Troubleshooting Shell-and-Tube Heat Exchangers

What is the most common cause of reduced heat transfer efficiency in a shell-and-tube heat exchanger?

• Excessive fluid velocity

• Fouling or scaling on tube surfaces

• Use of high-quality materials

• Increased baffle spacing

If a heat exchanger is leaking at the tube sheet joints, what is the most likely cause?

• Worn-out gaskets or improper gasket installation

• Too much pressure in the shell side

• Over-tightened bolts

• Misaligned baffles

What is the best corrective action if corrosion is found inside the tubes of a heat exchanger?

• Increase the operating pressure

• Replace corroded tubes and use corrosion-resistant materials

• Remove all baffles to improve flow

• Reduce the tube diameter

What could cause an excessive pressure drop across a heat exchanger?

• Fouling or blockage in the tubes

• Decreased fluid viscosity

• Increased tube diameter

• Removing the tube bundle

If there is insufficient heat transfer even after cleaning the heat exchanger, what could be the issue?

• Tube bundle misalignment

• Gasket failure

• Wrong fluid flow direction

• All of the above

A shell-and-tube heat exchanger is experiencing tube vibrations. What is the most likely reason?

• Excessive fluid velocity and improper baffle spacing

• Use of corrosion-resistant materials

• Over-tightened end caps

• High-quality tube welding

What is the recommended troubleshooting step if a heat exchanger is leaking at the head flanges?

• Apply more pressure to stop the leak

• Replace or reposition the gaskets and retighten the bolts in a cross-pattern

• Remove the tube bundle and reinstall it without gaskets

• Increase the flow rate to seal the gaps

What can be done to prevent excessive fouling inside a heat exchanger?

• Use proper filtration and periodic chemical cleaning

• Increase fluid temperature beyond design limits

• Decrease flow velocity to allow more deposits

• Remove baffles to allow smoother flow

If a heat exchanger’s tubes are getting blocked frequently, what is a possible solution?

• Increase cleaning frequency and use pre-filters

• Reduce the system’s pressure

• Decrease fluid velocity to allow particles to settle

• Remove the tube bundle permanently

What could cause a heat exchanger to develop leaks in the tubes?

• Erosion due to high fluid velocity

• Use of thicker tube walls

• Proper gasket installation

• Regular maintenance