TEMA & HTRI Heat Exchanger Design & Cost Saving Masterclass

Consultant/Trainer: Bert Boxma

This Masterclass can be tailored to a specific client’s needs. Built from a series of chosen modules, the Masterclass can provide an in depth practical understanding of major proven heat exchanger technologies and “state of art” fouling mitigation technologies. Pro’s and Con’s of several heat exchanger types can be explained with life operational examples. The Masterclass will mix theory and common practices using highly interactive case studies where attendees are encouraged to use in-house heat exchanger type selection software and rigorous design/rating world-class software from HTRI.


This Petrogenium course can be tailored for awareness/inexperienced staff, for intermediate and for experienced personnel. Furthermore the course can be customized for a specific refinery, plant or unit. The option for post-course consultancy/help-desk support is also available.

Participants could include a wide range of Technical Professionals who want to improve the performance of heat exchanger in their company for shell & tube and compact types but will greatly benefit:
  • Engineers in disciplines Process, Mechanical, Project acting as specialist or generalist.
  • Design Specialist in heat exchanger & heat Transfer Engineers to extend their knowledge HTRI; specific Engineers in various disciplines; Maintenance, Instrument, Turn-Around, & Cost Estimating

Learning Objectives

The participants of this Masterclass will be provided an in depth practical understanding of major proven heat exchanger technologies and “state of art” fouling mitigation technologies.


(Module 1 – 8 : Shell & Tube Heat Exchangers)

Module 1
This module presents an overview of the most common heat exchangers: market shares of different types over the years; discussion Shell & Tubular; Stream Analysis and examples of an HTRI calculation.

Module 2
In this module we will further broaden our knowledge of the Shell & Tube Heat exchanger. In particular the nomenclature of TEMA will be explained and where mechanical aspects have direct influence on the thermal design. This will be illustrated by showing many case studies.

Module 3
In this module tube-tubesheet connection will be discussed. Tube vibration is an important issue in design of Shell & Tubulars. How to avoid tube vibration? This module will give you excellent examples and remedies.

Module 4
Which measurements do you have to take to protect tubes from high velocities? When to apply an impingement plate or rods? Many case studies will illustrate these points. Saving cost; who is not sensitive for that? Explaining different TEMA types, you will learn to make the right cost saving decision in this module.

Module 5
Discussion of removable bundles from U-tube to Floating Heads and Texas Towers, are the main subjects of this module. Discussions about tube vibration and acoustic tube vibration using HTRI simulation. Handling high pressure in a Shell & Tubular? No problem! All the secrets of the Breech Lock heat exchanger will be shared in this module. A “must do” module for engineers eager looking for cost saving.

Module 6
Here we will concentrate on the shell side aspects. Tube support in different systems like conventional and advanced baffles like rods and expanded metal will be discussed. And what do you think of helical baffles? In this module we discuss with many examples the pro’s and con’s per type of baffle. If you like to know more of helical baffles, you can follow a Masterclass Helixchanger. Many cost savings are possible with this type.

Module 7
In this module you will get familiar with many tube varieties. What to think about a Twisted Tube or a High Flux tube? After following this module all these special types will be clear for you.

Module 8
In the last Shell & Tube module we show you how to operate the heat exchanger at high efficiency while using tube inserts. Never heard from them? We share the possible opportunities. Wire mesh or tordated strips? Watching our video simulations you will get an inside view what insert technology can offer you. Following this we will discuss special heat exchangers like a falling film evaporator and a Helitrans or Helifin. A case study will be discussed where we evaluate a conventional baffle design exchanger with Helixchanger, Twisted Tube en EM baffle design is included.

Module 9: Air Cooled Heat Exchangers, parts 1&2
In these modules we will discuss air coolers. What criteria will be used when specifying an air cooler? A forced draft, Induced draft or air-recirculation? Which fan shall we use? What is the noise level? How do we specify the air cooler: will it be built as a module or in a knocked down condition? Which type of tubes are applicable and which ones are best for which process application? After following this module you will be well briefed for discussions with air cooler specialists/suppliers.

Module 10: Double Pipe or Multi Tube Hairpin Heat Exchangers
In this module we will explain the double pipe and multi tube hairpin heat exchangers. These types are popular in off- shore but also in the food, power and chemical industry. If the Shell & Tube is smaller than 10 m2, than knowledge of this type a must have!. To apply Twisted Tube or longitudinal fin tubes? The secret is in the details. This module will provide you the required answers.

Module 11: Plate & Frame Gasketed Heat Exchanger
Plate & Fame Heat Exchangers are icons in the heat exchanger world. Used everywhere but do they really operate to the user’s satisfaction? In this module we will explain the secrets of the vendor. Ever heard of the freezing effect? Many examples and operational feed-back will be discussed such as gasket selection, Chevron Angle, Wide gap plates. What to do when fouling occurs in these types? A must follow module for those who work with Plate & Frame and for those who want to purchase!

Module 12: Spiral plate, Plate in Shell, Packinox, Spiral Coil, Printed Circuit, Brazed Aluminium heat exchanger
A very extensive module with many heat exchanger types including: Spiral plate, Plate in Shell, Packinox, Spiral Coil, Printed Circuit, Brazed Aluminium heat exchanger. Never heard of them? This is your chance to get acquainted in a short time to experience all the pro’s-and con’s. Do you have to cool a slurry? Which type to purchase? This module will give you the answers.

Module 13: Electrical heater, Submerged Combustion Vaporizer, Open Rack Vaporizer, Heat Exchanger Selection
No steam available as the heating medium? No worries; consider the purchase of an electrical heater. Just plug and play. But is it simple as that? This module will provide you the tips & tricks about electrical heaters. Also we explore special waste heat boilers like in the Shell Process SGHP. Do you need to vaporise LNG? Submerged combustion vaporizers and Open Rack Vaporisers will be discussed.