Heat Exchangers: Types, Applications, Design, Operation & Maintenance

Upcoming Sessions

Classroom sessions
Online sessions

Course Introduction

This Heat Exchangers: Types, Applications, Design, Operation & Maintenance Training Course provides a comprehensive understanding of the technical and operational aspects of heat exchangers used across thermal power plants, petrochemical facilities, and process industries. The course focuses on widely applied exchanger designs such as shell-and-tube heat exchangers (STHE), air-cooled heat exchangers (ACHE), and plate heat exchangers (PHE), highlighting their functional roles in heat transfer systems. Participants will develop a strong grasp of the fundamental heat transfer principles and the interrelationship between thermal, hydraulic, and mechanical parameters that influence efficient heat exchanger design and operation.

The Heat Exchangers Training Course is structured to bridge the gap between theory and industrial practice. It familiarises engineers and technicians with international codes, standards, and best practices applied during design, fabrication, operation, inspection, and maintenance stages. Special emphasis is placed on operational efficiency, fouling mitigation, performance monitoring, and maintenance strategies. Practical workshops, real-world case studies, and engineering examples are integrated throughout the course to support root cause analysis and effective troubleshooting of common heat exchanger problems encountered in industrial environments.

This COPEX Training Course will feature:

  • Key design characteristics of industrial heat exchangers
  • Practical understanding of heat transfer principles and mechanisms
  • International codes and standards for fabrication, operation, and maintenance
  • Common operational issues including fouling and performance degradation
  • Inspection practices addressing corrosion, erosion, and structural integrity

Objectives

By the end of this Heat Exchangers Training Course, participants will be able to achieve the following objectives, enabling them to apply sound engineering judgment in real operating environments:

  • Understand established design guidelines, specifications, and limitations associated with different types of heat exchangers used in industry.
  • Analyse thermal and hydraulic operational parameters, including flow arrangements, temperature profiles, pressure drops, and heat transfer rates.
  • Determine correct selection criteria for sizing and rating heat exchangers based on process requirements and operating conditions.
  • Identify operational problems such as fouling, vibration, corrosion, and scaling that lead to performance deterioration and reduced reliability.
  • Apply appropriate troubleshooting techniques to diagnose root causes and implement corrective actions for improved exchanger performance and longevity.

Training Methodology

This Heat Exchangers Training Course is delivered using a workshop-based methodology that combines structured lectures with interactive learning activities. Core concepts are introduced through focused presentations, followed by practical case studies and worked examples that demonstrate how theoretical principles are applied in real industrial situations. This approach ensures participants gain both conceptual understanding and practical insight.

Hands-on exercises and problem-solving sessions are integrated throughout the training course to reinforce learning outcomes. Participants are encouraged to share operational experiences, discuss challenges, and explore alternative solutions under guided facilitation. Individual learning goals are also discussed to ensure the course content addresses specific technical needs and supports practical application in the participants’ respective work environments.

Who Should Attend?

This Heat Exchangers Training Course is designed for technical professionals involved in the design, operation, inspection, and maintenance of heat exchange equipment. The course is suitable for individuals seeking to enhance their understanding of exchanger performance, reliability, and optimisation across industrial applications.

The training course will be especially beneficial for:

  • Maintenance professionals responsible for exchanger reliability and upkeep
  • Inspection personnel involved in condition assessment and integrity evaluation
  • Process supervisors overseeing thermal systems and process efficiency
  • Plant operators engaged in daily operation and monitoring of heat exchangers
  • Plant and technical managers responsible for operational performance and asset integrity

Course Outline

Day 1: 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 2: 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 3: 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 4: 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 5: 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

Providers and Associations

Anderson
Aztech Training
Coventry

Certificate

  • Copex Certificate of Attendance will be provided to delegates who attend and complete the course

Material published by Copex shown here is copyrighted. All rights reserved. Any unauthorized copying, distribution, use, dissemination, downloading, storing (in any medium), transmission, reproduction or reliance in whole or any part of this course outline is prohibited and will constitute an infringement of copyright.

Whats Makes Copex Courses Unique?

COPEX Training is your gateway to professional growth, with over 20 years of experience turning potential into success. Each year, we deliver over 1,000 courses in 50+ countries, earning a stellar 98% satisfaction rate. Trusted by global giants like BP, the United Nations, and HSBC, we partner with top certification bodies to provide career-focused training that empowers individuals and drives organizational breakthroughs. Our mission? To transform the way professionals learn and grow in today’s fast-changing industries. Through expert insights, cutting-edge methods, and hands-on approaches, we equip you with the skills and confidence to tackle challenges, seize opportunities, and thrive in your career.

Led by a passionate leadership team and supported by a network of world-class trainers, COPEX Training connects professionals worldwide with life-changing opportunities. We are committed to excellence, ensuring every participant leaves with the tools, expertise, and confidence to conquer an ever-evolving world.

Related Categories

Facilities & Asset Management

Frequently Asked Questions

This FAQ section provides quick answers to the most common questions about our services, procedures, and policies. We aim to make your experience with us as straightforward as possible. For further assistance, our support team is ready to help.

Enhanced Skills: Develop in-demand skills and knowledge in your chosen field.
Career Advancement: Improve your career prospects and increase your earning potential.
Increased Confidence: Gain confidence in your abilities and enhance your professional presence.
Networking Opportunities: Connect with other professionals and industry experts.
Improved Job Performance: Enhance your productivity, efficiency, and job satisfaction.
Personal Growth: Develop valuable personal and professional skills that can benefit you in all areas of life.

Our cancellation policy varies depending on the circumstances presented. Generally, cancellations must be initiated in formal writing at least 14 days prior to the commencement date of the training course. Further, the option to shift an existing registration to another training course on a later date is possible. Otherwise, a full refund will be initiated.

Our training courses courses are being held at five-star hotels in prime and iconic destinations across the globe. Cities such as Amsterdam, Barcelona, Dubai, Geneva, Istanbul, Kuala Lumpur, London, Houston, New York, Paris, Vienna, Zurich, etc.

Our training courses will run for 5 hours per day. The standard daily timing is from 8:30 am – 3:30 pm including the coffee/tea breaks and lunch.

The training course fee can be settled by either:

  • Bank transfer
  • Credit Card

Published training course fees are inclusive of the training venue, training manual, writing materials, lunch and coffee breaks with refreshments over the entire duration of the training course.

Upon successful registration, processing window will take not more than 24 hours from the time of registration. An email including the registration confirmation, invoice and joining instructions will be sent to the provided email address.

Enquiry

We can customize this training course for you!

At Copex Training, we offer customizable courses designed to fit your specific needs. whether it's refining procurement practices or enhancing leadership and management skills, we tailor our programs to meet your unique goals and challenges. Let us create a training solution that delivers real results for your team.

Other Specialized Training Courses

Explore a selection of specialized training courses designed to advance your skills and knowledge in key areas critical to professional success. COPEX provides a wide range of programs tailored to meet industry demands, empowering you to stay competitive in today’s dynamic landscape.

Classroom
Mastering Sports Facilities Management: Strategies for Excellence
The management of sports facilities today goes far beyond routine operations and maintenance. Modern sports venues are complex, multi-use en...
Classroom
Certified Engineering Technician (CET) Exam Preparation
Engineering technicians play a vital role in supporting the development, operation, and maintenance of technical systems across major indust...
Classroom
Certified Process Technician (CPT)
The Certified Process Technician (CPT) training course is specifically crafted for professionals working in high-risk and high-reliability i...
Classroom
Advanced Shutdown and Turnaround Management Excellence
Shutdowns and turnarounds are complex and high-risk events in industrial operations that require meticulous planning, strategic execution, a...
Classroom
VFD ACS 1000 Maintenance and Diagnostics for Reliability Engineers
The ACS 1000 Variable Frequency Drive (VFD) is a vital asset in modern industrial systems, providing accurate motor control, improved energy...
Classroom
Cathodic Protection Technician
Corrosion is a major threat to the longevity and safety of metallic structures such as pipelines, storage tanks, and offshore installations....
Classroom
Planned Shutdown, Critical Activities, Isolation, Start-up & Commissioning
Planned shutdowns are essential for maintaining the reliability and safety of process plant equipment while allowing for upgrades and major...
Classroom Online
Essential Skills for Oil & Gas Professionals
The Oil & Gas industry is experiencing its most significant transformation in decades due to rising production and falling demand. Sustained...
OMC Training
Copex Training
Typically replies within an hour
Sana
Thank you for contacting Copex Training
How may I assist you?
06:59