API 660: Shell & Tube Heat Exchangers: Design, Welding, Fabrication, Inspection, Testing, Operation, Maintenance & Troubleshooting

Introduction

This course is designed to provide participants with a detailed and up-to-date overview of API 660: Shell & Tube Heat Exchangers: Design, Welding, Fabrication, Inspection, Testing, Operation, Maintenance & Troubleshooting. It covers the importance role of API 660 in the process industry; the fundamentals of heat exchanger including the general scope and key terminologies used in API 660; the operating conditions and process requirements; the thermal and mechanical design considerations and fluid properties and their impact on design; selecting materials for shell, tubes and baffles; and the key components of a shell-and-tube heat exchanger. Further, the course will also discuss the design codes and standards, mechanical design aspects and tube sheet and tube bundle design; the baffles and support structures, nozzles and flanges design and welding and fabrication requirements; the API 660 inspection criteria, third-party inspection requirements and common non-conformities in heat exchangers; the non-destructive testing (NDT) methods, hydrostatic and pneumatic testing and tube integrity testing; and the quality assurance and documentation, factory acceptance testing (FAT) and site acceptance testing (SAT). During this interactive course, participants will learn the startup and shutdown procedures, operating parameter monitoring and efficiency optimization techniques; the fouling and scaling issues, tube-side and shell-side corrosion, vibration and mechanical damage and gasket leaks and sealing problems; the cleaning and maintenance procedures, performance monitoring and optimization and retrofitting and upgrades; the systematic troubleshooting approach, identifying root causes of exchanger failures and corrective actions and long-term solutions; the advanced heat transfer enhancements, special service heat exchangers and economic and environmental considerations; preparing for API 660 compliance audits; and common audit findings, corrective actions and documentation and record-keeping best practices.

Objectives

 Upon the successful completion of this course, each participant will be able to: -

• Apply and gain an in-depth knowledge on the design, welding, fabrication, inspection, testing, operation, maintenance and troubleshooting of shell and tube heat exchangers in accordance with API 660 standards
• Discuss the importance role of API 660 in the process industry
• Explain the fundamentals of heat exchanger including the general scope and key terminologies used in API 660
• Recognize the operating conditions and process requirements as well as thermal and mechanical design considerations and fluid properties and their impact on design
• Select materials for shell, tubes and baffles and identify the key components of a shell-and-tube heat exchanger
• Discuss design codes and standards, mechanical design aspects and tube sheet and tube bundle design • Describe baffles and support structures, nozzles and flanges design and welding and fabrication requirements
• Recognize API 660 inspection criteria, third-party inspection requirements and common non-conformities in heat exchangers
• Apply non-destructive testing (NDT) methods, hydrostatic and pneumatic testing and tube integrity testing
• Carryout quality assurance and documentation, factory acceptance testing (FAT) and site acceptance testing (SAT)
• Employ startup and shutdown procedures, operating parameter monitoring and efficiency optimization techniques
• Identify and troubleshoot fouling and scaling issues, tube-side and shell-side corrosion, vibration and mechanical damage and gasket leaks and sealing problems
• Apply cleaning and maintenance procedures, performance monitoring and optimization and retrofitting and upgrades
• Carryout systematic troubleshooting approach, identify root causes of exchanger failures and apply corrective actions and long-term solutions
• Recognize advanced heat transfer enhancements, special service heat exchangers and economic and environmental considerations
• Prepare for API 660 compliance audits and apply common audit findings, and corrective actions and documentation and record-keeping best practices

Training Methodology

This training course will utilise a variety of proven adult learning techniques to ensure maximum understanding, comprehension and retention of the information presented. This includes stimulating presentations supporting each of the topics together with interactive trainer lead sessions of discussion.

Who Should Attend?

This course provides an overview of all significant aspects and considerations of the design, welding, fabrication, inspection, testing, operation, maintenance and troubleshooting of shell and tube heat exchanger in accordance with API 660 standards for engineers and technical professionals, inspection and quality control personnel, operations and maintenance personnel, project and procurement professionals, fabricators and manufacturers and other technical staff.

Course Outline

• Types of Heat Exchangers and Their Applications
• Basics of Heat Transfer and Thermodynamics
• Shell-and-Tube Heat Exchanger (STHE) Working Principle
• Selection Criteria for Heat Exchangers

• General Scope of API 660
• Key Terminologies Used in API 660
• Roles of Manufacturers, Purchasers and Engineering Companies
• Applicability and Limitations of API 660
• Design Considerations & Service Conditions
• Operating Conditions and Process Requirements
• Thermal and Mechanical Design Considerations
• Fluid Properties and their Impact on Design
• Pressure Drop and Efficiency Calculations

• Selection of Materials for Shell, Tubes and Baffles
• Corrosion Resistance and Material Compatibility
• API 660 Material Standards and Compliance
• Special Materials for High-Temperature and Corrosive Applications
• Key Components of a Shell-&-Tube Heat Exchanger 
• Shell and Tube Bundle Configuration
• Tube Sheets, Baffles and Nozzles
• Expansion Joints and Floating Heads
• Gasket Materials and Sealing Mechanisms

• API 660 versus ASME Section VIII
• TEMA Classifications and their Relevance
• Compliance with PED and other International Codes
• Case Studies on Design Standard Conflicts

• Pressure and Temperature Limits
• Stress Analysis and Fatigue Considerations
• Thermal Expansion and Design Allowances
• Mechanical Load Calculations

• Fixed versus Floating Tube Sheet Designs
• Tube Expansion and Welding Methods
• Tube Bundle Extraction and Maintenance Considerations
• Material Selection for Tube Sheets and Corrosion Prevention

• Role of Baffles in Heat Transfer Enhancement
• Types of Baffles and their Spacing Guidelines
• Flow-Induced Vibration and Mitigation Techniques
• Support Structures for Mechanical Stability

• Nozzle Orientation and Connection Types
• Stress Analysis on Nozzle Loads
• Flange Types and Gasket Selection
• API 660 Requirements for Nozzle Reinforcement

• API 660 Welding Specifications
• Qualification of Weld Procedures and Welders
• Common Welding Defects and Inspection Methods
• Case Studies on Welding Failures

• Purpose and Importance of Inspection
• API 660 Inspection Criteria
• Third Party Inspection Requirements
• Common Non-Conformities in Heat Exchangers

• Radiographic Testing (RT) of Welds
• Ultrasonic Testing (UT) for Thickness Measurement
• Magnetic Particle Testing (MPT) for Crack Detection
• Dye Penetrant Testing (DPT) for Surface Defects

• Hydrostatic Pressure Test Procedures
• Pneumatic Pressure Test Requirements
• Leak Detection Methods and Acceptance Criteria
• Safety Precautions during Testing