WorksheetsTroubleshooting Shell-and-Tube Heat Exchangers
Total questions: 10
Worksheet time: 5mins
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
