation and maintenance
2.3 Condensers and Reboilers
• Types and Application
• General Design Considerations
2.4 Sizing and Specifying STHE
General guidelines and best industry practices, operability and maintainability considerations
2.5 Workshop 2
Worked examples – thermal design and rating of heat exchangers
Adjournment
Day III
3.1 Mechanical Design Features of STHE
Design parameters, design codes, standards and recommended practices (ASME, TEMA, API, HI, AIR, others), selection of materials,
component design, nozzle loadings, supports, lifting features, high pressure, low temperature, specials designs
3.3 Optimization and Performance Enhancement • Heat Integration Basics - Pinch technology, heat exchanger train optimization
• Extended Surface Tubes - Heat transfer augmentation techniques, fin characteristics and efficiency, heat transfer and pressure loss,
longitudinal, low and high finned tubes
• Intube Enhancement - Tube inserts, sintered coatings
• Tube Bundle Replacement - Alternative enhanced tube bundle designs, e.g. rodbaffle, heli baffle, twisted tube, etc.
3.4 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.
3.5 Workshop 3
Worked examples
Questions and Answers to Participants on Achievement of Learning Outcomes
There will be a one-hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session.
Daily Schedule: 8:00 Registration and Coffee (Day I only) 8:30 Session begins 12:00 Lunch 4:30 Adjournment
1.8 CEU / 18 PDH
Faculty
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.
The fee for this course is $1,695 + GST. If you register after February 19, 2010 the fee increases to $1,865 + GST.
On-Site Program
EPIC programs can also be delivered on-site at your premises. For more information on our on-site program, please contact Tim Chugh at 1-888-374-2338 ext. 242 or by email at tchugh@epic-edu.com.
Group Discounts, Cancellations And Withdrawals
Registration covers all program materials, refreshments during breaks and lunch but excludes accommodation. For organizations sending more than one participant, the following discounts to the course fee apply: 10% discount to the second, 15% to the third, 20% to the fourth and 25% to the fifth and subsequent registrations.
To withdraw from a course, you must send your 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 fourteen 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. If a speaker is not available due to unforeseen circumstances, another speaker of equal ability will be substituted. EPIC reserves the right to cancel or change the date or location of its events. EPIC's responsibility will, under no circumstances, exceed the amount of the fee collected. EPIC is not responsible for the purchase of non-refundable travel arrangements or accommodation or any associated cancellation/ change fees. To avoid any fees or charges, please call to confirm that the course is running before confirming travel arrangements and accommodations.
