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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

  • Frank Ashley


  • Sales Lead, Exchanger Optimizer, graduated in 2017 with a BS in Mechanical Engineering from Texas A&M University – Kingsville in Kingsville, Texas, USA. Frank’s education and experience have given him exposure to manufacturing methods and insight into building customer relationships. These skills have served him well in his role at HTRI, in which he leads the effort to increase the awareness and adoption of HTRI’s Exchanger Optimizer software tool. Frank has worked to develop and present material to a variety of customers related to the capabilities and uses of Exchanger Optimizer, tailoring those materials to the specific needs of each customer.

  • Samuel Bajomo


  • Senior Heat Transfer Specialist, Engineering Services, completed his BEng, MSc in Mechanical Engineering at University College London, London, United Kingdom (UK), majoring in Materials Science and Structural Mechanics. He began his career with MW Kellogg working on mechanical design of pressure vessels and heat exchangers and later transitioned into the heat transfer group as Principal Heat Transfer Engineer. In 2012 he moved to Wood Plc, London, UK where he oversaw the thermal and mechanical design of heat exchangers and fired equipment for several major oil and gas and petrochemical projects. His experience spans front-end engineering design (FEED), requisition, detailed engineering, and oversight of equipment manufacture. Bajomo then operated as an independent heat transfer consultant, working with equipment manufacturers and end-users on a wide variety of troubleshooting and design verification projects. His exchanger design and practical industry experience brings a uniquely qualified contractor’s perspective to HTRI’s Engineering Services team. Bajomo also currently serves on the board of the Institution of Mechanical Engineers (IMechE), Pressure Systems Group, and is a CEng MIMechE.

  • Lance Bishop


  • Lead Test Engineer, Research & Technology Center, graduated with a BS in Mechanical Engineering from Texas A&M University, College Station, Texas, USA. He worked for over ten years as a Plant Engineer at NRG Energy, Inc., where he conducted testing on different plant equipment and process systems, and modeled physical systems to determine points of efficiency and predict process scenarios. At HTRI, Bishop performs experimental tests for multiple areas of research, as well as maintenance of data acquisition and calibration equipment.

  • LiDong Huang


  • Principal Engineer, Experimental Research, holds a BS from Shanghai Maritime University and an MS from University of Shanghai for Science and Technology, Shanghai, China. He received his PhD in Mechanical Engineering from the University of Houston, Houston, Texas, USA, where he studied and developed methods for predicting subcooled flow boiling, film boiling, and critical heat flux. Before joining HTRI, Huang worked as an instructor and thermal engineer in the Department of Marine Engineering at Shanghai Maritime University. Since joining HTRI, he has focused primarily on boiling and two-phase flow phenomena but also has done some experimental and analytical work on plate heat exchangers, organic fouling, and single-phase mixed convection. Huang has taught numerous courses for HTRI. He is a member of ASME and a licensed Professional Engineer (PE) in Texas.

  • Peter Joosten


  • Senior Consulting Engineer & Regional Sales Manager, Australia/Oceania, works with HTRI’s Engineering Services and Global Sales teams. His principal responsibilities include developing and conducting training programs, providing technical support, and promoting membership in the HTRI consortium. He earned a Bachelor of Mechanical Engineering degree from Fontys University of Applied Science, Venlo, The Netherlands. Prior to joining HTRI, Joosten was a Senior Heat Transfer Engineer at W. E. Smith Engineering, Coffs Harbour, Australia. His primary role was the thermal design and analysis of all types of shell-and-tube exchangers, air coolers, economizers, feedwater heaters, and steam surface condensers. He was also responsible for the mechanical design and stress analysis of these units, as well as for analyzing and resolving operational issues. His previous experience with HTRI software gives him a valuable end-user perspective.

  • Andy Mountford


  • Senior Technical Lead, Training, provides technical support and training for HTRI. He earned a BSc and MSc in Chemistry and a PhD in Organometallic and Materials Chemistry from the University of East Anglia, Norwich, UK. During his tenure there, he conducted research at Wolfson Laboratory for Materials and Catalysis. He previously held the position of Thermal Design Supervisor at Tecnicas Reunidas in Madrid, Spain, gaining valuable experience using HTRI methods and software. Mountford oversaw the development of several high-profile PWR and BWR nuclear plant projects, as well as gained valuable experience in the thermohydraulic design of heat transfer equipment for the petrochemical and nitric acid/nitrates industries. His experience in using HTRI Xchanger Suite makes him uniquely qualified to bring an end-user’s perspective to the HTRI training program and to share techniques for effectively working with the software.