Heat Exchanger Operation - Training Guide
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MINIMUM RESOLUTION: 980 x 600 px
RECOMMENDED: 1920 x 1080 (16:9) or larger

SIMULATOR OVERVIEW
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Shell-and-tube heat exchanger simulator covering thermal duty, fouling factor, approach temperature, and flow management per TEMA standards and ASME Section VIII.

Standards: TEMA R/C/B · ASME Sec. VIII · API 660

INTERFACE LAYOUT
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- LEFT PANEL: System controls (Start/Stop/ESD/Reset, Mode toggle)
- CENTER: P&ID schematic with real-time process visualization
- RIGHT PANEL: System gauges, operational checklist, alarm list

OPERATING PROCEDURES
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  Step 1: Open tube-side isolation valves
  Step 2: Start tube-side flow (cold)
  Step 3: Open shell-side isolation valves
  Step 4: Start shell-side flow (hot)
  Step 5: Verify approach temperatures
  Step 6: Set temperature controller
  Step 7: Monitor pressure drops
  Step 8: Record overall U-value

SCENARIOS
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  Normal Operation:
  Start heat exchanger, establish flows, achieve design outlet temperatures.

  Fouling Detection & CIP:
  Monitor declining heat transfer — determine fouling factor and initiate CIP.

  Temperature Control via Bypass:
  Use bypass valve to control outlet temperature for variable loads.

ALARM RESPONSE
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  TUBE_LEAK [ALARM]: Tube leak detected — pressure differential
  SHELL_PRESS_HIGH [ALARM]: Shell-side pressure exceeds MAWP
  FOULING_HIGH [WARNING]: Fouling factor exceeds design allowance
  APPROACH_HIGH [WARNING]: Approach temperature exceeds 10°C
  TUBE_VIB [WARNING]: Flow-induced tube vibration detected

CONTROLS
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- START: Begin process operation
- STOP: Normal shutdown
- EMERGENCY STOP: Immediate shutdown of all systems
- RESET: Clear ESD condition and reset to standby
- TOGGLE MODE: Switch between Manual and Auto control
- Fullscreen: Click the fullscreen button in header
- EXIT: Return to BlueSim portal
- HELP: Opens this training guide