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

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 their 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 that 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, maintenance, and testing for shell and tube heat exchangers and also will help to carry out strength calculations and assessment of the 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 stipulations will be reviewed and discussed collectively with participants so as to address the difficulties and ambiguities they might have encountered during their work. This course will also help the design engineers to assess the work of the fabricators/ vendors as regards 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.


  • Importance of Heat Transfer
  • Categories of heat exchangers such as Plate type/ Double pipe/ Cooling towers/ Air cooled exchangers
  • Modes of heat transfer such as conduction/ convection/ radiation.
  • Introduction to Fluid Flow, velocities, and Pressure Loss.
  • Applicability of relevant codes under ASME/ TEMA/ API.
  • Introduction and Considerations in Thermal Design
  • Material selection criteria from ASME Section II. 


  • Heat Exchanger Terminology as per TEMA/ ASME.
  • Types such as Fixed/ Floating/ U tube sheet and applications.
  • Shell-And-Tube Heat Exchanger parts and detailed function.
  •  Mechanical design & thickness calculations as per ASME-VIII (Internal/ External pressure) for shells/ bonnets/ tubes.
  • Minimum thickness criteria from TEMA.
  • Tube Layouts and Number of Tubes in specified Shell Diameter (for ease of maintenance)
  • Exercise on (basic) thermal design of the exchanger


  • Thickness calculation for Tube sheet (Bending/ Shear) from TEMA.
  • Minimum requirement criteria for baffles/ tie-rods/ 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
  • Case study/ exercise on a mechanical design using TEMA/ ASME criteria


  • Inspection considerations (Radiography/ Ultrasonic/etc.)
  • Heat Exchanger Hydrostatic test/ Pneumatic test.
  • General reference from ASME Section-V and ASME Section-IX.
  • Corrosion and Fouling in Heat Exchangers
  • Maintenance and Cleaning Methods 
  • Preventive & Corrective Maintenance.
  • Effects of tube failure/ bad design on the operation of the exchanger.
  • Concept of MAWP.


  • Repair minimum requirement criteria from ASME PCC-2.
  • Re-tubing/ tube pulling/ plugging (friction/ mechanical plugs) of tubes
  • A 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 real-life typical fabrication assembly drawing/ calculations/ specification datasheet.
  • Discussions and queries
  • Final Exam (if required)


(Detailed Thermal Design and HTRI, are not part of this course)

(The main codes of discussion will be ASME VIII-1/ TEMA only. All other codes/ standards mentioned will be generally referred to, as required, to understand the concepts clearly.)

What is Shell and Tube Heat Exchangers training course objective?

  • 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 of 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.

Who should join Shell and Tube Heat Exchangers training course by PetroSync?

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

Mandar Mulay

Mechanical Engineer

Mandar Mulay has about 20 years hands on experience in design and integrity assessment of Piping Systems, Reactors & Storage Tanks, Pressure Vessels, Power Boiler, and Heat Exchanger. He is well conversant with the major industry codes & standards such as ASME Sec. I, ASME B 31.1, B31.3 , B31.4 and B31.8, ASME Sec VIII, BS-5500, TEMA, API -650, IS 803, API 579, ASME PCC-2 etc.

Major projects closely associated with, in his professional career so far are, Qatar Chemicals, Shell, Castrol India, Reliance Industries, Cargill Foods USA, etc. His proficiency in Power Boiler, Piping and Pressure Vessel Codes enables him to trace the similarities and differences of these codes. He also actively involved as Instructor for programs on the subjects of ASME codes, Integrity Assessment, Fitness for Service, etc.

Along with his career in Engineering and Design Department in a multinational company at a very senior post for the last 20 years, he is also visiting faculty to a well known Engineering College in India for their P.G. Courses in Piping Design and Engineering

Apart from being visiting faculty, He has also conducted several Training Courses ( ASME Sec. I, ASME Sec. VIII, ASME B 31.3 Piping Codes , API 579 FFS code, ASME PCC-2 Repair practices, and Heat Exchanger Design Operations & Maintenance ) in Saudi Arabia, Qatar, Bahrain and UAE for engineers from companies like Saudi Aramco, SABIC group of Companies, Qatar Petroleum, ADNOC, BAPCO, DEWA, Gulf Petrochemicals etc. He has already conducted many times the training courses in API 579, where the participants rated him “Excellent” for these courses.

  • Code PST0397-202401
  • Start Date 24 Jun, 2024
  • End Date 28 Jun, 2024
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3250
  • Code PST0397-202301
  • Start Date 04 Dec, 2023
  • End Date 08 Dec, 2023
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3150
Code Start Date End Date Locations Cost Instructor Register
PST0397-202401 24 Jun, 2024 28 Jun, 2024 Kuala Lumpur, Malaysia USD 3250 Mandar Mulay
PST0397-202301 04 Dec, 2023 08 Dec, 2023 Kuala Lumpur, Malaysia USD 3150 Mandar Mulay
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