Heat exchanger problems are not always accompanied by obvious symptoms such as leaks or channel intermixing. Some problems are minor but progressive, causing higher energy consumption and performance variability.
Process data around the heat exchanger is invaluable in analyzing and troubleshooting performance. Pressure, flow rate and temperature data from side 1 (usually the process channel) and side 2 (usually the cooling or heating media channel) inlets and outlets can indicate problems with either stream. This instrumentation is well worth the cost of installation for exchangers critical to process control and efficiency. They can signal operators when the process is about to become uncontrollable