COURSE OVERVIEW:

Shell-and-tube heat exchangers are the workhorses of the thermal processing industry, requiring precise engineering to ensure safety, efficiency, and longevity. This course provides an intensive look at the mechanical design and fabrication requirements governed by the ASME Boiler and Pressure Vessel Code (Section VIII) and the Tubular Exchanger Manufacturers Association (TEMA) standards. Participants will learn how to integrate thermal requirements with mechanical constraints to produce robust equipment capable of withstanding high pressures and temperatures.

The scope of this training covers the entire design process, from the selection of the TEMA configuration (e.g., AEL, BEM, AES) to the detailed calculation of component thicknesses. We will examine the critical design of tubesheets, shells, channels, and baffles, focusing on how to prevent common mechanical issues such as flow-induced vibration and thermal expansion stresses. Attendees will gain a deep understanding of the "TEMA Class" designations (R, C, and B) and how they dictate the severity of service and the resulting design margins.

Furthermore, the course provides a comprehensive overview of modern fabrication and quality control practices. We will explore advanced welding techniques for tube-to-tubesheet joints, the importance of proper heat treatment, and the rigorous inspection requirements mandated by industry codes. By understanding the transition from design drawings to the shop floor, engineers and fabricators can ensure that the finished heat exchanger meets all performance specifications and regulatory safety standards for pressure-retaining equipment.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Interpret and apply ASME Section VIII Division 1 rules for heat exchangers.
2. Utilize TEMA standards to select the appropriate exchanger configuration.
3. Calculate minimum required thicknesses for shells, heads, and nozzles.
4. Design tubesheets according to ASME and TEMA formulas.
5. Evaluate the impact of thermal expansion and the need for expansion joints.
6. Select appropriate materials for corrosive and high-temperature services.
7. Design baffles and support plates to prevent flow-induced vibration.
8. Specify requirements for tube-to-tubesheet joint strength and sealing.
9. Understand the differences between TEMA Class R, C, and B requirements.
10. Review fabrication drawings for compliance with design calculations.
11. Supervise the welding and assembly process for shell-and-tube units.
12. Define Nondestructive Examination (NDE) requirements for pressure welds.
13. Execute hydrostatic testing and final certification procedures.

TARGET AUDIENCE:

Mechanical Design Engineers, Pressure Vessel Engineers, Fabrication Supervisors, Quality Assurance Inspectors, and Plant Maintenance Engineers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.