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By Arthur H. Tuthill, reprinted from Chemical Engineering, Jan 1990. When designing a heat exchanger, the surface area needed to carry the heat load is calculated, then the design developed to meet heat exchanger standards and codes. Next come comparative cost estimates, factoring in knowledge from experience, and selection of the best tubing metal for the service. Most unexpected failures of heat exchangers can be traced to factors not fully taken into account when selecting tube materials -- water quality, character of the operation and maintenance, and exchanger design.

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