QATAR TECHNICAL PETROLEUM CENTER, P.O. Box 9955, Salwa Road, Doha, Qatar.Tel: +974 4458 1440. Fax: +974 4458 0414 Email: antonymgr@qtpc.qa URL: www.qtpc.qa

Heat Exchanger: Design, Performance Inspection and Operation

Course Duration : 5 Days Training

Daily Schedule : 7:30am - 3:30pm

Training Date : Upon Request

Training Venue : Doha

Traning Fees : TBI

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 heat exchangers that you gain from this course will enable you to improve their effectiveness and extend their life. This course discusses the basic concepts of heat exchanger and their different applications. The heat exchanger basic design methods will be covered. The construction of different types of heat exchangers will be presented. This course will focus on Operation, Maintenance and Troubleshooting of different types of heat exchanger. Heat exchanger selection and buying is considered. In addition fouling and corrosion of heat exchangers will be highlighted.

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QATAR TECHNICAL PETROLEUM CENTERQTPC - AN ISO 9001:2008 Regd.

Introduction

Upon completion of this training course, trainees will be able to:• Explain how heat is transferred in a typical heat exchanger and various factors affecting it.• Describe the operation of different types of heat exchangers.• Have a deep understanding of the physics behind heat exchanger design, operation, maintenance and troubleshooting • Aware of the different performance indicators and early signs of thermal or mechanical problems and how to resolve them efficiently • Perform and evaluate the thermal design of heat exchangers • Understand typical heat exchanger maintenance requirements. • Explain what fouling is and how it can be corrected.• Explain what leakage is and how it can be corrected.• Describe a general procedure for starting up and shutting down the heat exchangers.• Describe the maintenance regimens for heat exchangers• learn how to troubleshoot, diagnose, and correct operating problems Take decisions to be made on the repair and refurbishment of aging equipment.

Objectives

MODULE (1) HEAT TRANSFER TERMINOLOGY1.1 Importance of Heat Transfer1.2 Heat & Temperature 1.2.1 Specific Heat 1.2.2 Heat Sources 1.2.3 Temperature 1.3 Heat Capacity1.4 Thermal Equilibrium1.5 Overall Heat Transfer Coefficient MODULE (2) FUNDAMENTAL OF HEAT TRANSFER MECHANISMS

2.1 Conduction2.2 Convection2.3 Radiation2.4 Applications

Contents

QATAR TECHNICAL PETROLEUM CENTER, P.O. Box 9955, Salwa Road, Doha, Qatar.Tel: +974 4458 1440. Fax: +974 4458 0414 Email: antonymgr@qtpc.qa URL: www.qtpc.qa

Gas Turbines: Operation, Maintenance and TroubleshootingQATAR TECHNICAL PETROLEUM CENTER

QTPC - AN ISO 9001:2008 Regd.

MODULE (3) HEAT EXCHANGERS CLASSIFICATIONS3.1 Heat Transfer in Heat Exchangers3.2 Types of Flow through Heat Exchangers 3.2.1 Counter Flow Type 3.2.2 Parallel Flow Type 3.2.3 Cross Flow Type 3.2.4 Cross Counter Flow Type3.3 Categories of Heat Exchangers

MODULE (4) SURFACE HEAT EXCHANGERS4.1 Introduction4.2 Shell-And-Tube Heat Exchangers 4.2.1 Condensers 4.2.2 Feed Water Heaters 4.2.3 Lube Oil Coolers4.2.3 Air Cooler (Air Compressors after Coolers)4.2.4 Evaporators4.2.5 Brine Heaters4.2.6 Air Cooled Exchangers

MODULE (5) DIRECT CONTACT HEAT EXCHANGERS5.1 Direct Contact Heat Exchangers5.2 Types of Direct Contact Heat Exchanger 5.2.1 Spray Type 5.2.2 Tray Type 5.2.3 Combined Type 5.2.4 Shell and Storage Tank Arrangements5.3 Typical Direct Contact in Plants 5.3.1 Deaerator 5.3.2 Cooling Tower

MODULE (6) SHELL & TUBE HEAT EXCHANGERS CONSTRUCTION & PERFORMANCE6.1 Construction 6.1.1 Tubes 6.1.2 Shell 6.1.3 Baffles 6.14 Materials6.2 Fluid Routing Through Shell/Tube Heat Exchangers6.3 Factors that affect Heat Transfer6.4 Strategic for Optimizing Heat Exchangers Performance

QATAR TECHNICAL PETROLEUM CENTER, P.O. Box 9955, Salwa Road, Doha, Qatar.Tel: +974 4458 1440. Fax: +974 4458 0414 Email: antonymgr@qtpc.qa URL: www.qtpc.qa

Gas Turbines: Operation, Maintenance and TroubleshootingQATAR TECHNICAL PETROLEUM CENTER

QTPC - AN ISO 9001:2008 Regd.

MODULE (7) TYPES OF FLUID FLOW, FOULING AND CLEANING METHODS7.1 Types of Fluid Flow 7.1.1 Laminar Flow 7.1.2 Turbulent Flow7.2 Pipe Flow (Velocity Profile)7.3 Fouling in Heat Exchangers 7.3.1 Types of Fouling 7.3.2 Fouling Factor 7.3.3 Minimizing Fouling7.4 Cleaning Methods 7.4.1 On – Line Cleaning 7.4.1.1 Circulation of Sponge Rubber Balls 7.4.1.2 Brush and Cage Systems 7.4.1.3 Air Injection 7.4.1.4 Magnetic Devices 7.4.1.5 Soot Blowers 7.4.1.6 Use of Sonic Technology 7.4.1.7 Water Washing 7.4.1.8 Shot Cleaning 7.4.1.9 Use of Insets 7.4.2 Off – Line Cleaning 7.4.2 Off-Line Cleaning 7.4.2.1 Manual Cleaning 7.4.2.2 Mechanical Cleaning 7.4.2.3 Chemical Cleaning 7.4.2.4 Thermal Cleaning7.5 Heat Exchanger Protection by Galvanic 7.5.1 Cathodic Protection 7.5.2 Anodic Protection

MODULE (8) OPERATION AND MAINTENANCE:8.1 Operation of Heat Exchangers 8.1.1 Precautions 8.1.2 General Comments 8.1.3 Checks on Opening of Heat Exchangers 8.1.4 Checks before Heading of Heat Exchangers 8.1.5 On Line Checks 8.1.6 Procedures of Taking Heat Exchanger out of services 8.1.7 Testing of Heat Exchanger 8.1.8 Procedures of returning Heat Exchangers to Services8.2 Maintenance of Heat Exchangers 8.2.1 Cleaning out Blockage 8.2.2 Plugging Leakage 8.2.3 Tube Replacement 8.2.4 Maintenance Preparation and Safety Precautions8.3 Inspection and Repair 8.3.1 Determine appropriate inspection Frequencies 8.3.2 Primary causes of Heat Exchanger Deterioration

QATAR TECHNICAL PETROLEUM CENTER, P.O. Box 9955, Salwa Road, Doha, Qatar.Tel: +974 4458 1440. Fax: +974 4458 0414 Email: antonymgr@qtpc.qa URL: www.qtpc.qa

Gas Turbines: Operation, Maintenance and TroubleshootingQATAR TECHNICAL PETROLEUM CENTER

QTPC - AN ISO 9001:2008 Regd.

MODULE (9) TROUBLESHOOTING 9.1 Problems Associated with Heat Exchangers9.2 Effects of Problems on Heat Exchangers 9.3 Removing blockage9.4 Automatic Cleaning Methods 9.5 Stopping Leaks 9.6 Sacrificial Anodes 9.7 Heat Exchangers Troubleshooting9.8 Case Studies

MODULE (10) CODES AND STANDARDS10.1 Regulations10.2 Codes10.3 Standards and Specifications10.4 Pressure Vessel Codes11 Daily Discussion or Questions and Answer Session will be conducted at the mid of the each training day.

Who Should Attend?• Power Plant Engineers & Operators• Plant and Facility maintenance Engineers and Technicians• Building or Energy Managers• Air conditioning engineers• Industrial and Environmental Engineers• General Mechanical and Process Engineers. • Purchasing heat exchangers Managers & Sales Engineers• Plant and Facility Managers • Energy Managers• Hotel and Hospital Engineers

He has published over 50 papers on thermo-fluid systems and taught many courses in mechanical and process engineering such as heat transfer, thermodynamics, boilers and steam generation, Power plants, heat exchangers and others at Al-Balqa Applied University, JUST, Yarmouk and Philadelphia universities in Jordan, Yanbu Industrial College and Umm Al-Qura University at Saudi Arabia. With respect to Training courses, he has delivered many technical and management training courses in Gulf Region such as:

• Operation Maintenance and Troubleshooting of: Heat Exchangers, Cooling Towers, Steam Boilers, Flare System and Gas

Turbine.

• Troubleshooting in Chemical Plants.

• Corrosion in Petrochemical Industries.

• Process Plant shutdown, Start-Up and Commissioning.

• Computerized Maintenance Management Systems (CMMS).

• Maintenance scheduling and planning.

Dr. Mohammed Al-Odat, is graduated with PhD from University of Jordan and he is a professor of Mechanical and Process Engineering. He is a highly experienced consultant and trainer with over 20 years experience in various disciplines of process and Mechanical engineering. Currently he is a professor of Mechanical Engi-neering at Umm Al-Qura University-Saudi Arabia.

About the Course Instructor