Technical Resources
Heat Exchanger Troubleshooting Guide
Solve thermal fouling, scaling, pressure drops, and tube vibrations in your industrial heat transfer systems.
Common Heat Exchanger Issues & Diagnostic Matrix
1 Thermal Performance Decline & Fouling
Fouling is the accumulation of unwanted materials (scaling, biological matter, chemical deposits) on heat transfer surfaces, which insulates the plates or tubes and decreases thermal efficiency.
| Probable Cause | Diagnostic Indicator | Recommended Action |
|---|---|---|
| Scale formation (carbonate/silica) | High approach temp, increased pressure drop | Run chemical wash CIP with mild acidic solution |
| Particulate sedimentation or mud | Gradual drop in heat transfer coefficient | Flush system, increase fluid velocity, check filters |
| Bio-growth or algae fouling | Usually occurs on cooling tower/water loops | Inject biocides or chlorinate cooling water supply |
2 Excessive Pressure Drop & Flow Restraints
When the pressure drop across the exchanger exceeds design limits, pumps will work harder, utility costs rise, and flow rates will decrease below processing requirements.
| Probable Cause | Diagnostic Indicator | Recommended Action |
|---|---|---|
| Solid particles blocking channels | Sudden spike in pressure drop, flow blockage | Backflush the system or open unit to remove debris |
| Excessive flow rate (over-pumping) | Flow rate is higher than thermal design capacity | Install flow orifice or adjust pump speed / VFD |
| Incorrect plate assembly configuration | Occurs after manual reassembly of GPHE plates | Verify plate sequence/alignment matches drawing |
3 Tube Vibration & Mechanical Noise
High fluid velocities can cause mechanical vibration in shell & tube heat exchanger tubes. If untreated, vibration leads to wear at baffle contact points and tube failure.
| Probable Cause | Diagnostic Indicator | Recommended Action |
|---|---|---|
| Acoustical vibration in shell | High-pitched noise or hum, tube rubbing | Install derating orifice or acoustic baffles |
| Fluid-elastic instability (vibe) | Tubes hitting each other, leaks at tube sheets | Insert tube stakes or reduce shell-side flow velocity |
| Baffle wear / tube erosion | Leaks detected on pressure tests at shell joints | Plug damaged tubes, plan support baffle upgrades |
