Shell and Tube Heat Exchangers : Mechanical Design (ASME/TEMA), and Considering Operation & Maintenance VIRTUAL TRAINING

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Upcoming Course

Code Start Date End Date Location Cost Instructor Register
PST0397-202101  12 Jul 2021  16 Jul 2021  VIRTUAL TRAINING  USD 2495  Mandar Mulay   Register
PST0397-202102  27 Sep 2021  01 Oct 2021  VIRTUAL TRAINING  USD 2495  Mandar Mulay   Register

Past Course

Code Start Date End Date Location Cost Instructor Register
        Aaron A. Zick, Ph.D. 
PST0397-201601  05 Dec 2016  09 Dec 2016  Kuala Lumpur, Malaysia  SGD 3195  Mandar Mulay 
PST0397-201701  22 May 2017  26 May 2017  Kuala Lumpur, Malaysia  SGD 3195  Mandar Mulay 
PST0397-201702  25 Sep 2017  29 Sep 2017  Kuala Lumpur, Malaysia  SGD 3195  Mandar Mulay 
PST0397-201801  05 Feb 2018  09 Feb 2018  Kuala Lumpur, Malaysia  SGD 3195  Mandar Mulay 
PST0397-201802  01 Oct 2018  05 Oct 2018  Kuala Lumpur, Malaysia  SGD 3195  Mandar Mulay 
PST0397-201901  08 Jul 2019  12 Jul 2019  Kuala Lumpur, Malaysia  USD 2595  Mandar Mulay 
PST0397-201902  16 Dec 2019  20 Dec 2019  Kuala Lumpur, Malaysia  USD 2595  Mandar Mulay 
PST0397-202001  09 Mar 2020  13 Mar 2020  Kuala Lumpur, Malaysia  USD 2595  Mandar Mulay 
PST0397-2020  07 Dec 2020  11 Dec 2020  VIRTUAL TRAINING  USD 2335  Mandar Mulay 

This Five-day program offers a proper understanding of the ASME/ TEMA codes and standards, pertaining to mechanical design engineering, inspection and testing of the shell and tube heat exchangers and it’s relevant referred codes. This course emphasizes understanding of ‘stated’ and ‘implied’ requirements (i.e. content and intent) of the codes. The participants would be explained in detail the application of these code/ standard rules and mechanical design formulas for different design conditions and services.

ASME Section VIII/ TEMA are very commonly adopted guidelines which are comparatively easier to use, in comparison to BS/DIN/ other codes and standards.

This course is intended to give the participants the confidence for carrying out design, and maintenance and testing for shell and tube heat exchangers and also will help to carrying out strength calculations and assessment of integrity of existing exchangers. How to adopt code rules for different types of exchangers and with various service conditions will be illustrated with case discussions. Important code stipulation will be reviewed and discussed collectively with participants so as to address the difficulties and ambiguities they might have encountered during their working. This course will also help the design engineers to assess the work of the fabricators/ vendors as regards to drawing and calculation review/ approval.

Over and all the course will make the attendees comfortable with the use of ASME/ TEMA codes and standards and understand the basic concepts with better clarity. This will give the candidates a firm background for further studying in-service codes/ standards such as API-579, ASME PCC-2 or API-510.

Day 1

  • Importance of Heat Transfer
  • Concepts of Thermal Equilibrium
  • Introduction to Fluid Flow and Pressure Losses
  • Modes of heat transfer such as conduction/ convection/ radiation.
  • Applicability of relevant codes under ASME/ TEMA/ API.
  • Introduction and considerations in Thermal Design
  • Material selection criteria from ASME Section-II.

Day 2

  • Categories of heat exchangers such as Plate type/ Double pipe/ Cooling towers/ Air cooled exchangers.
  • Heat Exchanger Terminology as per TEMA/ ASME.
  • Shell-And-Tube Heat Exchanger parts and detailed function.
  • Types such as Fixed/ Floating/ U tubesheets.
  • Mechanical design & thickness calculations as per ASME-VIII (Internal/ External pressure).
  • Minimum thickness criteria from TEMA.
  • Case study/ exercise on (basic) thermal design of the exchanger

Day 3

  • Thickness calculation for Tubesheet (Bending/ Shear) from TEMA.
  • Minimum requirement criteria for baffles/ tierods/ tubes/ flanges/ impingement plates/ etc.
  • Baffles clearance and spacing with consideration to flow induced vibrations.
  • Tube Layouts and Number of Tubes in specified Shell Diameter (for ease of maintenance)
  • TEMA Standard References.
  • General introduction to API Standard for Petroleum and Natural Gas Industries
  • Heat Exchangers Hydrostatic test/ Pneumatic test.
  • Performance Evaluation Test for Heat Exchanger
  • Case study/ exercise on mechanical design using TEMA/ ASME criteria.

Day 4

  • Inspection consideration for new/ old heat exchangers
  • General reference from ASME Section-V.
  • Corrosion and Fouling in Heat Exchangers
  • Maintenance and Cleaning Methods
  • Preventive & Corrective Maintenance.
  • Effects of tube failure/ bad design on operation of the exchanger.
  • Concept of MAWP

Day 5

  • Repair minimum requirement criteria from ASME PCC-2.
  • Welding considerations from ASME Section-IX.
  • Retubing/ pulling/ plugging/ rewelding of tubes
  • Case study from ASME PCC-2 philosophy.
  • Final heat exchanger selection based on
    • Type of Duty
    • Operating Limitation
    • Materials of Construction
    • Safety and Reliability
    • Design Methods
    • Inspection of new Heat Exchangers during fabrication
    • Dimensions and Weight
    • Cost
    • Delivery
  • Review of a typical fabrication assembly drawing/ calculations/ specification data sheet from TEMA.
  • Discussions and queries
  • Familiarize participants with the concepts and technical terms of the codes.
  • Know the basic concepts of the codes and their design fundamentals.
  • Understand salient features and differences between codes and standards.
  • Know the design of pressure parts and major components.
  • Understand the problems in exchangers in-service & corrosion related issues.
  • Learn the maintenance aspects in shell & tube exchangers.
  • Get introduced to the repair techniques and considerations.
  • Discover the fabrication requirements, assembly and welding requirements.
  • NDE and Inspection procedures
  • Pressure testing.
  • General requirements for ASME certification.

The course is designed for, but not limited to, mechanical design, operations, maintenance, and  inspection professionals who are involved in equipment such as pressure vessels, heat exchangers, process columns, etc .

Job Title Includes:

  • Design Engineers / Managers
  • Mechanical Engineers / Managers
  • Maintenance Engineers / Managers
  • QAQC Engineers / Managers
  • Inspection Engineers / Managers
  • Reliability Engineers / Managers

Aaron A. Zick, Ph.D.

Founder and President


President, Zick Technologies (Since 10/93).

Petroleum engineering consulting and software development, specializing in the area of reservoir fluid phase behavior modeling. References available on request. Key achievements:

-Developed numerous equation-of-state and black-oil fluid characterizations for various major oil companies and as a sub-contractor for Pera A/S.

-Recommended phase behavior experimentation and modeling guidelines for several major oil companies.

-Wrote PhazeComp, a new, state-of-the-art program from Zick Technologies for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Wrote Streamz, unique Petrostreamz A/S software for translating, manipulating, and managing vast quantities of fluid stream information.

-Designed and helped write Pipe-It, unique Petrostreamz A/S software for managing and manipulating petroleum resources, processes, and projects.

-Taught numerous industry courses on phase behavior, equations of state, reservoir fluid characterization, and miscible gas injection processes.

-Designed and helped implement a new set of equation-of-state routines for the in-house reservoir simulator of a major oil company.

-Advised the architects of a major commercial reservoir simulator on ways to significantly improve their equation-of-state routines.


Director of Research, Reservoir Simulation Research Corporation (6/91–10/93).

Responsible for the research and development of more efficient, accurate, and reliable techniques for modeling reservoir fluid phase behavior within MORE® (a fully-compositional, equation-of-state reservoir simulator). Also responsible for improving three-dimensional visualization of reservoir simulator output, and for occasional consulting work. Key achievements:

-Designed and implemented new equation-of-state solution algorithms for MORE®, improving both efficiency and robustness while using less memory.

-Developed a powerful and flexible interface between MORE® and TECPLOT™ (three-dimensional surface contouring software from AMTEC Engineering).


Senior Principal Research Engineer, ARCO Oil and Gas Company (9/83–5/91).

Developed expertise in reservoir fluid phase behavior, phase behavior modeling, compositional reservoir simulation, and relative permeability modeling.  Designed and analyzed PVT experiments. Created equation-of-state reservoir fluid characterizations. Developed ARCO’s phase behavior modeling software and relative permeability modeling software. Helped develop several of ARCO’s compositional and limited compositional reservoir simulators. Key achievements:

-Discovered the true, condensing/vaporizing mechanism of oil displace­ment by enriched hydrocarbon gases.

-Represented ARCO on the Prudhoe Bay co-owners’ Enhanced Oil Recovery Task Force for the Prudhoe Bay Miscible Gas Project.

-Designed and analyzed most of the PVT and slim-tube experiments for the Prudhoe Bay Miscible Gas Project.

-Created the equation-of-state reservoir fluid characterization adopted by the operating companies for the Prudhoe Bay Miscible Gas Project.

-Developed the miscibility pressure correlations used by the facility operators for the Prudhoe Bay Miscible Gas Project.

-Developed EOSPHASE, a then state-of-the-art program for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Developed SLIMTUBE, a special-purpose, equation-of-state simulator for slim-tube displacements.

-Developed new, compositionally-consistent, three-phase relative perme­ability models for ARCO’s compositional simulators and wrote data-fitting software for those models.

-Developed the phase behavior and relative permeability routines for a new, limited compositional reservoir simulator and assisted on other aspects of it.

-Continually added improvements to various in-house reservoir simulators.

-Regularly taught in-house courses on the phase behavior of miscible gas displacement processes.



A. A. Zick, “A Combined Condensing/Vaporizing Mechanism in the Displacement of Oil by Enriched Gases,” presented at the 61st Annual Technical Conference and Exhibition of the Society of Petroleum Engineers, New Orleans, LA (October, 1986).

D. E. Tang and A. A. Zick, “A New Limited Compositional Reservoir Simulator,” presented at the 12th SPE Symposium on Reservoir Simulation, New Orleans, LA (March, 1993).