Us200503211a1 heat exchanger performance monitoring. Operating parameters of the system are monitored and fouling factors for heat transfer surfaces of the exchanger are determined. Heat exchanger fouling and estimation of remaining useful life. Implementation of online heat exchanger efficiency. Introduction to the dats fouling monitor technology. Heat exchangers are used in both cooling and heating processes. Unanticipated fouling can drive up energy costs and, if severe enough, result in an unscheduled shutdown to clean bundles or a process slowdown until the next shutdown. Monitoring leaks in heat exchangersinherent to the design and rough duty heat exchangers face during their operation, leaks can and do develop. Fouling factor monitoring industrial professionals. Unnoticed or increased heat exchanger fouling causes degraded performance and reduced energy efficiency and can result in an unscheduled shutdown or process slowdown.
Maintaining good performance in a heat exchanger network is a major part of any energy efficiency programme. Use of cfactor for monitoring of fouling in a shell and tube. This paper looks at the efficiency calculation and fouling monitoring using dcs software application and the result from the case. The software was designed but not necessarily limited to model heat exchanger networks in crude oil. Heat exchanger fouling and cleaning vii, july 1 6, 2007, tomar, portugal fouling monitoring and cleaning optimisation in a heat exchanger network of a crude distillation unit andrea heins 1, ramon veiga 1, carlos ruiz 2, andres riera 2 1 argentinean technology center cta repsol ypf. Learn how you can better monitor fouling levels of your heat exchangers. Heat exchanger software can give the available fouling as compared to design fouling. Htri is world leader in heat transfer research and prediction htri is now building a bridge between fouling experiments and refinery fouling management pht data is already being collected proper monitoring allows visualization of performance good monitoring practices allow observation of fouling trends. Mar 26, 20 emersons heat exchanger monitoring solution allows maintenance personnel to schedule optimal time to clean to sustain optimal heat transfer. Fouling factor monitoring posted in industrial professionals. Engineers can appraise heat exchanger performance several ways effectiveness, ua analysis, approach, estimation of fouling, comparisons with design, etc.
The challenge for this refiner was to proactively predict the endofcycle for a heat exchanger as a result of fouling. Monitoring of fouling is key to assess the performance of refinery heat exchangers, estimate resulting economic costs, and assist in planning of mitigation and cleaning. The fouling of a heat exchanger can be monitored via the overall fouling resistance, rf. Modelbased monitoring of fouling in a heat exchanger. The cfactor measures both tube plugging in a multiple pass shell and tube heat exchanger and uniform fouling. Preheat train monitoring allows better management of fouling. Where fouling occurs on the shellside, prediction is more difficult because of the complex geometries involved. Heat exchanger monitoring systems tube and shell heat exchangers. The nalco water monitor software is an advanced heat transfer modeling programme that determines the performance of critical exchangers and tracks energy savings at the furnace. This monitoring software has been developed by shell global solutions. Therefore, there is a profound interest in cutting down the energy losses due to fouling by proper monitoring and prevention methods.
Monitoring thermal efficiency of fouled heat exchangers 457 therefore, the value of ntu for one exchanger in the network can be obtained by replacing e by e in the expression developed for a 1 n exchanger eq. This projection is made assuming that a fresh heat exchanger a heat exchanger at an initial fouling level assumed in the design step is operating under the test conditions. These include advanced heat exchanger monitoring and operations improvement, crude oil. Heat exchangers performance monitoring in industrial plants. Improving heat exchanger operation with predictive. Inability to directly measure fouling levels for operating units compounds the proble.
Smartpm smartpm performance monitoring, analysis, and prediction software for shellandtube heat exchanger networks supports a greater understanding of oil refinery operational performance. Monitor determines the cost of heat exchanger fouling and the optimum cleaning frequency. Heat exchanger fouling and estimation of remaining useful life tutpol ardsomang1, j. Emerson introduces heat exchanger monitoring solution. Hi,i usually advise people to use the following equation to monitor fouling factor. Heat exchanger fouling is one of the most common and troublesome issues in process industries. Compute heat exchanger heat transfer factor for each exchanger in the network. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact. Nonavailability of a critical exchanger directly affects the production of the.
This article presents a fouling and cleaning analysis of a complex heat exchanger network in a crude preheat train, mitigating fouling effects through improved cleaning schedules. Introduction to the dats fouling monitor technology the deposit accumulation testing system dats fouling monitor is a microprocessor based, data acquisition system designed to control, monitor and record all parameters necessary to perform heat transfer analysis. With a clearer picture of how fouling is affecting your heat exchangers provided by emersons monitoring solutions, you can plan maintenance accordingly and clean the right bundles at the right time, keeping costs low and ensuring efficiency. A predictive tool for monitoring, diagnosing and treating heat exchanger fouling.
Andrea heins 1, ramon veiga 1, carlos ruiz 2, andres riera 2 1 argentinean technology center cta repsol ypf baradero sn 1925, ensenada, pcia. Key performance metrics like exchanger heat duty, heat transfer coefficient, fouling factor and cost of fouling are used to determine an overall health value for the exchanger. This chapter focuses on fouling monitoring and heat exchanger cleaning applications based on the authors experience in developing and deploying software based solutions primarily in oil refining. The fouling materials can consist of either living organisms or a nonliving substance inorganic or organic. Trending of fouling may be performed over time based upon the fouling factors, and a model of fouling may be selected from known sets of models, or a model may be. Improving heat exchanger operation with predictive analytics. European refinery tackles heat exchange issues and saves millions in the process.
Keep heat exchanger fouling from impacting production most of the heat required by chemical process plants comes from heat exchangers. Used in exchanger networks such as refinery preheat trains, smartpm predicts future performance, including the effects of fouling buildup, and can help achieve. Advanced heat exchanger monitoring and prescriptive. This may be done by the facility staff or remotely by.
The software, developed in visual basic 6, has the capability to input design and actual operating data and compute the water fouling base on meccanical and physical data of the exchanger. This is a costly expense, but not taking the heat exchanger out of service proves costly to downstream operations. Used in exchanger networks such as refinery preheat trains, smartpm predicts future performance, including the. Smartpm tm simulates complex networks of shellandtube heat exchangers to help engineers and plant operators manage fouling. The performance of heat exchangers usually deteriorates with time as. This really is what the original question should have been. Easily share your publications and get them in front of issuus. The plantweb insight heat exchanger app provides indepth monitoring of shell and tube heat exchangers by analysing plant sensor data gathered through existing. Emersons heat exchanger monitoring solution allows maintenance personnel to schedule optimal time to clean to sustain optimal heat transfer. As a first step for heat exchanger fouling monitoring the actual global heat transfer coefficients ua are usually calculated over time.
Hexxcell studio is used by plant personnel, maintenance engineers, energy efficiency analysts and heat transfer specialists around the world to predictively assess the thermal and hydraulic impact of fouling in heat exchangers, to devise mitigation strategies and optimally manage cleaning schedules and flow split operations. Htri offers several additional software products that can be independently licensed. Packinox heat exchangers combine the highpressure and hightemperature resistance of shellandtube heat exchangers with the outstanding heat transfer performance of plate heat exchangers. Accelerated heat exchanger fouling can be caused by many factors such as chemical composition, restricted flow or temperature excursions. Managing fouling in refinery networks digitalrefining.
Heat exchanger network design, monitoring and optimization uma maheshwar kiran ati. Putting iiot in reach of every industrial company with task. Fouling of heat exchangers causes excessive energy consumption, large pressure loss and sometimes process outages. To combat fouling, heat exchangers must be periodically removed from service and cleaned. Eam for heat exchangers is designed to monitor shellandtube exchanger conditions relative to a units original clean state. Jan 15, 2012 fouling factor monitoring posted in industrial professionals. Emersons heat exchanger monitoring solution allows you to improve operational efficiency by enabling you to detect accelerated fouling early, ensure proper desalter levels, and determine exactly which heat exchanger bundle needs to be cleaned in the next turnaround. The program can bu used for coolers, condensers and exaust steam condenser.
Monitoring leaks in heat exchangers turner designs. Assess heat exchanger performance chemical processing. Performance monitoring and predictive maintenance software for shellandtube heat exchanger networks. Our experienced technicians can apply corrosion protection to your heat exchanger. With nearly half of all refinery fouling costs attributable to crude atmospheric tower preheat train exchangers, and inherent complexity. Fengsimultaneous optimization of flow velocity and cleaning schedule for mitigating fouling in. Us7455099b2 heat exchanger performance monitoring and. Management of heat exchanger fouling consists of three elements. Monitoring heat exchanger fouling aspen technology. The heat exchanger solution embeds process and exchanger best practices into software using existing wired and new wireless instrument applications for automated monitoring enabling operations improvements and reduced energy costs. Bejaranoenergy recovery in heat exchanger networks in a dynamic, bigdata world.
A single packinox heat exchanger outperforms systems consisting of multiple large shellandtubes, both in terms of heat recovery and investment costs. Through monitoring and reconciling plant data, smartpm provides accurate performance predictions through detailed heat exchanger modeling. Energy saving potential of a simple control strategy for. As a result, facilities can reduce energy and capacity loss due to fouling by up to 10 percent. Our heat exchanger performance analysis software offers real time evaluation of the current and future conditions of the heat exchanger. Issuu is a digital publishing platform that makes it simple to publish magazines, catalogs, newspapers, books, and more online. Modelbased monitoring of fouling in a heat exchanger yoshiyuki yamashita department of chemical engineering, tokyo university of agriculture and technology, tokyo 184 8588 email. Htri is world leader in heat transfer research and prediction htri is now building a bridge between fouling experiments and refinery fouling management pht data is already being collected proper monitoring allows visualization of performance good monitoring practices allow observation of. Ifthere is a gradual decline in heat transfer, fouling may be the culprit. Heat exchanger monitoring and testing services kelvion. Heat exchanger fouling exacts a significant economic penalty to chemical manufacturers in terms of lost capacity, energy, equipment replacement and maintenance costs. Monitoring of heat exchanger fouling and cleaning analysis. Heat exchanger model with the details of temperatures differences. They are widely used in space heating, refrigeration, air conditioning, power stations, chemical plants, petrochemical plants, petroleum refineries, natural.
All process industries fluid heating heat exchangers. Everything to monitor and maximize heat exchanger efficiency. It signicantly decreases the thermal performance of heat exchangers. Hexxcell offers advanced heat exchanger monitoring and predictive maintenance software and services which provide optimal cleaning schedules to minimise the economic impact of fouling and manage maintenance operations. It can also monitor the effectiveness of chemistries and operating procedures, allowing refiners to select the most appropriate and economical strategy to meet their energy management goals. It contains a very rudimentary approach to fouling calculations and contains a first degree optimization model which is only really applicable to a single heat. It enables engineers to make informed decisions regarding maintenance or energy use, such as determining optimal exchanger cleaning schedules. Fouling and cleaning analysis of a heat exchanger network.
Heat exchanger network design, monitoring and optimization. This paper discusses a systematic approach to develop a realtimenear realtime digital window to continuously detect and predict heat exchanger performance degradation. May 30, 2019 heat exchanger monitoring the challenge for this refiner was to proactively predict the endofcycle for a heat exchanger as a result of fouling. Rf 1ud 1uc 1 exact monitoring of rf, addition to ud, needs an updated overall thermal resistance of the exchangers for the new. Fouling in the crude oil preheat trains is considered as 20% of all heat exchanger fouling 4. These include advanced heat exchanger monitoring and operations improvement, crude oil fouling testing services and much more. More often than not, the undesired outlet temperature.
Implementation of online heat exchanger efficiency calculation and fouling monitoring. Because fouling across heat exchanger bundles is not linear, one bundle can have a majority of the fouling and require the most. Hence to predict the formation of fouling a back calculation of cfactor plays an important role which shows the change in orifice coefficient that has taken place due to fouling. If heat exchanger repairs are needed, our technicians will respond quickly, especially in an. Optimizing cleaning schedules of heat exchanger networks. A predictive tool for monitoring, diagnosing and treating. Putting iiot in reach of every industrial company with. Upadhyaya2 1 department of industrial and systems engineering, university of tennessee, knoxville, tn 37996, usa. This chapter focuses on fouling monitoring and heat exchanger cleaning applications based on the authors experience in developing and deploying software. The operating efficiency of your heat exchanger if or when the next cleaning is required the total heat removal capacity overall heat transfer coefficient the amount of cross leakage and blockage total fouling factor and film thicknesses inlet and outlet temperatures inlet and outlet flow rates. Apr 24, 20 eam for heat exchangers is designed to monitor shellandtube exchanger conditions relative to a units original clean state. A technique is disclosed for evaluating and monitoring performance of a heat exchanger system. Abstract heat exchanger fouling exacts a significant economic. The process of the fouling monitor is composed of two steps.
Development of a fouling monitor for safetyrelated heat. When a heat exchanger leaks, xylene contaminates the steam. Troubleshooting shellandtube heat exchangers use these techniques and guidelines to. This software uses machine learning and other underlying innovations to empower the engineers and experts charged with creating value from their companys data. Fouling formation in any heat exchanger will reduce the onlinecalculated heat exchanger efficiency result and that can noted from the trend of histories efficiency data and from the fouling indicator. Then, calculation of the fouling factor rf is carried out, comparing the former with the value of u corresponding to the clean equipment uc. The software couples thermohydraulic network analysis with dynamic fouling simulations, enabling the user to reliably predict plant operational limitations, economic penalties and environmental impacts resulting from heat exchanger fouling. If fouling occurs inside the heat exchanger, we clean the deposits for you. A heat exchanger is a system used to transfer heat between two or more fluids. Fouling is the accumulation of unwanted material on solid surfaces. Unanticipated fouling can drive up energy costs and, if severe enough, result in an unscheduled shutdown to clean bundles or. The factor used to correct the log mean temperature. Traditionally rf is computed from the difference between the two overall thermal resistances takemoto, 1997. Monitoring the thermal efficiency of fouled heat exchangers.
65 1324 237 760 52 232 303 823 500 59 246 38 521 1316 137 243 706 637 1443 1116 915 1356 817 659 424 1411 454 263 604 224 1484 1262 1188 19