What is a possible consequence of poorly aligned channel heads in heat exchangers?

Poorly aligned channel heads in heat exchangers can lead to tube damage as a significant consequence. When channel heads are misaligned, it can result in uneven distribution of fluid flow or excessive mechanical stress on the tubes. This misalignment can create points of weakness where the tubes are susceptible to bending or abrasion, leading to wear over time. Additionally, the misalignment can contribute to improper sealing, which may allow leaks to develop, further complicating the potential for damage.

In contrast, while electrical failures, structural integrity loss, and corrosion are important considerations in heat exchanger operation, they are less directly associated with the alignment of channel heads. Electrical failures are typically related to the operation of control systems or sensors, structural integrity loss is more applicable to broader issues such as fatigue or corrosion over time, and corrosion often results from chemical interactions rather than mechanical misalignment. Thus, tube damage stands out as the most immediate and relevant consequence of poorly aligned channel heads in a heat exchanger context.