{"id":37726,"date":"2025-10-01T10:07:25","date_gmt":"2025-10-01T08:07:25","guid":{"rendered":"https:\/\/www.sacome.com\/?p=37726"},"modified":"2025-10-13T11:54:01","modified_gmt":"2025-10-13T09:54:01","slug":"the-9-most-common-mistakes-in-the-installation-and-commissioning-of-a-heat-exchanger","status":"publish","type":"post","link":"https:\/\/www.sacome.com\/en\/the-9-most-common-mistakes-in-the-installation-and-commissioning-of-a-heat-exchanger\/","title":{"rendered":"The 9 most common faults in the installation and commissioning of a heat exchanger"},"content":{"rendered":"

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The 9 mistakes in installation and use of a heat exchanger<\/span><\/h2>\n

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What are the 9 most common faults in the installation and commissioning of a heat exchanger?:<\/h2>\n

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In the more than 40 years of history of SACOME<\/b><\/a> <\/b>as a leader in the field of heat exchangers<\/b><\/a> and the process industry, our company has supplied thousands of units for a wide range of different applications<\/b>.<\/p>\n

In this article, we have compiled the most common faults that occur during the installation and commissioning of a heat exchanger<\/b>, errors that can have a negative impact on the performance of the equipment and, in some cases, can even lead to breakage or collapse<\/b>.<\/p>\n

We therefore recommend that our customers follow the advice of our Technical Department<\/b>, as well as the installation recommendations contained in our instruction and operating manual.<\/p>\n

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1. Incorrect arrangement of the fluid flow directions in the exchanger.<\/h2>\n

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Depending on the direction of flow of the hot and cold fluids in a piece of equipment, there are two ways to install a heat exchanger<\/b>, as shown in the following image:<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.0.48″ background_size=”initial” background_position=”top_left” background_repeat=”repeat”][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”3_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-1.jpg” alt=”New mathematical models applied to heat exchangers” title_text=”New mathematical models applied to heat exchangers” align=”center” _builder_version=”3.21″ max_width=”90%” module_alignment=”center” \/][et_pb_text _builder_version=”3.21″ header_2_text_align=”center” text_orientation=”center”]<\/p>\n

Countercurrent and equicurrent layout.<\/i><\/p>\n

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Except in some very specific applications, a heat exchanger<\/b> is more efficient when installed in countercurrent<\/b>, as this arrangement achieves a greater average logarithmic temperature difference (LMTD) between the hot and cold fluids, which translates into higher thermal performance<\/b> and, therefore, a smaller exchange surface area required. However, in some specific processes, a co-current arrangement<\/b> may be preferable, so our Technical Department<\/b> will recommend the best solution for your particular case during the design phase.<\/p>\n

That said, when the customer proceeds with the installation and commissioning of the equipment, they may mistakenly arrange the service inlets and outlets incorrectly, in which case the equipment may be installed in countercurrent instead of countercurrent, which, for the reasons explained above, may have a negative impact on the performance of the heat exchanger.<\/p>\n

To illustrate this situation, let’s look at an example. In the thermal calculation below, we reproduce a process calculated in countercurrent<\/b>:<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.21″][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”3_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-2.png” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][et_pb_text _builder_version=”3.21″ header_2_text_align=”center” text_orientation=”center”]<\/p>\n

Countercurrent calculation.<\/i><\/p>\n

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Now we will simulate the same exchanger with the same process, but this time we will consider a cross-flow arrangement<\/strong>:<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.21″][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”3_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-3.png” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][et_pb_text _builder_version=”3.21″ header_2_text_align=”center” text_orientation=”center”]<\/p>\n

Equicurrent calculation.<\/em><\/p>\n

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As we can see, the equipment goes from being able to perform the process perfectly (since the excess area is 14.92%) to having a negative excess area (-29.33%), meaning that there will be insufficient exchange area and the temperatures cannot be reached. The explanation for this is that the average logarithmic temperature difference (shown as EMTD in the spreadsheets) is reduced from 26 \u00b0C (for countercurrent) to 16 \u00b0C (for equicurrent), reducing the thermal performance of the equipment.
\nIn practice, to avoid this type of problem, it is sufficient to respect the layout of the inlets and outlets shown in the manufacturing plan that we send to the customer, which in the vast majority of cases corresponds to a counterflow layout.<\/p>\n

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2. Overpressures due to a poorly designed closed water circuit.<\/h2>\n

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There are various reasons why unusual overpressure can occur during the operation of a tubular heat exchanger<\/b>, such as water hammer or overheating of one of the working fluids, among others. This overpressure can lead to plastic deformation, partial or total rupture of the jacket or inner tubes, or collapse of the bellows, effects that can render the equipment unusable<\/b>.<\/p>\n

In this regard, we have attached some typical photos of heat exchanger collapse and, in particular, of the expansion joint, due to overpressure on the jacket side<\/b>:<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.21″][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”1_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-4.jpg” align=”right” _builder_version=”3.21″ \/][\/et_pb_column][et_pb_column type=”1_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-5.jpg” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][\/et_pb_column][et_pb_column type=”1_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-6.jpg” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][\/et_pb_column][et_pb_column type=”1_5″][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.21″][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”3_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-7.png” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][et_pb_text _builder_version=”3.21″ header_2_text_align=”center” text_orientation=”center”]<\/p>\n

Details of expansion joints deformed<\/em>
\nand cracked due to overpressure on the jacket side.<\/em><\/p>\n

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In the case in question, overpressure in a poorly designed hot water circuit, it is essential to install an expansion tank or vessel in the closed water loop. This component has the function of absorbing the increase in pressure of the heat transfer fluid (e.g. water or glycol water) when it is heated. As the temperature of this fluid increases, its volume also tends to increase, and if the fluid is in a closed volume and there is no component that can absorb this expansion, significant overpressures will occur that can cause elements such as the expansion joint or the inner tubes of the exchanger to collapse.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.21″][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”3_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-8.png” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][et_pb_text _builder_version=”3.21″ header_2_text_align=”center” text_orientation=”center”]<\/p>\n

How an expansion tank works.<\/em><\/i><\/p>\n

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Below is a typical diagram of a closed water loop<\/strong> where, among other necessary components such as pumps, pressure gauges, valves, drains, and sight glasses, we can see the expansion tank or vessel. This is a typical installation in heat recovery processes in a plant.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.21″][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”3_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-9.jpg” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][et_pb_text _builder_version=”3.21″ header_2_text_align=”center” text_orientation=”center”]<\/p>\n

Components of a closed water loop.<\/em><\/i><\/p>\n

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3. Locking the supports.<\/h2>\n

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Depending on the layout of the equipment (horizontal or vertical installation, one or more modules in series, etc.), the exchanger can be supported or mounted on the foundation<\/b> in one way or another. For example, in the case of a single module with a horizontal layout, it can be supported on two cradles or support legs, as shown in the following figure:<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.21″][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”3_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-10.png” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][et_pb_text _builder_version=”3.21″ header_2_text_align=”center” text_orientation=”center”]<\/p>\n

Exchanger on 2 support legs.<\/em><\/i><\/p>\n

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If the floor fixing bolts are anchored in such a way that they do not allow movement, excessive stress will be exerted on the expansion joint and on the tube-to-plate welds, which may cause cracks in these welds. Bearing this in mind, if the exchanger is fixed at two points, one of them should be left sliding or in such a way as to allow free expansion.<\/strong><\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”3.21″][et_pb_column type=”1_5″][\/et_pb_column][et_pb_column type=”3_5″][et_pb_image src=”https:\/\/www.sacome.com\/wp-content\/uploads\/2025\/07\/Ilustraci\u00f3n-11.png” alt=”Comparison of the adimensional Nusselt number in a SACOME HARD corrugated tube, compared to an equivalent smooth non-corrugated tube.” title_text=”Examples of SACOME corrugated tubes” align=”center” _builder_version=”3.21″ \/][et_pb_text _builder_version=”3.21″ header_2_text_align=”center” text_orientation=”center”]<\/p>\n

Detail of supports that allow free expansion.<\/em><\/i><\/p>\n

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In many cases, the support or frame<\/b> is included in the scope of supply, in which case we already take these construction details into account. However, if this is not the case and the customer decides to do it by other means, it is important that the installation company takes these details into account in order to avoid tension (and possible breakage) in the equipment. This is one of the recommendations included in our <\/b>instruction and operation manual<\/b><\/a>.<\/p>\n

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4. Poor design of the condensate line.<\/h2>\n

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In a condenser or water\/steam exchanger<\/b>, if condensate is not properly drained, the casing side may begin to flood, causing the steam to hit the liquid layer and cause loud noises and vibrations. To detect this anomaly<\/b>, simply touch the top and bottom of the equipment casing once it is operating<\/b> with steam. If the top is hot and the bottom is cold, the casing may be flooded to the point where the surface temperature changes. This anomaly is one of the types of water hammer that can occur in a process line.<\/p>\n

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Detail of a poorly designed condensate drain line.<\/em><\/i><\/p>\n

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5. Excessive fouling.<\/h2>\n

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Fouling<\/b> is a phenomenon that reduces the heat transfer coefficient, increases pressure drops, and can even activate and accelerate corrosion processes. There are different fouling mechanisms<\/b>: crystallization<\/b> (typical in very hard water rich in salts such as calcium carbonate, lime), sedimentation<\/b> (deposition of sand, rust or other suspended solids), chemical<\/b> (in processes where the product can be degraded by temperature), freezing<\/b> (when a fraction of the product freezes due to process temperatures), biological<\/b> (when untreated water is processed, allowing different types of organisms or microorganisms to proliferate), protein precipitation<\/b> (typical in milk products), among others.<\/p>\n

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Example of fouling on the jacket side.<\/em><\/p>\n

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Given the complexity of this phenomenon, the solution<\/b> is not usually straightforward and often involves different aspects<\/b>. In order to minimize the problem and increase production times between cleanings, the following actions can be taken:<\/p>\n