The design, performance and operation of modern heat exchangers requires an understanding of the principles of heat transfer and fluid flow, coupled with access to numerically based techniques and supporting data. This course will review heat transfer fundamentals as applied to tubular and plate devices.

1. ADVANCED HEAT EXCHANGER
DESIGN, INSPECTION AND
TROUBLESHOOTING
Your Expert Course Leader
Dr. John L Sproston
John Sproston (UK) B. Sc., M.Eng., Ph D is a Senior Mechanical & Instrumentation Engineer with over 45 years of
industrial experience in Process Control & Instrumentation, Liquid & Gas Flowmetering, Heat Exchanger
Engineering, Pumps, Compressors, Turbines and Control Valve Technology. He is currently a Senior Independent
Consultant to various petrochemical industries in the UK, USA, Oman, Kuwait and KSA wherein he provides
consultancy services on both the application and operational constraints of process equipment in the oil & gas
industries.

2. A D V A N C E D H E A T E X C H A N G E R D E S I G N , I N S P E C T I O N A N D
T R O U B L E S H O O T I N G
Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to info@asiaedge.net. Visit us at www.petroedgeasia.net for more information.
About this Training Course
The design, performance and operation of modern heat exchangers requires an understanding of the principles of heat
transfer and fluid flow, coupled with access to numerically based techniques and supporting data. This course will review
heat transfer fundamentals as applied to tubular and plate devices.
Upon completion of this course, delegates will have gained an understanding of the application of basic principles of heat
transfer and fluid flow to the design, operation and maintenance of shell and tube heat exchangers as well as compact and
air-cooled heat exchangers. Participants will gain an understanding of TEMA and ASME codes and learn how to numerically
analyze the different heat exchanger configurations. Attention will be paid to the recognition and solving of a wide variety
of industrial problems, taking existing case studies.
The course will also address the ways in which systematic techniques of inspection and maintenance (including Fouling
Control) can alleviate major problem areas.
Course Objectives
Upon the successful completion of this course, each participant will be able to:
 Design, inspect, maintain and operate heat exchangers and analyse their performance in a professional manner
 Employ the concepts of heat transfer coefficients and determine their overall effect on heat exchanger fouling
 Differentiate between the various types of heat exchangers
 Discuss the industrial features and other information that explain distributed types in relation to power cycles,
distillation, re-cuperators and regenerators
 Carry out heat exchanger analysis for counter flow, cross flow and multi-pass heat exchangers and to apply the
relevant correction factors
 Conduct a heat energy balance for different types of heat exchangers
 Choose the correct heat exchanger for a given application and its costing in line with the advantages and
disadvantages of its type and scope of its applications
 Determine the cooling performance of a range of heat exchangers and establish insights on the effectiveness/ NTU
method for heat exchanger analysis in terms of heat capacity ratios
 Interpret TEMA standards and terminologies for present-day shell and tube heat exchangers
Who Should Attend
The course is developed for project engineers, process engineers, plant and maintenance engineers and supervisors in the
oil, chemical and other process industries who require a wider and deeper appreciation of heat exchanger design,
performance, inspection, maintenance and operation. It should also prove useful to those generally knowledgeable on the
subject, but who may 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 they apply to shell and tube heat exchangers.

3. A D V A N C E D H E A T E X C H A N G E R D E S I G N , I N S P E C T I O N A N D
T R O U B L E S H O O T I N G
Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to info@asiaedge.net. Visit us at www.petroedgeasia.net for more information.
3 DAY COURSE OUTLINE
SESSION 1: Introduction and Definition of Heat Transfer
Coefficients
 Conduction
 Convection
 Overall Heat Transfer
 Logarithmic Temperature Differences
 Correction Factors
 Fouling
 Effectiveness
SESSION 2: Types of Heat Exchangers
 Double-Pipe
 Parallel-Flow and Counter-Flow
 Compact
 Shell and Tube
 Plate and Frame
 Regenerative
 Condensers
 Boilers
 Space Radiators
 Addition of Fins
SESSION 3: Worked Examples
 Calculation of Overall Heat Transfer Coefficient for a Heat
Exchanger
 Effect of Fouling on the Overall Heat Transfer Coefficient
 Introduction to Condensation of Steam in a Condenser
SESSION 4: Industrial Features and Additional Information
 Industrial Distribution of Different Types
 Condensation, Evaporation, Heat Recovery, Heat Rejection
 Power Cycles, Distillation, Recuperators, Regenerators

SESSION 5: Heat Exchanger Analysis in Detail
 Logarithmic Mean Temperature Difference Method
 Effectiveness- NTU Method
SESSION 6: Counter Flow, Cross Flow and Multi-Pass Heat
Exchangers
 Application of Correction Factors
 Worked Examples
 Various arrangements of split shells and their numerical
solution
SESSION 7: Heat Exchanger Energy Balance
 Pre-heat Calculations
 Energy Moduling
SESSION 8: Counter Flow Heat Exchanger
 Worked Example for Double-Pipe Arrangement
SESSION 9: Heat Exchanger Selection for a Given Process
 Course and Fine Filters
 General Points on Material Selection and Pressures
 Thermal Effectiveness
 Advantages and Disadvantages of Double-Pipe Arrangements
and Scope of Application
 Common Materials Used
 Shell and Tube Heat Exchangers
 Plate and Frame Heat Exchangers
 Advantages and Disadvantages of these Types and Scopes of
Application
 Air-Cooled Heat Exchangers
 Plate-fin heat Exchangers
 Printed Circuit Heat Exchangers
 Advantages and Disadvantages of these Types and Scopes of
Application
SESSION 10: Heat Exchanger Costing
 Scoping
 Quick-sizing
 Correction Factors
 Estimation of the Overall Heat Transfer Coefficient
 Estimating Cost
 ESDU Data
 Logarithmic Interpolation
 Worked Example
SESSION 11: Heat Exchanger Costing
 Worked Examples in Determining Heat Transfer Rate with and
without Effects of Fouling
SESSION 12: Problem Session
 Numerical Exercises on Multi-pass Heat Exchangers
SESSION 13: Cooling of an Automotive/Industrial Compact
Radiator
 Determination of Overall Heat Transfer Coefficient

4. A D V A N C E D H E A T E X C H A N G E R D E S I G N , I N S P E C T I O N A N D
T R O U B L E S H O O T I N G
Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to info@asiaedge.net. Visit us at www.petroedgeasia.net for more information.
SESSION 14: Effectiveness/NTU Method for Heat Exchanger
Analysis
 Heat Transfer Effectiveness, Capacity Ratios
 Worked Examples
SESSION 15: Upper Limit of Heat Transfer in a Heat Exchanger
 Counter Flow Heat Exchanger
 Effectiveness as a Function of NTU
 Worked Examples
SESSION 16: Shell and Tube Heat Exchangers
 Heat Exchanger Inspection
 Scope
 Construction
 TEMA Standards and Terminologies
 Fluid Allocation
 Design Problems, Design Enhancement
 Examples
SESSION 17: Heat Exchanger Maintenance
 Planning
 Precautions Required
 Plugging
 Ferruling
 Sleeving
 Shell Side Repairs
 Re-tubing
SESSION 18: Fouling Control of Heat Exchanger
SESSION 19: Heat Exchanger Inspection Techniques
 Visual, NDT
 Common Failures
 Inspection Tools
 Inspection Codes
SESSION 20: Design of Shell and Tube Heat Exchangers
 Achievement of Duty Required
 Developing Design Envelope
 Choosing the Best Design
 Pressure Drop and Tube Vibration Issues
SESSION 21: Worked Example on a Multi-pass Heat Exchanger
 Determination of Heat Transfer and Outlet Stream
Temperatures
SESSION 22: New Technologies in Heat Exchangers
 Improving heat exchanger design
Sessions commence at 9am on all days, with short intervals at 10.30am and
3.30pm respectively with light refreshment. Lunch will be provided at
12:30pm for 1 hour. Sessions will end at 5pm on all days.

5. A D V A N C E D H E A T E X C H A N G E R D E S I G N , I N S P E C T I O N A N D
T R O U B L E S H O O T I N G
Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to info@asiaedge.net. Visit us at www.petroedgeasia.net for more information.
About your Expert Course Director:
Dr. John L Sproston
John Sproston (UK) B. Sc., M.Eng., Ph D is a Senior Mechanical & Instrumentation Engineer with over 45
years of industrial experience in Process Control & Instrumentation, Liquid & Gas Flowmetering, Heat
Exchanger Engineering, Pumps, Compressors, Turbines and Control Valve Technology. He is currently a
Senior Independent Consultant to various petrochemical industries in the UK, USA, Oman, Kuwait and KSA wherein he
provides consultancy services on both the application and operational constraints of process equipment in the oil & gas
industries.
During his early career, Dr. Sproston held key positions in Rolls Royce (UK) where he was involved in the design of turbine
blading for jet engines, subject to pre-specified distributions of pressure. During this period and since, he has also been
closely involved in various aspects of Turbomachinery, Thermodynamics and Fluid Mechanics where he has become a
recognized authority in these areas.
Later, he joined the academic staff of University of Liverpool in UK as a Professor in Mechanical Engineering Courses. A
substantial part of his work has been concerned with detailed aspects of Flowmetering both of single & multiphase flows.
He has supervised doctoral research students in this area in collaboration with various European flowmeter manufacturers.
He joined Haward Technology Middle East in 2002 and was later appointed as European Manager (a post which has since
lapsed) and has delivered over 150 training courses in Flowmeasurement (single- and multi-phase), Control, Heat
Exchangers, Pumps, Turbines, Compressors, Valve and Valve Selection as well as other topics throughout the UK, USA,
Oman and Kuwait. During the last two years he has delivered Courses with other Training Companies operating in the Far
and Middle East.
He has published about 150 papers in various Engineering Journals and International Conferences and has contributed to
Textbooks on the topics listed above.

6. A D V A N C E D H E A T E X C H A N G E R D E S I G N , I N S P E C T I O N A N D
T R O U B L E S H O O T I N G
Train Your Whole Team At A Convenient Time And Location Through In-House Training.
Call us at +65 6741 9927 to enquire or email your query to info@asiaedge.net. Visit us at www.petroedgeasia.net for more information.
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A D V A N C E D H E A T E X C H A N G E R D E S I G N , I N S P E C T I O N A N D T R O U B L E S H O O T I N G
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