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Heat Exchanger Troubleshooting Short Course

Course Fee: US$650

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Design decisions can have a costly impact on heat exchanger operation. In this course, you learn by reviewing several real cases in which unit designs had critical commercial consequences for operators/ owners. Among other topics, this course may address

  • assessment of acoustic vibration in rectangular ducted bundles (Xace®)
  • vibration analysis of a shell-and-tube heat exchanger (Xist® and Xvib®), including a review of the velocity scaling applied to tubes near impingement plate edges
  • sizing of annular distributor (vapor belt) and associated tube vibration analysis (Xist and Xvib)
  • root cause analysis of tube failures in a steam generator (a reboiler/steam drum configuration modeled as a thermosiphon reboiler in Xist)
  • design review of an air-cooler/condenser (Xace) with excessive tubeside pressure drop during winter operation

In some cases, the units did not work in service; in others, the designs were revamped before the units began operation. Each case study is introduced as a problem; participants work individually or in groups to determine the cause and develop solutions. Prior to each case, the instructor reviews related HTRI methods. 

Suggested Participants

Engineers—from novice to expert—who want to ensure that design problems are identified before operation

HTRI Software

This course will make use of the following HTRI software: Xchanger Suite® components Xist®, Xace®, and Xvib®.  All training materials are based on the current software version.

Course Credits: 6 hours (PDH/CEU)


Outline

  1. Case 1: Steam generator with tube failure

  2. Case 2: Air-cooler with excessive pressure drop during winter operation

  3. Case 3: Shell erosion in an ethylene dichloride condenser

  4. Case 4: Waste heat recovery unit with acoustic resonance

Currently Scheduled


Upcoming Instructors

  • Syed Haq


  • Engineer, Research, earned his MS in Mechanical Engineering from Texas A&M University (TAMU), where he is pursuing his PhD in Mechanical Engineering. His PhD research focuses on improving thermal management of solid oxide fuel cells. At HTRI, Haq is involved in various research projects, including Air‑cooled Unit (ACU) experiments and simulations. His work includes prediction of hot air recirculation and hot air migration with wind. He has developed complex CFD models for several TEMA heat exchangers to predict stream analysis. Haq also investigates non‑Newtonian methods for HTRI. He has a publication in Building Environment, and his work was presented at the 4th Thermal and Fluids Engineering Conference in 2019.

  • Ashley Hinojosa


  • Engineer, Technical Support, graduated with a BS in mechanical engineering from Texas A&M University, College Station, TX. During her studies, she completed two internships with oil & gas equipment company Proserv, gaining experience with product testing and technical writing. She worked in heat exchanger sales, covering the Houston, Waco, and Dallas/Fort Worth areas, for almost two years before joining HTRI. As a member of the Engineering Services group, she focuses on technical support and contracts but also assists with development of other materials for HTRI's technical program.