Preventative maintenance is one of the most effective ways to keep industrial heat exchangers performing reliably over long operating cycles. While KAM THERMAL EQUIPMENT does not perform on-site maintenance, our engineering and manufacturing expertise gives facility teams the guidance they need to protect their shell & tube equipment and avoid preventable failures.
This guide outlines the core preventative steps industrial operators should implement to reduce fouling, minimize wear, and extend equipment life.
Why Preventative Maintenance Matters
Shell & tube heat exchangers are workhorses that often operate under demanding conditions. Over time, fouling, corrosion, and mechanical stress gradually reduce thermal efficiency. Most failures don’t happen suddenly—they develop slowly and quietly.
If you’re not already monitoring early warning signs, review our guide:
5 Early Warning Signs Your Heat Exchanger Needs Maintenance.
1. Perform Regular Visual Inspections
Routine visual checks help detect issues before they escalate into downtime. Facility teams should look for:
- Corrosion or pitting on the shell
- Moisture or seepage around flange connections
- Unusual noise, vibration, or stress
- Insulation damage or discoloration
For deeper inspection recommendations, see
our guide to routine heat exchanger inspections.
2. Track Temperature and Pressure Trends
Tracking performance data is essential for predicting problems early. Trends to monitor include:
- Inlet/outlet temperature changes
- Flow rate reductions
- Rising pressure drop across the exchanger
A consistent increase in pressure drop may indicate internal fouling or blockage. Learn more through our
tube bundle removal and replacement guide.
3. Maintain Proper Venting and Draining
Air pockets and trapped condensate reduce thermal performance and create conditions that accelerate corrosion. Proper venting ensures uniform heat transfer, while proper draining helps prevent water hammer and freeze damage.
If your system experiences temperature shock or cycling, review
How to Prevent Thermal Shock in Heat Exchangers.
4. Keep Fluids Clean and Properly Treated
Many fouling problems originate from process fluid quality. Operators should routinely test for:
- Suspended solids
- Chemical imbalance
- Biological growth
- Debris caused by upstream corrosion
For cases where cleaning is required, see
Mechanical vs. Chemical Cleaning for Heat Exchangers.
5. Establish a Tube Cleaning Schedule
Even under ideal conditions, tubes gradually accumulate deposits. Cleaning frequency depends on the application, process fluids, operating temperatures, and fouling tendency.
Straight tubes and U-tubes require different maintenance approaches. Learn more in
Straight Tube vs. U-Tube Cleaning Requirements.
6. Plan for Tube Bundle Replacement Before Failure Occurs
Preventative maintenance allows operators to identify when a bundle is approaching end of life. KAM Thermal Equipment manufactures:
- Custom replacement tube bundles
- Drop-in replicas of OEM and discontinued models
- Engineering upgrades for improved durability
Explore how bundle replacement works in
our tube bundle replacement guide.
Additional Resources
- How to Prevent Corrosion in Heat Exchangers
- Troubleshooting Heat Exchanger Leaks
- Benefits of Custom Shell & Tube Manufacturing
Service Areas
KAM Thermal Equipment serves industrial operators across the United States. Explore support by region:
Mid-Atlantic
Southeast
Midwest
South Central
Need a Replacement Tube Bundle?
KAM Thermal Equipment designs and manufactures custom shell & tube heat exchangers and replacement tube bundles built for long-term durability. If preventative maintenance identifies wear or declining performance, our team can engineer an exact-fit solution.