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Heat Exchanger Operation, Maintenance & Repair

Dates Venues Register
21/12/2025 - 25/12/2025 DUBAI

Introduction

Heat Exchanger Operation, Maintenance & Repair

What are the Goals?

By the end of this heat exchanger design course, participants will be able to:

  • Understand the design principles and selection criteria of different types of heat exchangers
  • Analyze heat transfer and hydraulic performance parameters for optimized operation
  • Apply international codes and standards for fabrication, inspection, and maintenance
  • Identify operational problems such as fouling, corrosion, and pressure drop issues
  • Perform performance monitoring, diagnostics, and root cause analysis
  • Apply effective troubleshooting and maintenance techniques to enhance lifecycle efficiency

Who is this Training Course for?

This heat exchanger training course is ideal for professionals responsible for the operation, maintenance, inspection, or technical management of thermal systems. It is especially beneficial for:

  • Maintenance Engineers and Technicians
  • Process Engineers and Supervisors
  • Plant Operators working with heat exchanger systems
  • Inspection and Reliability Personnel
  • Plant Managers and Technical Managers in energy and process industries

 

The Course Content

Day One: Types and Applications of Heat Exchangers
  • Heat Exchanger Types and Applications: Choice of Working Fluid
  • Heat Transfer Fundamentals and Heat Transfer Rates
  • Heat Exchanger Elements: Tube Bundles, Tube Sheets, Baffles and Nozzles
  • TEMA Nomenclature of Shell & Tube Heat Exchangers (STHE)
  • Air Cooled Heat Exchangers (ACHE) and Plate Heat Exchangers (PHE)
  • Condensers, Evaporators and Reboilers
Day Two: Thermal and Hydraulic Design of Heat Exchangers
  • Flow vs. Temperature Difference in STHE
  • Thermal Specification of Heat Exchangers: Sizing and Rating
  • Hydraulic Design of STE: Fluid velocity and Pumping Power Calculation
  • Aerodynamic Design of ACHE: Sizing of Fans and Drive
  • Sizing and Specifying of PHE Units: Compabloc Design     
  • Workshop: Case Studies, Examples & Solutions
Day Three: Mechanical Design of Heat Exchangers
  • Mechanical Design of Heat Exchangers
  • Calculation of Basic Elements of STHE
  • Piping Loads on Exchanger Nozzles
  • Material selection and Construction of Heat Exchangers
  • Fabrication Technologies of Heat Exchangers
  • Workshop: Case Studies, Examples & Solutions  
Day Four: Operation and Maintenance of Heat Exchangers
  • Fouling and scaling in tubes and shells: Problem Solutions and Remedies
  • Inspection Techniques of Vital Elements of Heat Exchangers
  • Corrosion & Erosion Reduction Techniques, Fitness for Service Analysis (FFS)
  • Control in Operation: Tube Vibration & Troubleshooting
  • Cleaning, Maintenance and Repair Techniques: Tube Plugging and Re-tubing
  • Workshop: Case Studies, Examples & Solutions  
Day Five: Performance Enhancement and Optimisation of Heat Exchangers 
  • Performance Monitoring and Testing
  • Performance Validation
  • Heat Transfer Augmentation Techniques
  • Tubes with external and internal fins
  • Heat Integration Basics: Pinch Technology
  • Workshop: Case Studies, Examples and Solutions

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