1. Fouling and Scaling
One of the most frequent issues in heat exchangers is fouling: the accumulation of deposits (such as mineral scale, biological growth or particulate matter) on the heat transfer surfaces. These deposits act as thermal insulators, reducing the effective heat transfer rate, raising pressure drops and cutting efficiency.
How a quality manufacturer addresses this:
- They select materials and surface finishes that minimise deposit adhesion and facilitate cleaning.
- They design the exchanger with access for cleaning (tube bundles removable or shell inspection ports).
- They advise on optimal cleaning schedules and provide service guidance. For example, the website of TMVT Industries Pvt. Ltd. notes that regular cleaning and inspection of the tubes and shell ensures optimal performance.
- They size the exchanger so that velocities are sufficient to reduce sedimentation or stagnant zones.
2. Corrosion and Material Degradation
Corrosion is another major headache: when fluids (whether water, oils, acids, gases) attack tubes, shells or joints, the result can be leaks, thinning walls, and ultimately failure. Material mismatch, galvanic corrosion, or inadequate protection worsen the problem.
Manufacturer-level solutions include:
- Using the right metallurgy for the application: stainless steel, copper, cupronickel, or carbon steel, depending on fluid compatibility. The TMVT site lists tubes in copper, stainless steel, carbon steel and cupronickel.
- Applying corrosion-resistant coatings or linings, specifying protective anodes if needed.
- Designing for easy inspection and replacement of vulnerable components.
- Following stringent standards (such as those from Tubular Exchanger Manufacturers Association (TEMA)).
3. Leaks & Weld Failures
Leaks in a heat exchanger lead to cross-contamination of fluids, loss of pressure, reduced efficiency and potential safety or environmental hazards. Welded joints, tube-to-tube-sheet joints, gasket failures and flange leaks are common origins.
How good manufacturers help prevent this:
- They adhere to recognised welding and fabrication standards, inspect welds, and pressure-test units before shipping.
- They design connections to accommodate thermal expansion and vibration, reducing stress on joints.
- They offer sheet & tube bundles with removable sections for tube replacement or re-welding.
- They ensure the right gasket material or mechanical sealing for the service conditions.
4. Excessive Vibration & Tube Failure
In high-velocity or pulsating-flow environments, heat exchanger tubes may vibrate, fatigue, rub against supports or erode. Over time this leads to tube breakage, leaks or catastrophic failure.
Manufacturer strategies to combat this:
- Selecting tube support systems, baffles, and spacing that minimise unsupported spans and limit vibration.
- Checking for flow-induced vibration during the design phase, using computational analysis or empirical data.
- Offering “floating tubesheet” or “U-tube” designs that allow for differential expansion without stressing joints.
- Advising end-users on operating limits (flow, pressure, temperature) to avoid vibration-inducing regimes.
5. High Pressure Drop / Loss of Efficiency
An exchanger might start off performing well, but over time increased fouling, tube blockage, inappropriate fluid velocities or improper design lead to higher pressure drop, lower capacity, and higher energy consumption.
How good manufacturers make a difference:
- They size the exchanger for the correct flow rates, temperature differentials and fluid characteristics. For example, TMVT offers custom sizes with shell diameters from 4″ NB to 24″ NB, tube lengths 3 to 20 feet.
- They optimise tube bundle layout, shell baffle spacing and design parameters to minimise pressure drop while maximising heat transfer.
- They provide monitoring instruments or recommend instrumentation: e.g., measuring ΔP across tube bundles to detect performance degradation.
- They offer aftermarket services such as bundle cleaning, inspection and refurbishment to restore performance.
6. Thermal Fatigue & Mechanical Stress
Repeated thermal cycling (heating-up/cooling-down), startup/shutdowns, or transient loads may cause differential expansion, fatigue cracking, and structural stress in heat exchangers.
Manufacturer best practices:
- Engineering with proper expansion joints, floating tubesheets or U-tube designs to accommodate expansion and contraction.
- Using robust supports and designing the shell/tube bundle to avoid excessive stresses under changing conditions.
- Advising customers on proper operating procedures (e.g., gradual warm-up, avoiding thermal shocks).
- Providing documentation of allowable thermal cycles and designing for the expected service life.
7. Inadequate Maintenance / Poor Service
Even a well-designed exchanger will underperform without proper maintenance: missed inspections, dirty tubes, neglected seals or gaskets all lead to problems.
What a trustworthy manufacturer will offer:
- Clear maintenance schedules, cleaning procedures and spare parts lists. TMVT states that “Regular cleaning and inspection of the tubes and shell are recommended to ensure optimal performance.”
- Access to service engineers or maintenance-support from the manufacturer or their network.
- Offering replacement tube bundles, upgrade options and refurbishing services rather than full replacement.
- Training end-user personnel on correct operation, inspection and handling.
Conclusion
Working with a reputable heat exchanger manufacturer is more than buying a piece of equipment, it's about partnering with experts who anticipate and resolve common problems before they become costly failures. From choosing the right materials, designing to avoid fouling and vibration, to providing service support and maintenance guidance, the best manufacturers deliver reliability, efficiency and peace of mind. When your equipment is built with these best practices in mind, you reduce downtime, save energy, protect your investment and keep operations running smoothly.