A shell and tube heat exchanger can be ruptured due to various reasons, including:
High pressure: If the pressure inside the heat exchanger exceeds its design limits, it can lead to a rupture. This can happen due to system malfunctions, blockages, or the failure of pressure relief devices.
Corrosion: Over time, the inner surfaces of the heat exchanger tubes can corrode due to the nature of the fluids being processed or the presence of contaminants. Corrosion weakens the tube walls, making them more susceptible to rupture.
Thermal stress: Rapid and extreme temperature changes can cause thermal stress in the heat exchanger, leading to cracks and eventual rupture. This can happen if there is a sudden change in the temperature of the fluids or if the system is not designed to handle thermal expansion properly.
Mechanical damage: External forces such as physical impact or excessive vibrations can cause damage to the heat exchanger, leading to leaks or rupture. Accidental incidents, improper handling, or inadequate support systems can contribute to mechanical damage.
Erosion: The constant flow of fluids through the tubes can cause erosion, especially when the fluids contain solid particles or have high velocities. Erosion can thin out the tube walls, making them more prone to rupture.
Fatigue: Over time, cyclic loading and stress variations can cause fatigue failure in the heat exchanger. This is particularly common in systems where there are frequent temperature fluctuations or pressure cycles. Fatigue cracks can propagate and eventually result in a rupture.
To prevent such failures, it is essential to adhere to proper design and construction standards, conduct regular inspections and maintenance, monitor operating conditions, and ensure the heat exchanger is operated within its specified limits.