Common Heat Exchanger Tube Defects and How to Identify Them


There are many types of #defects that can compromise the performance and safety of these crucial heat exchanger equipment. From fouling and corrosion to erosion and cracking, identifying these issues early on is key to avoiding costly downtime, repairs, and even accidents. Here are some common defects to look out for:



Corrosion is the most common defect found in heat exchanger tubes. It is caused by the

reaction of the metal with the fluid or gas being processed, leading to metal

loss and weakening of the tube walls. Common types of corrosion include pitting

corrosion, crevice corrosion, and erosion corrosion.



Fouling occurs when deposits accumulate on the inner surface of the heat exchanger

tubes, reducing their heat transfer efficiency. This can be caused by scaling,

sedimentation, or biological growth, and can lead to a decrease in the overall

performance of the system.


3️.Mechanical Damage

Mechanical damage can occur due to a variety of factors, including improper installation,

vibration, and impact. Common types of mechanical damage include denting,

bending, and scratching, which can affect the structural integrity of the tube.



Fatigue occurs when a heat exchanger tube is subjected to repeated cycles of stress,

leading to the gradual degradation of the material. This can lead to the

development of cracks and eventual failure of the tube.


5.Welding Defects

Welding is commonly used to join heat exchanger tubes, and defects in the welding

process can lead to significant problems. Common welding defects include

porosity, cracking, and lack of fusion, which can reduce the strength and

durability of the joint.




But how can you accurately detect these defects?


Acoustic Pulse Reflectometry (#APR) is a non-destructive testing method that can detect and locate defects inside heat exchanger tubes with precision. It sends sound waves into the tube and measures the reflections, allowing for the identification of the size and location of

the defects.


By using APR in conjunction with regular inspections, you can ensure the early

detection and prevention of tube defects, reducing the risk of costly downtime

and repairs.


Contact us for a presentation and demo of how our #APRIS works! Email:

© All 2023 All rights reserved. Talcyon Pte. Ltd.