A shell-and-tube heat exchanger preventive maintenance schedule lists the checks and jobs done on the equipment at fixed intervals, how long each takes, and in what order of frequency, so problems are found before the shell-and-tube heat exchanger fails. This page gives the schedule used in the PlantOps360 task library for shell-and-tube heat exchanger (/ condenser), which follows common industry practice for general-purpose equipment. It is also searched for as shell and tube heat exchanger, STHE, heat exchanger, condenser.
The maker’s manual and your site safety procedures always come first where they differ. Intervals set by law differ by state.
Shell-and-tube heat exchanger preventive maintenance schedule and checklist
| How often | Task | Estimated time |
|---|---|---|
| Weekly | Check inlet and outlet temperatures and pressure drop; check for leaks at flanges | 15 min |
| Monthly | Check insulation, supports and vents; drain low points | 30 min |
| Quarterly | Check performance by temperature approach; check expansion joints | 60 min |
| Half-yearly | Check tube fouling indication; check sacrificial anodes (if fitted) | 120 min |
| Annual | Open, inspect and clean tube bundle; pressure test; replace gaskets | 480 min |
Shell-and-tube heat exchanger maintenance frequency and yearly workload
At the estimated times, one shell-and-tube heat exchanger needs about 35 hours of preventive maintenance a year. The biggest single job is “Open, inspect and clean tube bundle; pressure test; replace gaskets” at 480 minutes, done annual. Multiply by the number of units you have to see the workload for your plant.
| Frequency | Tasks | Time per round | Hours per year |
|---|---|---|---|
| Weekly | 1 | 15 min | 13.0 h |
| Monthly | 1 | 30 min | 6.0 h |
| Quarterly | 1 | 60 min | 4.0 h |
| Half-yearly | 1 | 120 min | 4.0 h |
| Annual | 1 | 480 min | 8.0 h |
What goes wrong on a shell-and-tube heat exchanger without preventive maintenance
- Tube fouling and scaling
- Tube leaks
- Gasket and flange leaks
- Corrosion at the shell or tubesheet
What to watch between services
- Pressure drop across each side
- Outlet temperatures
- Leak indications
Safety and statutory notes for shell-and-tube heat exchanger maintenance
Cleaning and tube testing need isolation and, for pressure equipment, the inspection rules that apply.
Where a shell-and-tube heat exchanger preventive maintenance schedule is used
This equipment is used in the industries below. Each link opens the preventive maintenance schedule guide for that industry, and the maintenance software page where we have one.
- Preventive maintenance schedule for automotive plants · maintenance software for automotive
- Preventive maintenance schedule for engineering and fabrication shops
- Preventive maintenance schedule for electronics manufacturing plants · maintenance software for electronics
- Preventive maintenance schedule for pharmaceutical plants · maintenance software for pharmaceutical · maintenance software for api bulk drugs
- Preventive maintenance schedule for chemical, fertiliser and petrochemical plants · maintenance software for chemical
- Preventive maintenance schedule for food, dairy and beverage plants · maintenance software for food processing · maintenance software for dairy
- Preventive maintenance schedule for agro, grain, edible oil and sugar plants · maintenance software for sugar and distilleries
- Preventive maintenance schedule for fmcg and consumer goods plants · maintenance software for fmcg
- Preventive maintenance schedule for packaging, paper and printing plants · maintenance software for packaging · maintenance software for paper and pulp
- Preventive maintenance schedule for plastics, rubber and polymer plants · maintenance software for plastics · maintenance software for tyre and rubber
- Preventive maintenance schedule for textile and garment mills · maintenance software for textile
- Preventive maintenance schedule for steel, foundry, forging and metal plants · maintenance software for steel and metals
- Preventive maintenance schedule for cement, glass, ceramics and building materials plants · maintenance software for cement
- Preventive maintenance schedule for mines and mineral processing plants · maintenance software for mining
- Preventive maintenance schedule for oil, gas and refinery facilities · maintenance software for oil and gas
- Preventive maintenance schedule for thermal and hydro power plants · maintenance software for power plants
Related equipment maintenance schedules
- Plate heat exchanger preventive maintenance schedule
- Air-cooled heat exchanger preventive maintenance schedule
- Pressure vessel / air receiver preventive maintenance schedule
- Atmospheric storage tank preventive maintenance schedule
- Cryogenic tank and vaporiser preventive maintenance schedule
Browse the full list of equipment preventive maintenance schedules (317 types).
Run this shell-and-tube heat exchanger schedule in maintenance software
In preventive maintenance software, each row above becomes a recurring task on the asset with its checklist, time estimate and parts. Tasks can be triggered by calendar date, running hours, meter readings or production cycles, each completed task is recorded with the person and date, and a failed check can open a work order. For the method behind it, read the guide to the preventive maintenance schedule, or use the free generator to get a 12-month plan for your whole equipment list.
Build my preventive maintenance schedule (free Excel)
Frequently asked questions
How often should a shell-and-tube heat exchanger be serviced?
In our schedule a shell-and-tube heat exchanger has 5 tasks: 1 weekly, 1 monthly, 1 quarterly, 1 half-yearly, 1 annual. The biggest job is “Open, inspect and clean tube bundle; pressure test; replace gaskets”, which is done annual. Always follow the maker’s manual where it gives a different interval.
What is included in shell-and-tube heat exchanger preventive maintenance?
It covers routine checks and jobs such as “Check inlet and outlet temperatures and pressure drop; check for leaks at flanges”, “Check insulation, supports and vents; drain low points”, “Check performance by temperature approach; check expansion joints”, up to the annual overhaul or inspection. The full list with times is in the table above.
How many hours of maintenance does a shell-and-tube heat exchanger need per year?
About 35 hours per unit per year at the estimated times in our library, including all scheduled rounds. Use it to plan workload, not as a benchmark.
Is there a free shell-and-tube heat exchanger maintenance checklist?
Yes. The table on this page is a ready checklist. The free preventive maintenance schedule generator turns it into a 12-month Excel schedule for your list of equipment, with monthly workload hours.