Heat Exchanger Tube Leak Detection
Airborne Ultrasound Inspection.
When shell-and-tube heat exchangers leak, they reduce thermal efficiency, mix process fluids, and force critical systems like boilers, reactors, and turbines to consume more energy and wear out faster — putting production at risk.
Ultrasound provides a fast method to inspect heat exchangers for tube leaks, allowing you to take targeted action during planned downtime — and avoid costly surprises later.
How Ultrasound Leak Detection Works
When pressurized gases pass through an orifice, they create high-frequency ultrasonic signals. Ultrasound detectors isolate that sound even in noisy industrial environments.
For heat exchangers, this process uses an ultrasonic tone generator on one side of the exchanger, and an inspector with an ultrasound data collector — like the SDT340 or SonaVu Acoustic Imaging Camera — on the other. The tone floods the tube side with high-frequency ultrasound, making the leaks easy to spot.
This test is performed during planned downtime, making it an ideal add-on to an existing outage schedule. It’s fast, safe, and doesn’t require invasive disassembly.
What Are Tube Leaks Costing You?
Heat exchanger tube leaks are easy to miss. No alarms. No flashing lights. That’s why we recommend this simple, fast inspection — easily performed during scheduled downtime. Otherwise, heat exchanger tube leaks will cost you:
Energy Loss
Leaks reduce efficiency, raising fuel or power consumption.
Equipment Stress
Contaminated flows strain turbines, pumps, and boilers.
Safety Risks
Hazardous cross-contamination and emissions.
Downtime
One leaking tube can escalate into an emergency outage.
Ultrasound’s Proven Method for Heat Exchanger Leak Testing
Using a straightforward and proven ultrasound method during scheduled downtime, heat exchangers of any size can be rapidly tested for leaks.
The process is as simple as placing a tone generator inside the exchanger to emit a consistent ultrasonic signal, then scanning the exterior with an ultrasound leak detector. Even tiny leaks clearly reveal themselves through distinct ultrasonic sounds.
We have successfully implemented this quick ultrasound inspection method into regular maintenance routines for organizations worldwide, minimizing disruption and maximizing reliability. Our experienced team is ready, willing, and able to help—whether through training your personnel, assisting with integration, or performing inspection services directly.
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Learn MoreHow to Inspect a Heat Exchanger for Tube Leaks
01
Plan and Isolate
Drain and isolate the exchanger. Prep access points for testing.
02
Place the Transmitter
Insert the ultrasonic tone generator inside the tube side.
03
Scan the Shell Side
Sweep the shell and tube sheet with an airborne receiver.
04
Tag, Document, Repair
Mark the leak location, retest if needed, and log the results.
Get Started in Three Simple Steps
Frequently Asked Questions
Yes. Tube leak detection with ultrasound is typically done offline during a planned maintenance window.
Most units can be scanned in under an hour once set up. Full test including prep is often completed within half a day.
Ultrasound picks up high-frequency hissing from pinhole leaks and cracks invisible to other methods — often before they cause measurable pressure loss or process issues.
Finding even one leaking tube that would’ve led to an unplanned shutdown can cover the cost of the program. Add in improved energy efficiency and fewer emergency repairs, and ultrasound pays for itself quickly.
Yes. By identifying tube leaks early, ultrasound lets you act before they affect process control, energy usage, or equipment health — helping extend exchanger service life.
No. These same tools can detect compressed air and gas leaks, failed steam traps, valve leaks, mechanical friction, and even electrical discharge. It’s a multi-purpose condition monitoring technology.
Yes. With just basic training, your in-house team can perform inspections confidently. Tools are portable, intuitive, and designed for use by technicians and reliability teams alike.
Depending on the pressure and leak size, airborne ultrasound can be detected from several meters away. In high-pressure systems, leaks can often be pinpointed from over 20 meters using parabolic or focused sensors.
Ultrasound is non-invasive and doesn’t require applying pressure or introducing gases. It’s passive, contactless (in airborne mode), and poses no risk to equipment or personnel when performed properly.