Training

Solutions

Heat Exchanger Fouling

The course will dive into the possible mechanisms of fouling in heat exchangers and provide practical suggestion on how to better monitor, troubleshoot and clean heat exchangers in the refining industry.

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Learning Objectives

At the end of the course, the attendee will be able to:

  • Assess fouling based on scientific principles and perform data driven analysis of operational issues caused by fouling
  • Explain, discuss and analyse different types of fouling and their causes
  • Understand how various fouling control and mitigation techniques work and when they can be applied to specific problems
  • Have an understanding of the state-of-the-art fouling monitoring and how
  • Evaluate alternative cleaning methods

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Target Audience

Heat Transfer Engineers
Unit engineers
Energy and Profitability analysts
Process Engineers/Simulation groups

Duration

The full training lasts for one day, and it includes a half day session with the instructors to troubleshoot specific problems in the plant.

Course Outline

Introduction

  • Overview of fouling in the process industry
  • Impact of fouling in oil refineries: economic, operational, health and safety
  • Objectives of the course

Crude oil fouling science

  • Fouling Mechanisms
  • Routes to Crude Oil Fouling Formation
  • Events in Crude Oil Fouling
  • Variables Affecting Fouling
  • Importance of oil blending on fouling

Chemical Structure and Molecular Weight Characterization

  • Traditional analytical techniques
  • Advanced imaging techniques
  • Practical interpretation of characterizations

Modelling and design

  • Review of mathematical models for crude oil fouling
  • Review of design methodologies

Cleaning methodologies

  • Mechanical
  • Chemical
  • Ultrasonic

Monitoring and predictive maintenance of heat exchangers

Mitigation techniques

  • Mitigation by design
  • Coatings
  • Tube inserts
  • Shell-side fouling mitigation technologies
  • Online cleaning methods

Instructor Profile

Himanshu Joshi

A distinguished world leader in heat exchanger design and fouling mitigation with over 34 years of experience working for major oil companies, Himanshu has held various important roles such as Subject Matter Expert for fouling, heat exchanger technology application, and heat exchanger monitoring with a focus on energy conservation. During his career, he has been deeply involved in heat exchanger monitoring, leading the development of tools and​ the application of results. Himanshu has dealt with all aspects of heat exchangers including design, fabrication, field troubleshooting, training course development, and various R&D projects related to technology.​

Process Heat Transfer​

The course will cover all aspect of Process Heat Transfer introducing the attendees to the advantages and disadvantages of the main heat exchanger types (conventional and unconventional), fundamentals of heat transfer (in both single phase and two phase flow), theory of heat exchanger design, design methodologies, costing and operational aspects.​

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Learning Objectives

At the end of the course, the attendee will:​

  • Be able to Select the right type of heat transfer equipment for a specific duty including performance and cost considerations​
  • Gain a strong understand of the main phenomena underpinning performance of thermal equipment​
  • Be familiar with design methodologies for the main types of heat exchangers​
  • Understand operational implications of the choices made at the design stage​

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Target Audience

  • Heat Transfer Engineers​
  • Unit engineers​
  • Energy and Profitability analysts​
  • Process Engineers/Simulation groups​

Duration

The full training lasts for two days, and it includes a half day session with the instructors to troubleshoot specific problems in the plant. However, for ten or more participants, it will be possible to customize the topics so that it can be shorter or longer, depending on needs.​

Course Outline

Introduction to heat exchangers types​

Deep dive into Shell-and-tube heat exchangers:​

  • TEMA types​
  • Mechanical aspects and design ​
  • Heat transfer and pressure drop ​
  • Operational and maintenance issues ​
  • Thermal & hydraulic design – initial decisions ​
  • Thermal & hydraulic design: single phase​
  • Specification and standards ​
  • Safety aspects​

Condensers:

  • Types​
  • Thermal & hydraulic design

Reboilers, steam generators:

  • Types​
  • Thermal & hydraulic design ​
  • Compact heat exchangers ​
  • Air Coolers​
  • Fouling and fouling mitigation ​
  • Monitoring ​
  • Heat transfer enhancement ​
  • Heat integration

Instructor Profile

Himanshu Joshi

A distinguished world leader in heat exchanger design and fouling mitigation with over 34 years of experience working for major oil companies, Himanshu has held various important roles such as Subject Matter Expert for fouling, heat exchanger technology application, and heat exchanger monitoring with a focus on energy conservation. During his career, he has been deeply involved in heat exchanger monitoring, leading the development of tools and​ the application of results. Himanshu has dealt with all aspects of heat exchangers including design, fabrication, field troubleshooting, training course development, and various R&D projects related to technology.​