Industrial processors rely on consistent, reliable heat transfer. When your shell & tube heat exchanger begins losing performance, the early warning signs are subtle but extremely important. Catching these issues early prevents unplanned downtime, safety risks, and expensive repairs.
This guide covers five clear red flags you should never ignore.
1. Sudden Drops in Heat Transfer Efficiency
If process temperatures aren’t reaching their targets or warm-up cycles take longer than usual, fouling or internal leakage may be the cause. Efficiency loss is one of the most common maintenance triggers.
Likely causes:
- Scale or mineral buildup
- Biological fouling
- Restricted flow on shell or tube side
Learn more in our guide on
preventative heat exchanger maintenance.
2. Increasing Pressure Drop Across the Exchanger
As debris, corrosion, or scale accumulates, fluid pathways narrow and pressure drop increases. A rising differential is a reliable indicator of internal blockages.
If your system is trending upward in pressure drop, explore our
tube bundle replacement guide.
3. Visible External Leaks or Corrosion
Moisture around flanges, rust streaks, or pitting on shell components are all signs that the exchanger needs immediate inspection. Corrosion progresses quickly if not caught early.
Learn how to prevent these issues in our article on
heat exchanger corrosion prevention.
4. Cross-Contamination Between Streams
If one process fluid becomes contaminated with another, a tube leak or damaged joint is often the culprit. This should prompt immediate shutdown and inspection.
For more diagnostic help, read
How to Troubleshoot Heat Exchanger Leaks.
5. Unusual Noises, Vibration, or Water Hammer
Noises like hissing, banging, or vibration often indicate improper drainage or rapid temperature fluctuations. Thermal shock can permanently damage tubes and gaskets.
Learn how to prevent this in our article:
How to Prevent Thermal Shock in Heat Exchangers.
Related Resources
- How Routine Inspections Extend Heat Exchanger Life
- Mechanical vs. Chemical Cleaning: Which Is Best?
- Straight Tube vs. U-Tube Cleaning Requirements
- Why Custom Shell & Tube Manufacturing Improves Performance
Heat Exchanger Service Areas
KAM Thermal Equipment serves industrial clients across the United States. Explore support by region:
Mid-Atlantic
Southeast
Midwest
South Central
Need Professional Maintenance or Inspection?
KAM Thermal Equipment provides custom shell & tube manufacturing, tube bundle replacements, refurbishments, and diagnostic services. If you’re seeing any of these warning signs, our team is ready to help.