This 2-day training course has been designed for in-depth introduction, it will familiarize engineers and technicians with the various standards and practices used for design, manufacture, operation, and maintenance of heat exchangers. To all these engineers with diverse backgrounds and expertise, the principle of heat exchangers design and codes will allow them to understand the recommended practices. Detailed troubleshooting and diagnostics, Condition Monitoring, maintenance, and reliability program will supplement the course. Applications in continuous, Emergency and Prime Mover service considerations will be discussed in detail.

This training is focused in understanding how to improve equipment and its systems Availability, Reliability, Maintainability and Overhaul by discussing the operating variables which impact reliability.

Performance Assessment and RLA discussion will be in depth. Participants will learn Use of Operational and Maintenance manuals, Specific Operating Instruction Manuals, Performance Curves / Tables.


Our Consultant Has Over 27+ years of experience in Mechanical Power Engineering , Consulting , Training & Development includes. A highly experienced Professional Engineer with Six Sigma qualification & demonstrated ability to lead diverse teams of professionals to new levels of success in a variety of highly competitive industries, cutting-edge markets, and fast-paced environments. Over 27 years of experience in the Engineering industry in the field of Maintenance and reliability engineering, Risk-based analysis and studies, performance evaluation of Power Plants, Plant maintenance repair & overhaul of Turbo Machinery in Oil & Gas, Petrochemical, Power Generation, and Aviation Industry. Strong technical qualifications with an impressive track record comprising of Plant and Equipment Maintenance Strategies. Proven ability to successfully analyze an organization's critical engineering requirements, identify deficiencies and potential opportunities, and develop innovative and cost-effective solutions for enhancing efficiency, increasing reliability, Maintenance cost reduction, and improving engineering processes. Highly sought after Technical Trainer in Process, Power Generation and Aviation in RCM Based Maintenance & Reliability Program Development / Implementation Strategies, Turbo Machinery, Risk-Based Maintenance Study, Plant Asset Management & Reliability Analysis.



  • Introduction General

  • • Program outline
    • Terms, Definitions, Symbols and Abbreviations
    • Design Codes API Standard 660
    • Regulations
    • Nomenclatures
    • Vendor and Purchaser
    • Documentation
    • Reports

  • Types and Applications of
    Heat Exchangers

  • • Overview and Basic Fundamentals
    • Heat Exchanger Types and Application
    • Heat Transfer Fundamentals and Heat Transfer
    • Coefficients
    • LMTD-Method
    • Geometry of Shell & Tube Heat Exchangers (STHE)
    • Double Pipes TEMA Nomenclature, Front End
    • Head Types, Shell Types
    • Rear End Types, Double Pipe Units, Selection
    • Guidelines

  • Thermal and Hydraulic Design
    of Heat Exchangers

  • • Sizing and Specifying the Heat Exchanger
    • Flow vs. Temperature Difference in STHE
    • Temperature Difference in STHE
    • Condensers and Reboilers

  • Mechanical Design of Heat Exchangers

  • • Mechanical Design of Heat Exchangers
    • Basic Design of Heat Exchangers
    • Special Design Considerations
    • Piping Loads on Exchanger Nozzles
    • Materials of Construction on Heat Exchangers
    • Fabrication of Heat Exchangers

  • Operation and Maintenance of Heat Exchangers

  • • Inspection and Testing
    • Quality Control
    • Pressure Testing
    • Welding and Heat Treatment
    • Repair vs. Replace - Factors to Consider
    • Dimensional Tolerances
    • Heat Exchanger Inspection Methods
    • Risk Based Maintenance Approach
    • Performance Monitoring and Testing
    • Cost-Effective Maintenance and Repair of Heat Exchangers
    • Nameplates and testing

  • Troubleshooting

  • • Heat exchangers problems
    • Fouling in Heat Exchangers
    • Costs of fouling
    • Types of Fouling
    • Fouling Mechanisms
    • Conditions Influencing Fouling
    • Fouling control
    • Fouling cleaning methods
    • Leakage/Rupture of the Heat Transfer Surface
    • Cost of leakage
    • Cause of differential thermal expansion
    • Corrosion
    • Corrosion effects
    • Causes of corrosion
    • Type of corrosion
    • Stress corrosion
    • Galvanic corrosion
    • Pitting
    • Uniform or rust corrosion
    • Crevice corrosion
    • Materials of Construction
    • Fabrication
    • Past failure incidents
    • Failure scenarios and design solutions

  • Performance Enhancement and
    Optimization of Heat Exchangers

  • • Heat Transfer Augmentation Techniques
    • Finned Tubes
    • Heat Integration Basics
    • Pinch Technology
    • Heat Exchanger Train Optimization
    • Tube Bundle Replacement - Alternative Enhanced Tube
    • Bundle Designs

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