Feedforward flow control for heat transfer systems

Abstract

A heat transfer system comprising one or more heat exchangers and one or more variable control pumps controlling the flow through the one or more heat exchangers. At least one variable control pump is on the supply side of the heat exchanger for controlling the flow of a first circulating medium and at least one flow control mechanism is on the load side of the heat exchanger for controlling the flow of a second circulating medium. Sensors are used to detect variables of the first and second circulating mediums. At least one controller is configured to control at least one parameter of the first or second circulating medium by using a feed forward control loop calculated from the detected variables to control at least one of the variable control pumps or the flow control mechanism to achieve control of the at least one parameter.

Description

[0001] This application is a divisional application of PCT patent application number PCT / CA2019 / 051428, entitled "Feedforward Flow Control for Heat Transfer Systems," filed by the applicant, XEMS Ltd., on October 4, 2019. That PCT patent application entered the Chinese national phase on April 2, 2021, and its Chinese patent application number is 201980065657.7 (this divisional application is a re-filed divisional application of Chinese patent application number 202211462048.5).

[0002] Cross-references to related applications

[0003] This application claims priority to the following applications: U.S. Provisional Patent Application No. 62 / 741,943, entitled "Automatic Maintenance and Flow Control of Heat Exchangers," filed October 5, 2018; PCT Patent Application No. PCT / CA2018 / 051555, entitled "Automatic Maintenance and Flow Control of Heat Exchangers," filed December 5, 2018, which claims priority to U.S. Provisional Patent Application No. 62 / 741,943; and U.S. Provisional Patent Application No. 62 / 781,456, entitled "Feedforward Flow Control of Heat Transfer Systems," filed December 18, 2018. This application is also a continuation-in-part of PCT patent application number PCT / CA2018 / 051555, entitled "Automatic Maintenance and Flow Control of Heat Exchangers," filed December 5, 2018, which claims priority to U.S. Provisional Patent Application No. 62 / 741,943, entitled "Automatic Maintenance and Flow Control of Heat Exchangers," filed October 5, 2018. The entire contents of all the foregoing documents are incorporated herein by reference in the detailed description below. Technical Field

[0004] The example embodiments generally relate to heat transfer systems and heat exchangers. Background Technology

[0005] Building heating, ventilation and air conditioning (HVAC) systems may include a central cooling water unit, which is designed to supply chilled water to the air conditioning unit to reduce the temperature of the air leaving the conditioned space and then circulate it back into the conditioned space.

[0006] Cooling water units are used to supply chilled water or air to buildings. Cooling water units can consist of active and passive mechanical devices that work together to reduce the temperature of the return water before supplying it to the distribution loops. In cooling water units, heat exchangers are used to transfer heat between two or more circulation loops. Similarly, heating units may include one or more boilers that supply hot water to the distribution loops from one or more other boilers or from a secondary loop having a heating source.

[0007] In some conventional HVAC systems, remote sensors (typically installed at the furthest point served or along two-thirds of the line) are used to control pumps to achieve specific load requirements or setpoints. Pumps can be increased or decreased in a binary (on / off) or incremental manner, and feedback control continuously checks the remote sensors until the specific load requirement or setpoint is reached and not exceeded. These types of HVAC systems can be slow to respond and inflexible in terms of supply and load requirements and different setups.

[0008] Some conventional industrial practices design the performance of heating, cooling, and piping systems around a single point, representing the most extreme conditions or loads a building may experience during its operational lifespan. A challenge with some existing systems is that, under partial loads, pumping systems can be susceptible to instability, poor occupant comfort, and energy and economic waste.

[0009] Traditional selection of one or more pumps can lead to wasted resources and inefficient operation. Building load constraints may change, so equipment (such as pumps, boiler units, coolers, boosters, heat exchangers, or others) may not be required to operate at full load to serve system requirements. Furthermore, inappropriate equipment selection may necessitate refurbishment or complete replacement with more suitable equipment (such as pumps, boiler units, coolers, boosters, heat exchangers, or others).

[0010] When operating under partial load, contaminants can accumulate in the components of cooling water units or heating units, a process known as scaling.

[0011] To perform manual maintenance on the heat exchanger of a cooling water unit, the unit can be shut down, the heat exchanger removed and disassembled, and contaminants manually removed or flushed away. The heat exchanger is then reassembled and installed back into the cooling water unit. This process is inefficient.

[0012] In some conventional methods, heat exchangers are typically maintained manually according to a fixed schedule set by the manufacturer or building maintenance manager. When using a fixed schedule for manual maintenance, there is a risk of over-maintenance or under-maintenance, which is inefficient.

[0013] In some existing methods, the pressure difference across the heat exchanger is measured under full flow conditions, and once the pressure difference reaches a certain point under full flow conditions, service personnel will perform manual cleaning.

[0014] Other difficulties of the existing system can be understood by considering the specific implementation described below. Summary of the Invention

[0015] An example embodiment is a heat transfer system for supplying a variable load, comprising: a heat exchanger defining a first fluid path and a second fluid path; a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; a variable flow control mechanism for providing a variable flow rate of a second circulating medium through the second fluid path of the heat exchanger; a sensor for detecting a variable, the sensor comprising: a first at least one sensor for sensing at least one variable indicating the first circulating medium, and a second at least one sensor for sensing at least one variable indicating the second circulating medium; and at least one controller configured to control at least one parameter of the first or second circulating medium by detecting the variable using the first at least one sensor and the second at least one sensor, and using a feedforward control loop to control the flow rate of one or both of the first variable control pump or the second flow control mechanism, the feedforward control loop implementing control of the at least one parameter based on the detected variables of the first and second circulating media.

[0016] Another example embodiment is a method for supplying a variable load using a heat transfer system including a heat exchanger defining a first fluid path and a second fluid path. The heat transfer system includes: i) a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; ii) a variable flow control mechanism for providing a variable flow rate of a second circulating medium through the second fluid path of the heat exchanger; and iii) a sensor for detecting variables, the sensor including: a first at least one sensor for sensing at least one variable indicating the first circulating medium; and a second at least one sensor for sensing at least one variable indicating the second circulating medium. The method is performed by at least one controller and includes: detecting variables using the first at least one sensor and the second at least one sensor, and controlling the flow rate of one or both of the first variable control pump or the variable flow control mechanism using a feedforward control loop, the feedforward control loop controlling at least one parameter of the first or second circulating medium based on the detected variables of the first and second circulating media.

[0017] An example embodiment is a heat transfer system comprising a plate counter-current heat exchanger and a variable control pump for controlling the flow rate through the heat exchanger. The heat exchanger may be a smaller design, using less material, having a smaller footprint, and sized for use in turbulent flow under higher pressure cycling. The control pump has a larger power capacity to accommodate the higher pressure differential imparted by the control pump through the smaller heat exchanger. The example embodiment is a system and method for controlling the control pump along a control curve.

[0018] An example embodiment is a heat transfer system that includes one or more heat exchangers and one or more flow control mechanisms, such as a control pump or variable control valve that controls the flow rate through the heat exchangers. To supply a variable load, the control pump can be controlled to operate at a flow rate less than the full flow rate (e.g., the operating flow rate).

[0019] Another example embodiment is a non-transitory computer-readable medium having instructions stored thereon that can be executed by at least one controller to perform the described methods and functions.

[0020] Another example embodiment is a heat transfer module including: a hermetically sealed housing defining a first port, a second port, a third port, and a fourth port; a plurality of parallel heat exchangers within the hermetically sealed housing defining a first fluid path between the first and second ports and a second fluid path between the third and fourth ports; a first pressure sensor within the hermetically sealed housing configured to detect a pressure measurement input to the first fluid path of the heat transfer module; a second pressure sensor within the hermetically sealed housing configured to detect a pressure measurement input to the second fluid path of the heat transfer module; a first differential pressure sensor within the hermetically sealed housing and spanning the input to output of the first fluid path of the heat transfer module; and a second differential pressure sensor within the hermetically sealed housing and spanning the second fluid path of the heat transfer module. The heat transfer module includes: an input to an output; a first temperature sensor within a sealed housing configured to detect a temperature measurement of the input of a first fluid path of the heat transfer module; a second temperature sensor within a sealed housing configured to detect a temperature measurement of the output of the first fluid path of the heat transfer module; a third temperature sensor within a sealed housing configured to detect a temperature measurement of the input of a second fluid path of the heat transfer module; a fourth temperature sensor within a sealed housing configured to detect a temperature measurement of the output of the second fluid path of the heat transfer module; corresponding temperature sensors within a sealed housing to detect a temperature measurement of the output of each fluid path of each heat exchanger of the heat transfer module; and at least one controller configured to receive data indicating the measured values ​​from a pressure sensor, a differential pressure sensor, and a temperature sensor. Attached Figure Description

[0021] Reference will now be made to the accompanying drawings by way of example, which illustrate exemplary embodiments, and in the drawings: Figure 1A A graphical representation of a building system is shown, illustrating a cooling water unit for supplying chilled water to a building. An example embodiment can be applied to this building system.

[0022] Figure 1B It shows Figure 1A Graphical representation of other aspects of the cooling water unit shown.

[0023] Figure 1C A graphical representation of another example cooling water unit is shown, which has a water-side energy-saving unit with a dedicated cooling tower and parallel load sharing.

[0024] Figure 1D A graphical representation of another example cooling water unit is shown, which has a water-side energy-saving unit with a dedicated cooling tower and load sharing.

[0025] Figure 1E A graphical representation of an example heating unit is shown.

[0026] Figure 1F A graphical representation of an example cooling water unit with a direct cooling loop is shown.

[0027] Figure 1G A graphical representation of an example heating unit with a zone heating loop is shown.

[0028] Figure 1H A graphical representation of an example heating unit used for heating drinking water is shown.

[0029] Figure 1I A graphical representation of an example building system for waste heat recovery is shown.

[0030] Figure 1J A graphical representation of an example building system used for geothermal heating isolation is shown.

[0031] Figure 2A A graphical representation of a heat exchanger according to an example embodiment is shown.

[0032] Figure 2B A perspective view of an example heat transfer module with two heat exchangers according to an example embodiment is shown.

[0033] Figure 2C A perspective view of an example heat transfer module with three heat exchangers according to an example embodiment is shown.

[0034] Figure 2D It shows Figure 2C A partial cross-sectional view of the contents of the heat transfer module.

[0035] Figure 2E A perspective view of an example heat transfer system is shown, which includes... Figure 2C The heat transfer module and two dual-control pumps.

[0036] Figure 3A A graphical representation of the network connectivity of a heat transfer system with local settings is shown.

[0037] Figure 3B A graphical representation of the network connectivity of a heat transfer system with remote settings is shown.

[0038] Figure 4A A diagram showing an example thermal load profile, such as that of a building.

[0039] Figure 4B A diagram showing an example flow load profile, such as that of a building.

[0040] Figure 5 An example detailed block diagram of a control device according to an example embodiment is shown.

[0041] Figure 6 A control system for coordinated control of an apparatus is shown according to an example embodiment.

[0042] Figure 7A A flowchart of an example method for automatically maintaining a heat exchanger, according to an example embodiment, is shown.

[0043] Figure 7B A flowchart is shown as an example method for determining one or more control pumps that need to be maintained on a heat exchanger.

[0044] Figure 7C A flowchart is shown as an alternative example method for determining one or more control pumps that need to be maintained on a heat exchanger.

[0045] Figure 7D A flowchart is shown as an alternative example method for determining one or more control pumps that need to be maintained on a heat exchanger.

[0046] Figure 8 A graph showing the simulation results of the braking power of a control pump operated by various heat exchangers (including one with automatic maintenance) having various fouling factors, according to an exemplary embodiment, is presented.

[0047] Figure 9 A graph showing the test results of the heat exchanger coefficient value (U value) versus the flow rate of the clean heat exchanger is presented.

[0048] Figure 10 A graph showing an example operating range and selection range for a variable speed control pump used in a heat transfer system is provided.

[0049] Figure 11A A graph of system head versus flow rate is shown, with a selection range for choosing one or more candidate heat exchangers for the heat transfer system.

[0050] Figure 11B A graph showing cooling capacity versus flow rate is presented, with a selection range for choosing one or more candidate heat exchangers for the heat transfer system.

[0051] Figure 11C A graph showing heating capacity versus flow rate is presented, with a selection range for choosing one or more candidate heat exchangers for the heat transfer system.

[0052] Figure 12A A graphical user interface is shown for selecting the control pump and heat exchanger for the heat transfer system.

[0053] Figure 12B Another graphical user interface is shown, which is used to... Figure 12A Those provide other parameters to select the control pump and heat exchanger for the heat transfer system.

[0054] Figure 13 A flowchart of an example method for feedforward loop control of a heat transfer system, according to an example embodiment, is shown.

[0055] Similar reference numerals can be used to denote similar parts in different figures. Detailed Implementation

[0056] At least some example embodiments relate to processes, process equipment, and systems in an industrial sense, meaning processes that use inputs (e.g., cold water, fuel, air, etc.) to output one or more products (e.g., hot water, cold water, air). In such systems, heat exchangers or heat transfer systems can be used to transfer thermal energy between loops (fluid paths) of two or more circulating media.

[0057] In an example embodiment, the architecture for device modeling via performance parameter tracking can be deployed on a data recording structure or on a control management system implemented by a controller or processor executing instructions stored in a non-transitory computer-readable medium. Previously stored device performance parameters stored on the computer-readable medium can be compared and contrasted with real-time performance parameter values.

[0058] In some example embodiments, performance parameters for each device's performance are modeled using model values. In some example embodiments, the model values ​​are discrete values ​​that may be stored in tables, distribution plots, databases, tuples, vectors, or multi-parameter computer variables. In some other example embodiments, the model values ​​are the values ​​of performance parameters (e.g., the standard unit of measurement for that particular performance parameter, such as imperial or SI units).

[0059] Device coefficients are used to specify the behavioral response of individual units within each device group category. Each individual unit within each device category can be modeled individually by specifying each coefficient corresponding to a specific set of operating conditions for the behavioral parameters in question. Device coefficients can be used for direct comparison or as part of one or more equations to model the behavioral parameters. It is understood that, according to the example embodiments, individual units may have varying individual behavioral parameters and can be modeled and monitored individually.

[0060] A mathematical model that defines the efficiency performance of mechanical equipment has constants and coefficients in its parameterized equations. For example, the coefficients can be those of a polynomial or other mathematical equations.

[0061] The ability to specify these coefficients during manufacturing and track them throughout the entire lifecycle of a mechanical project to accurately predict real-time performance allows for preventative maintenance, fault detection, installation and commissioning verification, as well as benchmarking and long-term monitoring of energy or fluid consumption performance.

[0062] In example embodiments, control schemes dependent on coefficient-based unit modeling architectures can be configured to optimize energy or fluid consumption of individual devices or the entire system, and monitored throughout the lifecycle of equipment including heat exchangers or heat transfer systems. Example coefficients for heat exchangers include the heat transfer coefficient (U-value) or heat transfer capacity (Qc).

[0063] Many HVAC building systems do not operate at full load (working load). In example embodiments, based on a determined coefficient, the controller can determine during live operation whether scaling is present in the heat exchanger, which accumulates when the building system operates at partial load for extended periods. In some examples, the controller can determine that heat exchanger maintenance is required due to scaling and can flush the heat exchanger during live operation of the building system by operating it at full load (working load).

[0064] An example embodiment is a heat transfer system for supplying a variable load, comprising: a heat exchanger defining a first fluid path and a second fluid path; a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; a variable flow control mechanism for providing a variable flow rate of a second circulating medium through the second fluid path of the heat exchanger; a sensor for detecting a variable, the sensor comprising: a first at least one sensor for sensing at least one variable indicating the first circulating medium, and a second at least one sensor for sensing at least one variable indicating the second circulating medium; and at least one controller configured to control at least one parameter of the first or second circulating medium by detecting the variable using the first at least one sensor and the second at least one sensor, and using a feedforward control loop to control the flow rate of one or both of the first variable control pump or the variable flow control mechanism, the feedforward control loop implementing control of the at least one parameter based on the detected variables of the first and second circulating media.

[0065] Another example embodiment is a method for supplying a variable load using a heat transfer system including a heat exchanger defining a first fluid path and a second fluid path. The heat transfer system includes: i) a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; ii) a variable flow control mechanism for providing a variable flow rate of a second circulating medium through the second fluid path of the heat exchanger; and iii) a sensor for detecting variables, the sensor including: a first at least one sensor for sensing at least one variable indicating the first circulating medium; and a second at least one sensor for sensing at least one variable indicating the second circulating medium. The method is performed by at least one controller and includes: detecting variables using the first at least one sensor and the second at least one sensor, and controlling the flow rate of one or both of the first variable control pump or the variable flow control mechanism using a feedforward control loop, the feedforward control loop controlling at least one parameter of the first or second circulating medium based on the detected variables of the first and second circulating media.

[0066] Figure 1A An example HVAC building system 100, such as a cooling water unit, is shown according to an example embodiment. Figure 1A As shown, building system 100 may include, for example, a cooling water control pump 102, a cooler 120, a control pump 122, and two cooling towers 124. In example embodiments, there may be more or fewer devices within each equipment category. In some example embodiments, other types of equipment and rotating devices may be included in building system 100.

[0067] Building system 100 can be adapted to supply buildings 104 (as shown), campuses (multiple buildings), areas, vehicles, units, generators, heat exchangers, or other suitable infrastructure or loads. Each control pump 102 may include one or more corresponding pump units 106a (one is shown, while...). Figure 2E The diagram shows two pump units for a single control pump 102 and a control device 108a for controlling the operation of each respective pump unit 106a. The specific circulating medium may vary depending on the specific application and may include, for example, ethylene glycol, water, air, fuel, and the like. As understood in the art, for example, cooler 120 may include at least a condenser and an evaporator. Before the circulating medium is sent to cooling tower 124, the condenser of cooler 120 collects unwanted heat through the circulating medium. The condenser itself is a heat exchanger, and example embodiments involving heat exchangers (including automatic maintenance and flushing) may be applied to the condenser, if applicable. The evaporator of cooler 120 is where the cooling circulating medium is generated, and the cooled circulating medium exits the evaporator and flows to building 104 via control pump 102. Each cooling tower 124 may be sized and configured to provide cooling by means of evaporation and may include, for example, a corresponding fan. In the example, each cooling tower 124 may include one or more cooling tower units.

[0068] Building system 100 may be configured to supply chilled water to air conditioning units in building 104 to lower the temperature of air leaving the conditioned space and then recirculate it back into the conditioned space. Building system 100 may include active and passive mechanical devices that work together to lower the temperature of the returned water before supplying it to the distribution loops.

[0069] Reference Figure 1B Building system 100 may include heat exchanger 118, which is, for example, via cooler 120 ( Figure 1A The heat exchanger 118 is the interface that provides thermal connection to the secondary circulation system. Figure 1AThe various locations within the building system 100. The building system 100 may include one or more loads 110a, 110b, 110c, 110d, wherein each load 110a, 110b, 110c, 110d may have varying usage requirements based on the needs of air conditioning, HVAC, ducting systems, etc. Each 2-way valve 112a, 112b, 112c, 112d may be used to manage the flow rate to each corresponding load 110a, 110b, 110c, 110d. In some example embodiments, as the pressure differential across the load decreases, the control device 108a responds to the change by increasing the pump speed of the pump device 106a to maintain or achieve an output setpoint (e.g., pressure or temperature). If the pressure differential across the load increases, the control device 108a responds to the change by decreasing the pump speed of the pump device 106a to maintain or achieve the setpoint. In some example embodiments, the applicable loads 110a, 110b, 110c, 110d may represent cooling coils that supply circulating medium to the cooler 120, each cooling coil having, for example, associated valves 1f, 112b, 112c, 112d. In some examples, the applicable loads 110a, 110b, 110c, 110d may represent fan coils, each fan coil including a cooling coil and a controllable fan (not shown) that blows air across the coil. In some examples, the fan has a variablely controllable motor to control the temperature of the area to be cooled. In other examples, the fan has a binary controllable motor (i.e., only in the on or off state) to control the temperature of the area to be cooled. The control device 108a and control valves 112a, 112b, 112c, 112d can respond to changes in the cooler 120 by increasing or decreasing the pump speed of the pump device 106a or by variably controlling the opening or closing amount of the control valves 112a, 112b, 112c, 112d or by controlling the fan to achieve a specified output setpoint.

[0070] A control pump 122 (more than one control pump is possible) is used to provide flow control from the cooling tower 124 to the cooler 120 (which may include a heat exchanger 118). The control pump 122 may have a variable-controllable motor and may include a pump assembly 106b and a control assembly 108b. In various examples, the control pump 122 may be used to control the flow from a cooling or heating source to the heat exchanger 118. In some examples, the heat exchanger 118 is separate from the cooler 120. In other examples, the cooler 120 is integrated with the heat exchanger 118. In some examples, the heat exchanger 118 is connected to one or two control pumps 102, 122 (e.g., see...). Figure 2EIntegration. In other examples, heat exchanger 118 is separated from control pumps 102 and 122 using piping, fittings, intermediate devices, etc. Control pumps 102 and 122 may be referred to as variable control pumps. Control pumps 102 and 122 are variable flow control mechanisms. In other example embodiments, other types of variable flow control mechanisms, such as variable control valves, may be used.

[0071] Still referencing Figure 1B The output characteristics of each control pump 102, 122 can be controlled to achieve, for example, a temperature setpoint or pressure setpoint at a combined output characteristic represented or detected by an external sensor 114, shown as load 110d at a point in building 104 (the highest point in this example). The external sensor 114 represents or detects the sum or aggregate of the individual output characteristics of all control pumps 102, 122 under load (in one example), flow rate, and pressure. In the example embodiment, information regarding the local flow rate and pressure of control pumps 102, 122 can also be represented or detected by a corresponding sensor 130. In the example embodiment, the external sensor 114 can be used to detect temperature and thermal load (Q). Thermal load (Q) can refer to a hot temperature load or a cold temperature load. In the example, the external sensor 114 for temperature and thermal load can be placed at each load (110a, 110b, 110c, 110d), or a single external sensor 114 can be placed at the highest point of load 110d. Other example operating parameters are described in more detail herein.

[0072] One or more controllers 116 (e.g., processors) may be used to coordinate the outputs (e.g., temperature, pressure, and flow) of some or all of the devices in building system 100. In some example embodiments, controller 116 may include a master centralized controller, and / or in some example embodiments, may have some functionality assigned to one or more devices throughout the building system 100. In example embodiments, controller 116 is implemented by a processor that executes instructions stored in memory. In example embodiments, controller 116 is configured to control or communicate with loads (110a, 110b, 110c, 110d), valves (112a, 112b, 112c, 112d), pumps 102, 122, heat exchanger 118, and other devices.

[0073] Refer again Figure 1A and 1BIn some example embodiments, building system 100 may represent a heating cycle system (“heating unit”) with appropriate adaptation. The heating unit may include a heat exchanger 118, which is an interface in thermal communication with a secondary cycle system such as a boiler system. Instead of cooler 120, the boiler system may include one or more boilers 140 (not shown here). In the example, control valves 112a, 112b, 112c, 112d manage the flow rate to the heating elements (e.g., loads 110a, 110b, 110c, 110d). Control devices 108a, 108b and control valves 112a, 112b, 112c, 112d can respond to changes in the heating elements (e.g., loads 110a, 110b, 110c, 110d) and the boiler system by increasing or decreasing the pump speed of pump device 106a, or variably control the opening or closing amount of control valves 112a, 112b, 112c, 112d to achieve a specified output setpoint (e.g., temperature or pressure). In some examples, one or more boilers 140 are separate from heat exchanger 118. In other examples, one or more boilers 140 are integrated with heat exchanger 118.

[0074] Each control device 108a, 108b may be contained in a pump control card 226 (“PC card”), which is integrated into the corresponding control pump 102, 122. The controller (with communication device) of heat exchanger 118 may be contained in a heat exchanger card 222 (“HX card”) integrated into heat exchanger 118. In this example, PC card 226 may be a desktop device that includes a touchscreen 530a (for controlling pump 102, in...). Figure 5 (shown in the image), processor (controller 506a, Figure 5 ) and communication subsystem 516a ( Figure 5 It can be manufactured separately and then integrated into the corresponding control pumps 102, 122. The HX card 222 is integrated with the heat exchanger 118 and in some examples can be a tablet-type device similar to the PC card 226 with a touch screen 228, and in some examples it does not have a touch screen 228.

[0075] Figure 1C A graphical representation of another example cooling water unit according to an exemplary embodiment is shown, which has a water-side energy-saving unit with a dedicated cooling tower 124 and parallel load sharing. In this example, the cooling tower 124 supplies coolers 120 and heat exchangers 118 in parallel. Loads 110a, 110b, 110c, and 110d are air conditioning loads supplied in parallel by coolers 120 and heat exchangers 118.

[0076] exist Figure 1CIn its construction, the supply flow typically operates at full speed. Since operating the cooling tower 124 is relatively cheaper than operating the cooler 120, it is preferable to maximize the flow rate through the cooling tower 124. In cases where the cooling tower 124 is used under partial load, it is recommended to control the flow rate (T)... 载荷、供应 Alternatively, a maximum supply-side delta T with a constant temperature range and constant load-side delta T (ΔT) can be used to ensure that the load side reaches its design temperature. For additional savings, the user can limit T using the maximum supply-side delta T with a constant temperature range and constant load-side delta T. 供应、进 (Tsource, in) and T 载荷、出 The minimum temperature gap between (Tload, out). If the additional heat exchange is too low, a sample temperature gap of 1F (or the applicable delta at Celsius) can be used so that no pump energy is consumed.

[0077] Figure 1D A graphical representation of another example cooling water unit according to an exemplary embodiment is shown, which has a water-side energy-saving unit with a dedicated cooling tower 124 and load sharing. The cooling tower 124 supplies heat exchanger 118. Heat exchanger 118 provides a cooling circulating medium to cooler 120. The cooler provides further temperature reduction and supplies loads 110a, 110b, 110c, and 110d as air conditioning loads. As shown, heat exchanger 118 can also directly supply loads 110a, 110b, 110c, and 110d via a cooler bypass piping system.

[0078] Since the cooler 120 uses the most energy in system 100, it is advantageous for pump 122 to operate at full speed. In cases where cooling tower 124 is used under partial load, it is recommended to control T... 载荷、供应 Alternatively, use the maximum supply-side delta T with constant temperature range and constant load-side delta T to ensure the load-side reaches its design temperature. For additional savings, users can limit T to the maximum supply-side delta T with constant temperature range and constant load-side delta T. 供应、进 and T 载荷、出 The minimum temperature gap between them. If the additional heat exchange is too low, it is recommended to use a temperature gap of 1F (or the applicable delta at Celsius temperature) so as not to consume pump energy.

[0079] An input is retained on the pump, which allows system 100 to switch between load sharing and independent operation of cooling tower 124.

[0080] In another example not shown, according to an example embodiment, the vehicle system may include a similar system for air conditioning for the vehicle. The air conditioning system, including a compressor and condenser, circulates refrigerant through heat exchanger 118 to cool ambient air or recirculate air into the vehicle's passenger compartment. In some examples, the cold ambient air may bypass heat exchanger 118 via a bypass piping system or valve.

[0081] Figure 1E A graphical representation of an example heating unit according to an example embodiment is shown. The heating unit includes a boiler 140 that supplies heat exchanger 118. Heat exchanger 118 transfers heat energy to loads 110a, 110b, 110c, and 110d, which may be parallel loads serving as peripheral heating units.

[0082] When boiler 140 is a condensing boiler, its efficiency increases as the return water temperature decreases. To achieve the lowest possible return temperature, the supply-side flow rate should be minimized without significantly impacting the load side. The recommended control method is to maximize the supply-side delta T with a constant temperature range and a constant load-side delta T. If the user flexibly uses varying T... 载荷、出 Further energy efficiency improvements can be achieved by using the maximum supply-side delta T with variable temperature range and variable load side delta T.

[0083] For non-condensing boilers, the efficiency does not change much with return temperature; therefore, the recommended approach is to have a constant temperature range and a constant load-side delta T with a maximum supply-side delta T.

[0084] Figure 1F A graphical representation of an example cooling water unit with a direct cooling loop according to an exemplary embodiment is shown. Cooler 120 supplies parallel heat exchangers 118. Cooler 120 includes a condenser and an evaporator. Each heat exchanger 118 transfers heat energy to provide a cooled circulating medium to each corresponding load 110a, 110b, 110c, 110d. Loads 110a, 110b, 110c, 110d may represent air handling units on corresponding floors or areas.

[0085] exist Figure 1F In its design, cooler 120 controls the supply temperature, which can be based on the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) (RTM) 90.1. For cooler 120, a higher return temperature results in more efficient operation (efficiency increases by approximately 2% per 1°F or equivalent delta Celsius). The recommended control method is T... 载荷、出 Control, or the maximum supply side delta T with constant temperature range and constant load side delta T. If the user flexibly uses varying T...载荷、出 Further energy efficiency improvements can be achieved by using the maximum supply-side delta T with variable temperature range and variable load side delta T.

[0086] In other examples, Figure 1F A similar configuration can be used for direct heating loops. For condensing boiler 140, the recommended control method is to have a constant temperature range and a constant load-side delta T, with the maximum supply-side delta T. If the user flexibly uses varying T... 载荷、出 Further energy efficiency improvements can be achieved by using the maximum supply-side delta T with variable temperature range and variable load-side delta T. For the non-condensing boiler 140, the efficiency does not vary significantly with the return temperature; therefore, the recommended approach is to use the maximum supply-side delta T with constant temperature range and constant load-side delta T.

[0087] Figure 1G A graphical representation of an example heating unit with a zone heating loop according to an exemplary embodiment is shown. The zone may consist of multiple buildings 104. A boiler 140 supplies heat exchangers 118 in parallel, for example, one heat exchanger 118 for each respective building 104. For each building 104, each heat exchanger 118 transfers heat to a corresponding load 110a, 110b, 110c, 110d. In other examples, a similar configuration may be used for a zone cooling loop.

[0088] In this configuration, a smart energy valve is sometimes used instead of the supply-side pump 122 when required by the application. One optimization method is to return the highest temperature on the supply side during cooling and the lowest temperature on the supply side during heating. The recommended control method is to have a maximum supply-side delta T with a constant temperature range and a constant load-side delta T. If the user flexibly uses varying T... 载荷、出 Further energy efficiency improvements can be achieved by using the maximum supply-side delta T with variable temperature range and variable load side delta T.

[0089] Figure 1H A graphical representation of an example heating unit for heating drinking water according to an example embodiment is shown. Boiler 140 may be a hot water boiler supplying heat exchanger 118. Heat exchanger 118 transfers heated drinking water to hot water storage tank 142 to supply heated drinking water to loads 110a, 110b, 110c, 110d, which may be faucets, sleeves, etc. In this configuration, it is typically necessary to maintain hot water storage tank 142 at a constant temperature. One example control method is to control T... 载荷、出 .

[0090] Figure 1IA graphical representation of an example building system 100 for waste heat recovery is shown according to an example embodiment. A heat source, such as a computer room, removes heat to a heat exchanger 118 via a circulating medium to cool the computer room. The heat exchanger 118 then transfers the heat to any water that needs preheating. In this mode, as much heat as possible is utilized for recovery. One example method is to make T... 载荷、进 and T 载荷、出 Maximize the delta T between them. Another example method is to control T. 供应、出 The desired return temperature. Note that, depending on the specific viewpoint, the references to "supply" and "load" can be switched here.

[0091] In another example, according to an example embodiment, the vehicle system may include a similar system for waste heat recovery. A heat source, such as the vehicle's engine, has had its heat removed to a heat exchanger 118 via a circulating medium to cool the engine. The heat exchanger 118 then transfers the heat from the air in the air circulation system to the passengers inside the vehicle.

[0092] Figure 1J A graphical representation of an example building system 100 for geothermal heating isolation is shown according to an example embodiment. A heat source, such as geothermal energy, is used to heat a circulating medium to a heat exchanger 118. The heat exchanger 118 then transfers the heat to provide hot, clean water to one or more loads 110a, 110b, 110c, 110d. In this configuration, it is desirable to avoid T 供应、出 In cases of extreme cold, transfer as much heat as possible, as this can harm nearby organisms. In such situations, a minimum temperature setting can be used to control T. 供应、出 .

[0093] If any of the four temperature sensors measuring the inlet temperature of the hot and cold sides of the heat exchanger 118 are unavailable or out of range, the pump control on the supply-side control pump 122 can default to a constant speed and the pump control on the load-side control pump 102 can default to a sensorless mode.

[0094] Figure 2AA graphical representation of a heat exchanger 118 according to an example embodiment is shown. In the example, the heat exchanger 118 is a plate counter-flow heat exchanger. The heat exchanger 118 includes a frame 200, which is a sealed housing. The heat exchanger 118 defines a first fluid path 204 for a first circulating medium and a second fluid path 206 for a second circulating medium. The first fluid path 204 is not in fluid communication with the second fluid path 206. The first fluid path 204 is in thermal contact with the second fluid path 206. The first fluid path 204 can flow in the opposite flow direction (counter-flow) to the second fluid path 206. In the example, the heat exchanger 118 is a brazed plate heat exchanger (BPHE). A plurality of brazed plates 202 are parallel plates that facilitate heat transfer between the first fluid path 204 and the second fluid path 206. The first fluid path 204 and the second fluid path 206 flow between the brazed plates 202, typically in alternating fluid paths of the brazed plates 202. Multiple brazing plates 202 are sized to create brazing patterns that induce turbulence to facilitate heat transfer between the first fluid path 204 and the second fluid path 206. Increased turbulence in the heat exchanger 118 (reducing the likelihood of turbulence) results in a higher pressure drop across the heat exchanger 118. The turbulence facilitates the loosening of fouling on the brazing patterns of the brazing plates 202. For smaller heat exchangers 118 (which use less material), the higher pressure drop increases turbulence (reducing the likelihood of turbulence), but also requires higher pump energy consumption. In other examples, the heat exchanger 118 is a shell-and-tube (S&T) type heat exchanger or a plate heat exchanger (PHE).

[0095] The load side is the side connected to a load that requires heat, such as a building or room. The variable flow rate through the load side is controlled by control pump 102. The supply side is connected to the heat source to be transferred, such as cooler 120, boiler 140, or a regional source. The variable flow rate through the supply side is controlled by control pump 122. Two conventions can be used to label parameters in the heat transfer loop. The first convention is to obtain parameters such as temperature and flow rate from heat exchanger 118. That is, for example, the water temperature entering heat exchanger 118 from the supply side is referred to as T. 供应、进 The temperature of the water flowing out of heat exchanger 118 from the supply side is called T. 供应、出 .

[0096] An alternative convention is to label parameters such that, on the supply side, the supply section is taken as the fluid supplied from the source to the heat exchanger 118, and the return section is taken as the fluid returning to the source. On the load side, the supply section is taken as the fluid supplied to the load, and the return section as the fluid returning from the load. This is derived from the cooler and fan coil convention. For calculation purposes, this specification will primarily refer to the first convention, which refers to the inlet and outlet as observed from the heat exchanger 118.

[0097] In the example embodiment, any or all of the control pumps 102, 122 may be replaced or used in combination with other types of variable flow control mechanisms, such as variable control valves. For example, in the example embodiment, instead of the load-side control pump 122, another type of flow control mechanism, such as a variable control valve, is used instead of the control pump 122. The supply side may be connected to a heat source to be transferred, such as a cooler 120, a boiler 140, or a regional source, which may have its own pump (not necessarily controlled by controller 116) and provide a constant or variable flow rate to heat exchanger 118. The variable flow rate on the supply side of heat exchanger 118 is controlled by a variable control valve. Information detected by one or more of the described sensors can be used to determine the variable control (e.g., opening amount) of the variable control valve to achieve the desired flow rate.

[0098] In an example not shown, the variable control valve includes a controller and a variable valve controlled by the controller. The controller of the variable control valve may be configured to communicate with controller 116, for example, to receive instructions regarding a variable opening amount or flow rate, and, for example, to send the current status of the variable opening amount or flow rate. In some examples, the variable control valve may include a variable controllable ball valve. Other example variable control valves include cup valves, gear valves, screw valves, etc. The variable control valve may include onboard sensors and may perform self-regulation, monitoring, and control using its controller. In some examples, the variable control valve may be pressure-independent. In some examples, the variable control valve may be a 2-way variable control valve.

[0099] like Figure 2A As shown, the frame 200 of the heat exchanger 118 may include four ports 208, 210, 212, and 214. Port 208 is used for supply, inlet, or provision. Port 210 is used for supply, outlet, or return. Port 212 is used for load, outlet, or provision. Port 214 is used for load, inlet, or return. In this example, the frame 200 is a non-removable, integral, sealed housing because maintenance is performed by flushing through ports 208, 210, 212, and 214.

[0100] Various sensors can be used to detect and transmit measured values ​​from the heat exchanger 118. Sensors may include those integrated with the heat exchanger 118, including sensors for the following: temperature supply, inlet (T... 供应、进 Temperature supply and output (T) 供应、出 Temperature load, output (T) 载荷、出 Temperature load, inlet (T) 载荷、进The pressure difference between supply, inlet and supply, outlet; the pressure difference between load, inlet and load, outlet; the pressure at supply, inlet; and the pressure at load, inlet. Depending on the specific parameters or coefficients being detected or calculated, more or fewer sensors may be used in various examples. In some examples, sensors include flow sensors for: flow rate, supply (F... 提供 ); and flow, supply (F 供应 These are typically located outside the heat exchanger 118 and may be situated, for example, at control pumps 102, 122 or external sensors 114 or loads 110a, 110b, 110c, 110d.

[0101] Baseline measurements from the sensors are stored in memory for comparison with subsequent real-time operational measurements from the sensors. For example, baseline measurements can be obtained through factory testing using test equipment. In some examples, baseline measurements can be obtained during real-time system operation.

[0102] Example embodiments include a heat transfer module that may include one or more heat exchangers 118 within a single sealed housing (frame 200), wherein, Figure 2B A heat transfer module 220 with two heat exchangers 118 is shown, while Figure 2C and 2D A heat transfer module 230 with three heat exchangers 118 is shown.

[0103] Figure 2E A heat transfer system 240 is shown, comprising a heat transfer module 230 and pumps 102, 122. In the example, the heat transfer module may include one, two, three, or more heat exchangers 118 within a single sealed housing (frame 200). The heat transfer system 240 provides a reliable and optimized heat transfer solution, comprising one or more heat exchangers 118 and pumps 102, 122, by providing an optimized heat transfer system solution rather than simply providing equipment sized to fit the operating conditions. The heat transfer system 240 can be used in liquid-to-liquid HVAC applications, with typical applications in residential, commercial, industrial, and public buildings, district heating or cooling, etc. Applications include cooling, heating, water-side energy savers (e.g., cooling towers), condenser isolation (e.g., lakes, rivers, or groundwater), district heating and cooling, pressure relief, boiler heating, thermal storage, etc. The heat transfer system 240 can be shipped as a complete package or optionally as a module that can be quickly assembled on-site.

[0104] Figure 2BA perspective view of a heat transfer module 220 with two heat exchangers 118a and 118b according to an example embodiment is shown. The heat transfer module 220 includes an HX card 222 for receiving measurements from various sensors of the heat transfer module 220, determining that the heat transfer module 220 requires maintenance, and connecting this maintenance requirement to a controller 116 or control pumps 102 and 122. Ports 208, 210, and 214 are shown; note that port 212 is not visible in this view. A touchscreen 228 can be used as a user interface for user interaction with the respective heat transfer module 220. The touchscreen 228 can be integrated with the HX card 222 in a tablet computer-type device.

[0105] Each heat exchanger 118a, 118b may have one or more shut-off valves 224 controllable by HX card 222. Therefore, each heat exchanger 118a, 118b in the heat transfer module 220 is selectively opened or closed by HX card 222, respectively. In the example shown, four shut-off valves 224 are present across each heat exchanger 118a, 118b.

[0106] Various sensors can be used to detect and transmit measured values ​​of parameters of the heat transfer module 220. Sensors may include temperature sensors for the following applications: temperature supply, inlet (T...) 供应、进 Temperature supply and output (T) 供应、出 Temperature load, output (T) 载荷、出 Temperature load, inlet (T) 载荷、进 The temperature sensors may also include temperature sensors, each for the corresponding temperature output of the supply and load fluid path for each heat exchanger 118a, 118b (four in total in this example). Therefore, a total of eight temperature sensors can be used in the example heat transfer module 220.

[0107] The sensor may also include sensors for: supply, inlet and supply, outlet pressure difference; load, inlet and load, outlet pressure difference; supply, inlet pressure; load, outlet pressure. Depending on the specific parameter or coefficient to be detected or calculated, more or fewer sensors may be used in various examples. Such sensors may be housed within a sealed housing (frame 200). In some examples, the sensor includes a flow sensor for: flow rate typically outside the heat transfer module 220, supply (F... 提供 ); and flow, supply (F 供应 ).

[0108] Figure 2C A perspective view of a heat transfer module 230 having three heat exchangers 118a, 118b, and 118c according to an example embodiment is shown. Figure 2DA partial cross-sectional view of the contents of the heat transfer module 230 is shown, depicted without the frame 200. (See attached image.) Figure 2D As shown, the multiple brazing plates 202 of each of the heat exchangers 118a, 118b, and 118c are vertically oriented.

[0109] The heat transfer module 220 includes an HX card 222 for receiving measurements from various sensors within the heat transfer module 220, determining if maintenance is required, and connecting the required maintenance to the controller 116 or control pumps 102, 122. Ports 208, 210, and 214 are shown; note that port 212 is not visible in this view. Various sensors can be used to detect and transmit measured values ​​of parameters of the heat transfer module 220, the above of which pertain to the heat transfer module 220 (…). Figure 2B The sensor described has two heat exchangers 118, 118b. For example, a total of ten temperature sensors can be used in the example heat transfer module 230, namely, one for each port 208, 210, 212, 214 (four in total), one for each output of each heat exchanger 118a, 118b, 118c for the supply path (three in total), and one for each output of each heat exchanger 118a, 118b, 118c for the load path (three in total).

[0110] Figure 2E A perspective view of an example heat transfer system 240 is shown, which includes... Figure 2C The heat transfer module 230 and two control pumps 102 and 122 are included. Control pumps 102 and 122 are each dual-control pumps, as shown in the figure, each having two pump units. Dual-control pumps allow for redundancy, standby use, and pump unit efficiency. In some examples, the dual-control pumps may have two separate PC cards 226. Similar configurations can be used for... Figure 2B Heat transfer module 220 or such Figure 2A The separate heat exchanger 118 is shown. (As shown) Figure 2E As shown, control pump 102 is connected to port 212 for loading, output, or supplying. Control pump 122 is connected to port 208 for supplying, inlet, or providing. In other examples, control pumps 102 and 122 are not directly connected to each port 212 or 208, but are upstream or downstream of each port 212 or 208, and are connected via intermediate piping or other intermediate devices such as filters, in-line sensors, valves, fittings, pipes, suction guides, boilers, or coolers.

[0111] The heat transfer module 230 has a dedicated HX card 222 with WIFI communication capability. The HX card 222 can be configured to store heat transfer performance diagrams for each heat exchanger 118a, 118b, and 118c in the heat transfer module 230 based on factory testing. The HX card 222 can poll data from ten temperature sensors, two pressure sensors, and two differential pressure sensors. The HX card 222 can also poll flow measurement data from two control pumps 102 and 122. If the control pumps 102 and 122 are nearby and can communicate via WIFI (via PC card 226), data is polled directly from the pumps; otherwise, a wired connection or a local area network is used to collect flow measurement data. The control pumps 102 and 122 can receive data from the HX card 222 and display the inlet and outlet temperatures of the fluid being pumped by the control pumps 102 and 122, as well as the differential pressure across the heat exchanger module 230, on the pump display screen.

[0112] Various sensors allow controller 116 to calculate the exchanged heat in real time based on flow measurements (determined by pumps 102, 122, or external sensor 114) and the temperature on each side of heat exchanger module 230. Additionally, for heat exchanger modules with two or three heat exchangers 118, each branch at the outlet connection can have a temperature sensor to allow for fouling / clogging prediction in each individual heat exchanger 118. For each heat exchanger 118, data collected by HX card 222 and pump PC card 226 can be used to calculate the overall heat transfer coefficient (UL) in real time. 值 ), and compared it with the overall clean heat transfer coefficient (U 净 The data will be compared to predict scaling and maintenance / cleaning needs. The collected data will be used to calculate total heat transfer in real time and optimize system operation to minimize energy costs (for pumping and supply) while meeting load requirements. Internet connectivity will be achieved via a dedicated HX card 22 and a pump PC card 226. Data will be uploaded to the cloud 308 for data logging, analysis, and control.

[0113] A suction guide (not shown) can be integrated with a filter having a standard sieve aperture of #20 (or higher) in heat transfer modules 220, 230. In the example, the suction guide is a multi-functional pump accessory that provides a 90° elbow, guide vanes, and an in-line filter. The suction guide reduces pump installation costs and floor space requirements. If a suction guide is unavailable, a Y-type filter with a suitable mesh can be included. Alternatively, a mesh filter can be installed on the supply side.

[0114] Figure 3A A graphical representation of the network connectivity of a heat transfer system 300 with local system settings is shown. The heat transfer system 300 includes a building automation system (BAS) 302, which may include a controller 116. Figure 1A and 1B BAS 302 can communicate with control pumps 102, 122 and heat exchanger module 220 via router 306 or via short-range wireless communication. Smart device 304 can communicate directly or indirectly with BAS 302, control pumps 102, 122 and heat exchanger module 220. Smart device 304 can be used for commissioning, setup, maintenance, alarm / notification, communication and control of control pumps 102, 122 and heat exchanger module 220.

[0115] Figure 3B A graphical representation of the network connectivity of a heat transfer system 320 with remote system settings is shown. BAS 302 can communicate with control pumps 102, 122, and heat exchanger module 220 via router 306 or via short-range wireless communication. Smart device 304 can access one or more cloud computer servers on cloud 308 via an internet connection. Smart device 304 can communicate directly or indirectly with BAS 302, control pumps 102, 122, and heat exchanger module 230 on cloud 308. Smart device 304 can be configured for commissioning, setup, maintenance, alarm / notification, communication, and control of control pumps 102, 122, and heat exchanger module 230. The cloud server stores valid measurement records and their serial numbers for various devices. These records and notes can be viewed when maintenance and service are required. This can be part of the service application (“app”) of smart device 304.

[0116] Each heat transfer module 230 may have an HX card 222. The function of the HX card 222 is to connect to all sensors and devices on the heat transfer module 230 via physical connection (Controller Area Network (CAN) bus or direct connection) and / or wireless connection. The HX card 222 can also collect information from the pump PC card 226 via physical connection or wirelessly.

[0117] HX card 222 collects and processes all sensor measurements and other information, and controls the required flow to the supply-side control pump 122. HX card 222 also sends sensor readings to the supply-side control pump 122 and the load-side control pump 102 so that they can display real-time information on their respective one or more displays. HX card 222 can also send sensor measurement information to cloud 308. In this example, all calculations related to the heat exchanger can be handled by HX card 222 for more direct processing. In this example, other devices can be configured to display data previously calculated by HX card 222.

[0118] Users can modify settings locally by connecting to the HX card 222 using the wireless smart device 304 or BAS 302. Users can also remotely modify restricted settings by connecting to the cloud 308. These settings are restricted according to security limitations.

[0119] When HX card 222 and control pumps 102 and 122 are connected via router 306, smart device 304, PC card 226, and HX card 222 can communicate using router 306. When HX card 222 and control pumps 102 and 122 are not connected via router 306, HX card 222 can automatically turn on a Wi-Fi hotspot to enable communication between smart phone 304, PC card 226, and HX card 222. When HX card 222 turns on a Wi-Fi hotspot, it can communicate with the cloud 308 via its built-in IoT card, Ethernet connection, SIM card, etc.

[0120] PC card 226 can connect to HX card 222 wirelessly or via a physical connection and provide pump sensor data to HX card 222. PC card 226 can receive data (measurements, alarms, calculations) from HX card 222 and display it on the pump display screen.

[0121] As understood in the art, PC card 226 can wirelessly connect to HX card 222 using the ModBUS protocol. Other protocols may be used in other examples. For communication to occur between PC card 226 and HX card 222, the IP addresses of both PC card 226 and HX card 222 need to be known. Internal identifiers may also be built into PC card 226 and HX card 222 to allow them to easily find each other on a local area network. PC card 226 is capable of sending information to other devices, receiving information from other devices, and controlling them.

[0122] When in use, the BAS 302 can connect wirelessly to the HX card 222 and PC card 226 via a router or through a direct connection. In the example, the BAS 302 has the highest control privileges and is capable of overriding one or more HX cards 222 and one or more PC cards 226.

[0123] HX card 222 provides historical measurement data to cloud 308 for storage. An application can be installed on smart device 304, allowing users to view the data and generate reports. Cloud 308 can use historical data to create reports and provide performance management services.

[0124] Smart device 304 can locally connect to HX card 222 via router 306 to modify settings. In this example, smart device 304 can also connect to cloud 308, where users can modify a limited number of settings.

[0125] Applications (Apps), web server user interfaces, and / or websites can be provided to give users access to all the available functions on PC Card 226 or Cloud 308.

[0126] Heat transfer systems 300 and 320 can be configured to provide information to users via PC card 226 and remotely via online services and a control pump manager. Input to HX card 222 can collect readings and measurements from two temperature sensors on the cold-side fluid and two temperature sensors on the hot-side fluid across the entire heat transfer module 230. Duplex and triplex heat transfer modules 220 and 230 can have additional temperature sensors at the outlet of each individual heat exchanger 118a, 118b, 118c to calculate the temperature difference across each individual heat exchanger 118a, 118b, 118c. The absolute temperature difference between two temperature sensors is called the delta T. HX card 222 and PC card 226 can communicate in real time and provide data to cloud 308 for data logging and processing.

[0127] Heat transfer systems 300 and 320 can be operated using demand-based control. Changes in the heat load (typically on the load side) within the building will result in changes in flow demand. In some examples, one or more control pumps 102 on the load side will adjust their speed based on sensorless (e.g., parallel or coordinated sensorless) operation to meet flow demand in real time. In some examples, control pump 102 calculates flow rate in real time, and HX card 222 obtains signals from temperature sensors installed at the inlet and outlet of one or more heat exchangers 118. The temperature difference is calculated in real time on HX card 222 and along with the flow rate used to calculate the required heat load (Q) for system loads 110a, 110b, 110c, and 110d of building 104 in real time.

[0128] The HX card 222 calculates the optimal flow rate and temperature on the supply side for the most energy-efficient system operation. The supply-side fluid flow rate can be controlled using various heat transfer loop control methods.

[0129] Heat transfer systems 300 and 320 can monitor the amount of time the system operates under partial and full load (working load), and when the partial load operation time exceeds the set time limit, pumps 102 and 122 can be operated at full load flow to automatically flush heat exchanger 118. Operating the pumps at full load flow activates the self-cleaning capability of heat exchanger 118. This feature is programmed using parameters such as the self-cleaning hourly cleaning frequency per operating hour and the start time of self-cleaning per day. Example default self-cleaning: full load flow operation time is 30 minutes every 168 hours (7 days) with partial load operation time at 3 AM. The default partial load threshold is set at 90% of full load flow (working flow).

[0130] In some examples, the user has access to sensor readings on the HX card 222. Connected pumps 102 and 122 can display real-time sensor data on it. The HX card 222 uploads historical sensor data to the cloud 308, where the user can access the sensor data.

[0131] In some examples, the HX card 222 can enable heat transfer algorithms (e.g., various heat transfer loop controls), real-time fouling tracking, and real-time error monitoring and maintenance tracking.

[0132] PC card 226 can be communicatively connected to HX card 222, and the touch screen 530a corresponding to control pumps 102, 122 can be used for this purpose. Figure 5 The Cloud 308 displays other trends, scale tracking, and maintenance log information. It can monitor information and performance reports, track customer errors, and provide current usage, savings, and recommended actions.

[0133] The HX card 222 can store data for each heat exchanger, such as the heat transfer module model and serial number, design point, and mapped heat transfer performance curves (U-value as a function of flow rate). For each individual heat exchanger 118, the mapped data of the heat transfer curve will be tested indoors.

[0134] Service history can be stored on Cloud 308. Service history can be uploaded to HX Card 222 via the web server UI, PC Card 226, or Cloud 308. If Cloud 308 does not have a latest version, HX Card 222 can push records to Cloud 308. If Cloud 308 has a latest version, Cloud 308 can push records to HX Card 222.

[0135] In some examples, for the HX card 222, data sampling (temperature and pressure at the hot and cold side inlet and outlet, and flow rates on the hot and cold sides) can be performed starting every minute but not exceeding every 5 minutes. The data can be periodically updated and stored on the cloud 308. All input and calculated parameters can be updated based on the sampling time and can be displayed on the control pumps 102 and 122. Calculated parameters include delta T, differential pressure, flow rate, and U. 污垢 (The total heat transfer coefficient of the heat exchanger after a period of operation) and the heat exchanged (calculated for both the supply-side fluid and the load-side fluid), total pumping energy and system efficiency (the heat exchanged divided by the total heat pumping energy, in Imperial Btu / h, in Metric kW).

[0136] The control pumps 102 and 122 can be connected to a corresponding touchscreen 530a on the PC card 226. Figure 5The touchscreen 530a displays trending heat exchanger performance data. Users can access the relationships between exchanged heat and time, temperature input and output and time, and pressure difference and time via the touchscreen 530a. The touchscreen 530a can also display heat transfer performance data for the corresponding fluid sides to which pumps 102 and 122 are connected.

[0137] The performance management service can provide additional trend data: delta T over time for both the hot and cold fluid sides, and heat transfer efficiency over time, in the form of heat energy exchanged per electrical kilowatt (or kW) by pumps 102 and 122 (on the supply and load sides) in the form of Btu / hr (kW).

[0138] According to the example embodiment, another example of trend data (determined coefficients of heat exchanger 118) provided by the performance management service is the heat transfer capacity (Qc) of each heat exchanger 118 or the future heat transfer capacity of each heat exchanger 118, based on trend line analysis over time, historical data from the same or similar heat exchangers 118, or mathematical calculations. The remaining lifetime of the heat transfer capacity of each heat exchanger 118 can also be determined by the controller 116, for example, when the heat transfer capacity will reach a specified amount.

[0139] The following are examples of various control operations (flow control modes) for heat transfer systems 300 and 320: 1. Constant speed control. 2. T 供应、出 Control (feedforward control mode or method). 3. T 供应、出 4. Proportional flow matching. 5. Maximum supply-side delta T with constant temperature range and constant load side delta T. 6. Maximum supply-side delta T with variable temperature range and variable load side delta T.

[0140] In some example embodiments of the control operation of heat transfer systems 300 and 320, a feedforward control system is used. In the feedforward control system, the controller 116 within the control system transmits control signals to the PC card 226 based on information sensed from one or more sensors in the environment. The output of the feedforward control system responds to the effect of the control signals in a predetermined manner calculated based on the sensed information; in contrast to systems that use only feedback, this system iteratively adjusts the output to consider only the measurement results of the output on the load. In the feedforward control system, the adjustment of the control variables is not solely based on error. The feedforward control system is based on knowledge of the process in the form of a mathematical model of the building system 104, as well as knowledge or measurements of process disturbances.

[0141] In the feedforward control system, control signals are provided from controller 116 to PC card 226, and the effect of the system output on the load is known by using a mathematical model. Any new corrections or adjustments can be made using new control signals from controller 116 to PC card 226, and so on.

[0142] In some examples of the control operation of heat transfer systems 300 and 320, a combination of feedforward control and feedback control is used.

[0143] In the example, controller 116 is configured to switch between one or more of the six types of flow control modes. In such an example, at least one of the control modes is feedforward control. For example, controller 116 is configured to switch to one type of flow control mode or switch from one type of flow control mode to a different second type of flow control mode, or switch from a different second type of flow control mode to one flow control mode, which is feedforward control.

[0144] In the example, the decision by controller 116 to switch to a different control mode is based on information sensed from one or more sensors in the environment, such as changes in operating conditions or degradation or failure of a part of the system. In some cases, for example, when sensor information from one or more sensors is no longer available, the control mode is switched to a flow control operating mode that does not require data from those sensors. In some examples, the flow control mode selected by controller 116 is one that optimally maintains a constant load-side temperature. In some examples, the flow control mode selected by controller 116 is one that minimizes the energy consumed by the transferred thermal load.

[0145] In other examples, the controller 116 makes decisions to switch control modes based on rules, such as the time of day, a specific season of the year, for maintenance, manual control, etc.

[0146] The various control operations of heat transfer systems 300 and 320 will now be described in more detail.

[0147] 1. Constant speed control.

[0148] The supply-side pump operates at a constant operating point speed. This speed can be changed if necessary. Note that this type of control is not considered feedforward control.

[0149] 2. T 供应、出 Control (feedforward control mode or method).

[0150] The outlet temperature on the supply side of heat transfer modules 220 and 230 is maintained at a fixed setpoint according to design conditions, or dynamically controlled by BAS 302. T is controlled by changing the pump flow rate on the supply side. 供应、出 .

[0151] Traffic flow is calculated as follows: F 供应 = [C 载荷 ×ρ 载荷 × F 载荷、测量 × abs(T 载荷、进、测量值 – T 载荷、出、测量值 )] / [C 供应 ×ρ 供应 ×abs(T) 供应、出、目标值 – T 供应、进、测量值 )], in, ρ load is T 载荷、出、测量值 – T 载荷、进、测量值 Fluid density at average value, C 载荷 It is T 载荷、出、测量值 – T 载荷、进、测量值 The specific heat capacity of the fluid on the load side at the average value. T is given 供应、出、目标值 .

[0152] The control algorithm can use other methods to obtain T. 供应、出 Stability (target and measured T) 供应、出 (convergence between). An example is in T. 供应、出 Temperature feedback is used, and the feedback method described above and the feedforward method described below are used to achieve fast and stable convergence.

[0153] 3. T 载荷、出 Control (feedforward control mode or method).

[0154] The supplied temperature on the load side of heat transfer modules 220 and 230 is maintained at a fixed setpoint according to design conditions, or is supplied by a source from T. 供应、进 Temperature difference control is achieved by adjusting the pump flow rate on the supply side to control the setpoint.

[0155] Traffic flow is calculated as follows: F 供应 = [C 载荷 ×ρ 载荷 × F 载荷 × abs(T 载荷、进、测量值 – T 载荷、出、目标值 )] / [C 供应 ×ρ 供应 × abs(T 供应、出、测量值– T 供应、进、测量值 )], in: T 载荷、出、目标值 Given by the design setpoint or by T 供应、进 Temperature difference control is set.

[0156] The control algorithm can use other methods to obtain T. 载荷、出 Stability (required and measured T) 载荷、出 (convergence between them).

[0157] In cases of supply-side temperature fluctuations (e.g., temperature reset as provided by ASHRAE 90.1), the load-side supply temperature of heat transfer modules 220 and 230 can be set to switch with the supply-side inlet temperature (also known as temperature reset). Heat transfer modules 220 and 230 have the option to maintain the design-defined temperature difference between the load-side outlet temperature and the supply-side inlet temperature even after a supply-side inlet temperature change. Heat transfer modules 220 and 230 measure T... 供应、进 And adjust F 供应 To maintain (T) 供应、进、设计值 – T 载荷、出、设计值 To do this.

[0158] 4. Proportional flow matching.

[0159] Proportional flow matching is used to indicate that the supply-side volumetric flow rate will be based on [ρ]. 载荷 × C 载荷 × abs(T 载荷、进、设计值 –T 载荷、出、设计值 ) ] / [ρ 供应 × C 供应 × abs(T 供应、出、设计值 – T 供应、进、设计值 The ratio of the absolute value of the supply-side flow rate to the load-side volumetric flow rate is used in the terminology. For example, if the ratio is 1.2:1, the required supply-side flow rate is 1.2 times the load-side flow rate. The input used to calculate this ratio is taken from the design conditions of the selected software. If any of these conditions change in the future, the user can modify these parameters. Other specific ratios may be used in other embodiments. In some examples, the ratio can be adjusted during either automatic or manual runtime operation.

[0160] 5. Maximum supply side delta T with constant temperature range and constant load side delta T.

[0161] Controller 116 reduces the supply-side flow rate to achieve a lower return temperature to the source in heating and a higher return temperature in cooling—maximizing the supply-side delta T. This is beneficial for applications using boilers and coolers, as the return temperature directly affects equipment efficiency. In this control method, the supply-side flow rate is reduced to ensure that the temperature difference between the supply-side provided temperature and the load-side provided temperature remains the same according to the design, and T... 载荷、进 and T 载荷、出 The load-side design difference remains the same. For partial load conditions, the reduction in supply-side flow rate is even less than in proportional flow matching scenarios. For condensing boilers, lower return temperatures help improve boiler efficiency. For coolers, higher return temperatures improve cooler efficiency. Additionally, lower supply-side flow rates save pumping energy.

[0162] Supply-side flow is determined by the following methods: 1. Read the temperature and flow rate at the inlet and outlet of the hot and cold sides (4 temperatures and 2 flow rates). Extract the readings at a set frequency (e.g., every 5 seconds, and verify during testing).

[0163] 2. Calculate the current heat load requirement (load side) using the following formula: Q 载荷 = C × m × abs(T 进 –T 出 ) = C 载荷 × ρ 载荷 × F 载荷、测量值 × abs(T 载荷、出、测量值 – T 载荷、进、测量值 ).

[0164] 3. Determine T 载荷、出、目标值 and T 载荷、进、目标值 : T 载荷、出、目标值 = T 供应、进、测量值 +(T) 载荷、出、设计值 – T 供应、进、设计值 + / - variance The variance can range from 0F to 20F degrees (or equivalent Celsius), with a default value of 0.5F (or equivalent Celsius), and is confirmed by testing.

[0165] T 载荷、进、目标值 = T 载荷、进、目标值 +(T) 载荷、进、设计值 – T 载荷、进、设计值 + / - variance The variance can range from 0F to 20F degrees (or equivalent Celsius), with a default value of 0.5F (or equivalent Celsius), and is confirmed by testing.

[0166] 4. Determine the flow rate F on the target load side. 载荷、目标值 (Using the above equation Q = m × C × (T) 进 –T 出 ): F 载荷、目标值 = Q 载荷 / (ρ 载荷 × C 载荷 × abs(T 载荷、出、目标值 – T 载荷、进、目标值 )), Use T 供应、进、测量值 F 载荷、目标值 And T 载荷、出、目标值 and T 载荷、进、目标值 We solve F using the following rules. 供应、目标值 : I. Initial guess F 供应、目标值 If Q 载荷、测量值 Q 载荷、设计值 Then F 供应、目标值 = Q 载荷 / Q 载荷、设计值 ×F 供应、设计值 .

[0167] II. Calculate T 供应、出、目标值 : For cooling mode (T) 供应、进、测量值 < T 供应、出、测量值 And T 载荷、出、测量值 < T 载荷、进、测量值 ): T 供应、出、目标值 = T 供应、进、测量值 + Q 载荷 / (ρ 供应 × C 供应 × F 供应、目标值 ).

[0168] For heating mode (T) 供应、进、测量值 > T 供应、出、测量值 And T 载荷、出、测量值 > T 载荷、进、测量值 ): T 供应、出、目标值 = T 供应、进、测量值 – Q 载荷 / (ρ 供应 × C 供应 × F 供应、目标值 ).

[0169] III. Using the equation above (Q) HX = U × A × (LMTD)) and F 供应 T供应、进、测量值 T 供应、出、目标值 F 载荷、目标值 T 载荷、出、目标值 and T 载荷、进、目标值 The input is used to calculate Q. HX .

[0170] IV. If abs(Q) HX –Q 载荷 ) / Q 载荷 If < 0.01, then our F is determined. 供应、目标值 .

[0171] Otherwise, record F. 高 and F 低 .

[0172] a. In the first iteration, F 高 =The maximum full-speed flow rate of the supply-side pump, and F 低 = 0.

[0173] If Q HX Q 载荷 Then F 低 Updated to equal F 供应、目标值 Choose F, which is 20% larger than previously guessed. 供应、目标值 And return to step I.

[0174] If Q HX Q 载荷 Then F 高 Updated to equal F 供应、目标值 Choose F, which is 20% smaller than previously guessed. 供应、目标值 And return to step I.

[0175] b. If Q in step a HX 载荷， And Q HX 载荷 , will F 低 Updated to equal F 供应、目标值 Choose F, which is 20% larger than previously guessed. 供应、目标值 And return to step I.

[0176] If Q in step a HX Less than Q 载荷 And Q HX Q 载荷 Continue to step c, until the remaining step 4.

[0177] If Q in step a HX Q 载荷， And Q HX 载荷 , will F​​​高 Updated to equal F 供应、目标值 Choose F, which is 20% smaller than previously guessed. 供应、目标值 And return to step I.

[0178] If Q in step a HX Q 载荷 And Q HX Q 载荷 If so, continue to step c, until the remaining step 4.

[0179] c. In subsequent iterations, If Q HX 载荷 Then F 低 Updated to equal F 供应、目标值 Select the new F 供应、目标值 For (F) 高 + F 供应、目标值 ) / 2, and return to step I.

[0180] If Q HX Q 载荷 Then F 高 Updated to equal F 供应、目标值 Select the new F 供应、目标值 =(F 低 + F 供应、目标值 ) / 2, and return to step I.

[0181] 6. Maximum supply-side delta T with variable temperature and variable load delta T.

[0182] This algorithm is similar to "5. Maximum supply-side delta T with constant temperature distance and constant load side delta T" above, the difference being that T 供应、进 and T 载荷、出 The temperature distance between them can be varied to maximize the supply-side delta T(T) 供应、进 –T 供应、出 (The absolute difference between them). The load side can also vary according to current real-time requirements.

[0183] The controller will check the modified flow rate. If the approximate temperature on the load side or supply side is below T... 最下距 Then the algorithm will limit F 供应 Any further reduction in temperature. This prevents the approach temperature from becoming too low when the capacity calculation is invalid.

[0184] For each application, the algorithm has three setting parameters that are set at the factory and modified on-site as needed.

[0185] i)T 载荷、出、重置 ​This parameter defaults to 3F (or equivalent Celsius) at 30% of the working load and 0F (or equivalent Celsius) at 100% of the working load, and varies linearly between these two points.

[0186] ii. T 最小、距 This parameter is a limiting factor that can be adjusted between 1F and 20F, with a default value of 1.5F (or equivalent Celsius).

[0187] iii) F 载荷、转换、最小 This is a parameter setting that continues until the load-side supply temperature resets to its maximum value.

[0188] Supply-side flow is determined by the following methods: 1. Read the temperature and flow rate at the hot and cold side inlet and outlet (4 temperatures and 2 flow rates). Extract readings at a set frequency (e.g., 1 minute).

[0189] 2. Calculate the current heat load requirement (load side) using the following formula: Q 载荷 = C(p, t) × m × abs(T) 进 –T 出 ) = C 载荷 × ρ 载荷 × F 载荷、测量值 × abs(T 载荷、出、测量值 –T 载荷、进、测量值 ), in, ρ load is T 载荷、出、测量值 – T 载荷、进、测量值 Fluid density at average value, C 载荷 It is T 载荷、出、测量值 – T 载荷、进、测量值 The specific heat capacity of the fluid on the load side at the average value.

[0190] 3. Determine T 载荷、出、目标值 and T 载荷、进、目标值 .

[0191] Calculate the maximum variance: T 转换、最大 = max(l –(F) 载荷、测量值 – F 载荷、转换、最小 ) / (F 载荷、设计值 – F 载荷、转换、最小 ))×(T 载荷、出、重置 ), 0).

[0192] For cooling, T 载荷、出、目标值 = T 供应、进、测量值 +(T)载荷、出、设计值 – T 供应、进、设计值 + / - Variance + T 转换、最大 .

[0193] For heating, T 载荷、出、目标值 = T 供应、进、测量值 +(T) 载荷、出、设计值 – T 供应、进、设计值 + / - variance – T 转换、最大 .

[0194] The purpose of variance is to compensate for measurement inaccuracies, and variance can range from 0F to 20F degrees (or equivalent degrees Celsius). The default value is 0.5F (or equivalent degrees Celsius).

[0195] 4. Determine the target load side flow F 载荷、目标值

[0196] Use F 载荷、测量值 F 供应、进、测量值 And T 载荷、出、目标值 and T 载荷、进、目标值 We solve F using the following rules. 供应、目标值 : I. Initial guess F 供应、目标值 F 供应、目标值 = Q 载荷 / 载荷、设计值 × F 供应、设计值 .

[0197] II. Calculate T 供应、出、目标值

[0198] For cooling mode (T) 供应、进、测量值 < T 供应、出、测量值 And T 载荷、出、测量值 < T 载荷、进、测量值 ): T 供应、出、目标值 = T 供应、进、测量值 + Q 载荷 / (ρ 供应 × C 供应 × F 供应、目标值 ).

[0199] For heating mode (T) 供应、进、测量值 > T 供应、出、测量值 And T 载荷、出、测量值 > T 载荷、进、测量值 ): T 供应、出、目标值 = T 供应、进、测量值 – Q 载荷 / (ρ 供应 × C 供应 × F 供应、目标值 ).

[0200] III. Using F 供应、目标 T 供应、进、测量值 T 供应、出、目标值 F 载荷、测量值 T 载荷、出、测量值 and T 载荷、进、测量值 To calculate Q HX .

[0201] IV. If abs(Q) HX –Q 载荷 ) / Q 载荷 If < 0.01, then our F is determined. 供应、目标值 .

[0202] Otherwise, record F. 高 and F 低 .

[0203] a. In the first iteration, F 高 =The maximum full-speed flow rate of the supply-side pump, and F 低 = 0.

[0204] If Q HX Q 载荷 Then F 低 Updated to equal F 供应、目标值 Choose F, which is 20% larger than previously guessed. 供应、目标值 And return to step I.

[0205] If Q HX Q 载荷 Then F 高 Updated to equal F 供应、目标值 Choose F, which is 20% smaller than previously guessed. 供应、目标值 And return to step I.

[0206] b. If Q in step a HX Q 载荷， And Q HX Q 载荷 , will F 低 Updated to equal F 供应、目标值 Choose F, which is 20% larger than previously guessed. 供应、目标值 And return to step I.

[0207] If Q in step a HX Less than Q 载荷 And Q HX Q 载荷 Continue to step c, until the remaining step 4.

[0208] If Q in step a HX Q载荷， And Q HX Q 载荷 , will F 高 Updated to equal F 供应、目标值 Choose F, which is 20% smaller than previously guessed. 供应、目标值 And return to step I.

[0209] If Q in step a HX Q 载荷 And Q HX Q 载荷 If so, continue to step c, until the remaining step 4.

[0210] c. In subsequent iterations, If Q HX Q 载荷 Then F 低 Updated to equal F 供应、目标值 Select the new F 供应、目标值 For (F) 高 + F 供应、目标值 ) / 2, and return to step I.

[0211] If Q HX Q 载荷 Then F 高 Updated to equal F 供应、目标值 Select the new F 供应、目标值 =(F 低 + F 供应、目标值 ) / 2, and return to step I.

[0212] V. If abs(T) 供应、出、目标值 – T 载荷、进、测量值 ) <T 最小 The method then proceeds to step 3, and if T 转换、最大 If -0.5F > 0, then adjust T. 转换、最大 Reduce by 0.5F.

[0213] Otherwise, we have already determined our F 载荷、目标值 .

[0214] Figure 13A flowchart of an example method 1300 for feedforward loop control of one of heat transfer systems 300, 320 according to an example embodiment is shown. One or more processors may display a graphical user interface for selecting components of heat transfer systems 300, 320. At step 1302, one or more processors may receive a design setpoint for building 104. As a suitable recommendation for installation in building 104, one or more specific models of components of building system 100, including load-side control pump 102, supply-side control pump 122, and heat exchanger 118 (or heat exchanger modules 220, 230), are output to a display screen. At step 1304, one or more processors receive a selection of a desired model of load-side control pump 102, supply-side control pump 122, and heat exchanger 118 (or heat exchanger modules 220, 230), and install and operate these components in building system 100.

[0215] Step 1306 and subsequent steps can be performed by controller 116 and / or HX card 222 and / or PC card 226. At step 1306, controller 116 detects at least one variable from at least one sensor relative to each of the supply and load sides of heat exchanger 118. At step 1308, controller 116 applies a mathematical model between at least one parameter to be controlled and at least one variable. At step 1310, controller 116 uses a feedforward control loop based on the mathematical model and the detected at least one variable to control the flow rate of load-side control pump 102 and / or supply-side control pump 122 to achieve control of at least one parameter.

[0216] For heat transfer systems 300 and 320: (A) Energy impact prediction: Scaling effect can be used to calculate excessive pressure loss and increase in pumping energy due to scaling in each fluid loop; (B) Based on the scaling in systems 300 and 320, heat exchanger 118 will be automatically flushed to reduce performance loss; (C) It can assess the impact of self-flushing / cleaning over time and predict the percentage impact of flushing (to assess temporary or permanent scaling). (D) In ​​some examples, the rinsing / self-cleaning cycle can be set to an unplanned time until the dirt reaches a level of severity beyond which emergency cleaning will occur; (E) An economic trigger for on-site cleaning (chemical) by service personnel can be sent via notification; (F) One heat exchanger of the isolated heat transfer module is used for in-situ cleaning or servicing, while the remaining heat exchangers 118 continue to provide services (heat transfer function service) to the building 104. (G) The rate of scaling can be automatically learned to tend toward a predetermined cleaning date, thus allowing scheduled maintenance cleaning instead of emergency cleaning.

[0217] Figure 4A It shows a method for use in buildings such as 104 ( Figure 1B The graph 400 shows example heat load profiles for loads such as 110a, 110b, 110c, and 110d, for example, for a planned or measured “design day.” The load profiles show the percentage of operating time versus the percentage of heat load (heat load refers to either hot or cold load). For example, as shown, many example systems may need to operate at only 0% to 60% of their load capacity for 90% or more of the time. In some examples, pump 102 may be selected to operate at or around 50% of its peak load for optimal efficiency. Note that the American Society of Heating, Refrigerating and Air-Conditioning Engineers (RTM) 90.1 energy efficiency standard requires that the control unit require pump motor demand of no more than 30% of the design wattage at 50% of the design water flow (e.g., 70% energy saving at 50% of peak load). Heat load can be measured in BTU / hr (or kW). It should be understood that a “design day” may not be limited to 24 hours but can be determined as a shorter or longer system period, such as a month, a year, or many years.

[0218] Similarly, Figure 4B It refers to building 104 (for the planned or measured "design date"). Figure 1B Figure 420 shows the example flow load profiles for loads 110a, 110b, 110c, and 110d of building 104. Figure 1B The loads 110a, 110b, 110c, and 110d define the pumping energy consumption. Example embodiments relate to optimizing the selection of heat exchanger 118, control pumps 102 and 122, and other devices of building system 100 when building 104 operates at less than 50% (100%) of its operating capacity flow rate most of the time.

[0219] Pumps 102 and 122 can be selected and controlled to optimize them for partial loads rather than 100% loads. For example, controlling pumps 102 and 122 can cause the corresponding variable controllable motors to be controlled along a head versus flow rate “control curve”, thereby maximizing energy efficiency (e.g., 50%) during partial load operation of a particular system, as shown in load profile graph 400. Figure 4A ) or load profile curve 420 ( Figure 4B In this case, other example control curves can use different parameters or variables.

[0220] Figure 5An example embodiment of a method for controlling a first control pump 102a is shown. Figure 1A and Figure 1B A detailed block diagram of an example of the first control device 108a is shown. A second control pump 122 having a second control device 108b can be constructed in a similar manner to the first control pump 102 and has similar components. The first control device 108a can be embedded in a PC card 226. The first control device 108a may include one or more controllers 506a, such as a processor or microprocessor, that control the overall operation of the control pump 102. The control device 108a can communicate with other external controllers 116 or the HX card 222 of the heat exchanger 118, or other control devices (one shown, referred to as the second control device 108b), to coordinate the control of pumps 102, 122, etc. Figure 1A and 1B The controlled total output characteristic 114 of the controller 506a. The controller 506a interacts with other device components, such as memory 508a, system software 512a stored in memory 508a for executing application programs, input subsystem 522a, output subsystem 520a, and communication subsystem 516a. Power supply 518a supplies power to the control device 108a. The second control device 108b may, where appropriate, have the same, more, or fewer blocks or modules as the first control device 108a. The second control device 108b interacts with components such as the second control pump 122 (…). Figure 1A and 1B The second device is associated with ).

[0221] Input subsystem 522a can receive input variables. Input variables may include, for example, sensor information or information from device detector 304 (FIG. 3). Other example inputs may also be used. Output subsystem 520a can control output variables, such as controlling one or more operable elements of pump 102. For example, output subsystem 520a may be configured to control at least the speed of the motor (and impeller) of pump 102 to achieve a desired output setpoint for temperature (T), thermal load (Q), head (H), and / or flow rate (F). Other example output variables, operable elements, and device characteristics may also be controlled. Touchscreen 530a is a display screen that can be used to input commands based on direct pressure from the user on the display.

[0222] The communication subsystem 516a is configured to communicate directly or indirectly with another controller 116 and / or the second control device 108b. The communication subsystem 516a can also be configured for wireless communication. The communication subsystem 516a can also be configured for direct communication with other devices, which may be wired and / or wireless. Examples of short-range communication are Bluetooth (RTM) or direct Wi-Fi. The communication subsystem 516a can be configured to communicate over networks such as wireless local area networks (WLANs), wireless (Wi-Fi) networks, public terrestrial mobile networks (PLMNs) (using a user identity module card), and / or the Internet. These communications can be used to coordinate the control of pumps 102, 122 ( Figure 1A and 1B (The operation of )

[0223] Memory 508a can also store other data, such as load profile curves 400 (Figure 4) or 420 (Figure 4) for the "design date" or average annual load used for measurement. Figure 4B ). Memory 508a can also store information related to the system or building 104 ( ). Figure 1A and 1B Other relevant information, such as height, flow capacity, and other design conditions. In some example embodiments, memory 508a may also store performance information of some or all of the other devices 102 in order to determine the appropriate combination of outputs to achieve the desired setpoint.

[0224] Figure 7AA flowchart of an example method 700 for automatically maintaining a heat exchanger 118 according to an example embodiment is shown. Method 700 is executed by a controller 116 (which, in this example, may include processing performed by an HX card 222). At step 702, the controller 116 operates control pumps 102 and 122 across the heat exchanger 118 based on system loads 110a, 110b, 110c, and 110d. At step 704, when system loads 110a, 110b, 110c, and 110d are supplied, the controller 116 determines, based on real-time operational measurements, that maintenance (i.e., flushing) of the heat exchanger 118 is required. At step 706, the controller 116 performs automatic maintenance (flushing) on ​​the heat exchanger 118 by controlling the flow rate to a maximum flow rate. In various examples, the maximum flow rate can be controlled by adjusting pumps 102, 122 to their respective maximum flow capacity, or the maximum flow rate supported by loads 110a, 110b, 110c, 110d (i.e., operating loads), or the maximum flow capacity of heat exchanger 118. The maximum flow rate is used to flush out scale in heat exchanger 118. In an example embodiment, step 706 can be performed during the real-time supply of system loads 110a, 110b, 110c, 110d to address the increase in flow rate with appropriate compensation. At step 708, controller 116 determines whether the flushing from step 706 was successful; if so, method 700 returns to step 702. If not, controller 116 alerts another device, such as BAS 302 or smart device 304, that manual inspection, repair, or replacement of heat exchanger 118 is required.

[0225] Another example of automatic maintenance and flushing of heat exchanger 118 is controlling one or both of control pumps 102, 122 to a maximum flow rate and controlling one or both of control pumps 102, 122 from the maximum flow rate, for example, between the maximum flow rate and another specified flow rate level. In another example, this control between the two flow rates is a sine function.

[0226] Another example of automated maintenance and flushing of heat exchanger 118 is controlling one or both of control pumps 102, 122 to provide a pulsation of flow. In one example, controller 116 sets the flow rate of control pumps 102, 122 to a specified flow level, and then controls control pumps 102, 122 to return to that specified flow level with short bursts of increased flow. In some examples, the current desired flow rate already used to supply system loads 110a, 110b, 110c, 110d (for building 104) is controlled to increase the flow rate with short bursts and quickly return to the current desired flow rate. This maintenance is less disruptive and can be performed during normal operation of building 104 and during the supply of system loads 110a, 110b, 110c, 110d. An example of a burst is increasing the flow rate from a specified flow level to an increased flow level within a specified time period, then returning to the specified flow level within a second specified time period, and repeating this process for a third specified time period or until a successful flush is detected.

[0227] If the pulse determining the flow rate is ineffective for flushing heat exchanger 118, in some examples, controller 116 may then perform automatic maintenance using the maximum flow rate of one or both of the control pumps 102, 122 through heat exchanger 118. Effectiveness or success (as opposed to ineffectiveness or failure) can be determined by a variable of heat exchanger 118 exceeding a threshold, which is the heat transfer coefficient (U) of heat exchanger 118, the delta pressure across heat exchanger 118, or the heat transfer capacity of heat exchanger 118.

[0228] Step 704 will now be described in more detail. Figure 7B , 7C Different alternative example embodiments of step 704 are outlined in 7D. Figure 7BIn step 722, controller 116 compares the real-time operational measurements of heat exchanger 118 with a new, clean heat exchanger 118 as a baseline. At step 722, controller 116 determines the baseline heat transfer coefficient (U) of the new, clean heat exchanger 118. Step 722 can be performed using test equipment, or it can be performed using runtime setup and commissioning when installed in building system 100, or both. At step 724, controller 116 determines the real-time heat transfer coefficient (U) of heat exchanger 118 while controlling pumps 102, 122 to operate in real-time to supply system loads 110a, 110b, 110c, 110d. At step 726, controller 116 performs a comparison calculation between the real-time heat transfer coefficient (U) of heat exchanger 118 and the baseline. In this example, the comparison calculation is a fouling factor calculation. At step 728, controller 116 determines whether the calculation meets the criteria. If yes, at step 730, controller 116 concludes that pumps 102 and 122 perform automatic maintenance on heat exchanger 118. If no, controller 116 cycles back to step 724, whereby the real-time heat transfer coefficient (U) of heat exchanger 118 is determined.

[0229] Figure 7C A flowchart illustrating an alternative example of step 704 is shown, which determines that control pumps 102, 122 will perform maintenance on heat exchanger 118. In this example, controller 116 compares real-time operating measurements of heat exchanger 118 to a baseline of a freshly cleaned heat exchanger 118. At step 740, maintenance (flushing) of heat exchanger 118 has been completed. In other examples, at step 740, the system has already operated at full load (full flow) for a specified time period, which has a similar effect. At step 742, controller 116 determines the baseline heat transfer coefficient (U) of the freshly cleaned heat exchanger 118. Step 742 can be performed while still supplying loads 110a, 110b, 110c, 110d to building system 100. At step 744, controller 116 determines the real-time heat transfer coefficient (U) of heat exchanger 118 while controlling pumps 102 and 122 to operate in real-time to supply system loads 110a, 110b, 110c, and 110d. At step 746, controller 116 calculates a comparison between the real-time heat transfer coefficient (U) of heat exchanger 118 and a baseline. At step 748, controller 116 determines whether the calculation meets a criterion; if so, at step 750, controller 116 concludes that pumps 102 and 122 perform automatic maintenance on heat exchanger 118. If not, controller 116 cycles back to step 744, whereby the real-time heat transfer coefficient (U) of heat exchanger 118 is determined.

[0230] Figure 7DA flowchart illustrating another alternative example of step 704 is shown, which determines that control pumps 102, 122 will perform maintenance on heat exchanger 118. In this example, controller 116 determines that heat exchanger 118 has been operating continuously under partial load for a specified period of time and therefore requires flushing. At step 760, controller 116 resets a timer. At step 762, controller 116 determines whether heat exchanger 118 has been operating continuously under partial load, which can be any partial load or a specified maximum value, such as up to 90% of full load. If so, timer 764 is started at event 764. If not, controller 116 cycles back to step 760. At step 766, controller 116 determines whether the partial load has occurred continuously for a specified period of time, such as at least 7 days. If so, at step 768, controller 116 concludes that control pumps 102, 122 will perform automatic maintenance on heat exchanger 118. If not, this means that loads 110a, 110b, 110c, and 110d are operating at full load (full flow) regardless, so controller 116 cycles back to step 760 and resets the timer again.

[0231] In another alternative embodiment of step 704, controller 116 is configured to determine that heat exchanger 118 requires maintenance due to fouling by: predicting the actual current heat transfer coefficient (U) of heat exchanger 118 based on previous measurements from flow, pressure, and / or temperature sensors during real-time operation measurements while supplying variable loads; and calculating a comparison between the predicted actual coefficient value of heat exchanger 118 and the cleanliness coefficient value of heat exchanger 118. This prediction can be performed based on: previous actual measurements; first-principles considerations of the physical properties of the device; test data from test equipment, sensor data from previous actual operations, or other previously stored data from one or more actual devices having the same or different physical properties; and / or machine learning. Examples of predictable parameters for heat exchanger 118 include: flow capacity, fouling factor (FF), heat transfer capacity (Qc), and heat transfer coefficient (U). This prediction can be based on inferring future performance and parameters of the heat exchanger from past readings and calculations using a polynomial fit over time.

[0232] Performance parameter services can be provided by controller 116. Example trend data (or coefficients) provided by the performance management service are the heat transfer capacity (Qc) or heat transfer coefficient (U-value) of heat exchanger 118, and the future heat transfer capacity or heat transfer coefficient of heat exchanger 118 based on trendline analysis over time, historical data from the same or similar pumps 100, 102, or mathematical calculations. The remaining service life of the heat transfer capacity or heat transfer coefficient of each heat exchanger 118 (which would result in no intervention, such as automatic or manual maintenance) can also be determined by controller 116. Similar trend data regarding fouling factor (FF) and heat transfer coefficient (U) (over time, and for future plans) can be provided.

[0233] Refer again Figure 7A Step 706 (performing automated maintenance on heat exchanger 118) will now be described in more detail. Step 706 is typically performed during the real-time supply of loads 110a, 110b, 110c, and 110d. Step 706 can be performed without disassembling heat exchanger 118 or without providing a bypass loop for heat exchanger 118. In one example, both pumps 102 and 122 operate simultaneously at full load flow (or full permissible load) for 30 minutes. In another example, both pumps 102 and 122 operate sequentially at full load flow (or full permissible load), one at a time (e.g., each for 30 minutes). In other example embodiments, instead of full flow, pumps 102 and 122 can be controlled to alternate between a specified flow rate sequence, such as 90% flow and full flow, to help remove scale. In other example embodiments, such as when loads 110a, 110b, 110c, and 110d are biaxial loads, pumps 102 and 122 can be controlled to provide reflux to heat exchanger 118. The reflux can be performed alone or as part of a specified flow sequence.

[0234] In another example, maintenance of heat exchanger 118 applies only to one fluid path. For example, when there is fluid from cooling tower 124 ( Figure 1A or hot, dirty geothermal water ( Figure 1J When supplying fluid, automatic maintenance can be performed by only one pump 122 on the supply side to flush only the supply fluid path, which may contain a large amount of dirt.

[0235] In another example, step 706 can be delayed to a suitable off-duty time, such as on weekends or after get off work, where the variable changes in maintenance traffic will be less noticeable and the instantaneous loads 110a, 110b, 110c, and 110d will be more predictable.

[0236] Refer again Figure 7AStep 708 (determining whether flushing was successful) will now be described in more detail. Step 708 may be the same calculation as step 724 or step 744. Step 708 may be the calculation or determination of the real-time heat transfer coefficient (U) of heat exchanger 118 as a new baseline coefficient (U) during the real-time operation of control pumps 102, 122 to supply system loads 110a, 110b, 110c, 110d. Therefore, immediately following the flushing performed at step 706, controller 116 calculates the current heat transfer coefficient (U) of heat exchanger 118 and compares it with the baseline coefficient (U). If the calculation between the current heat transfer coefficient (U) and the baseline coefficient (U) (e.g., fouling factor, percentage difference, ratio, etc.) exceeds a threshold difference, the flushing is unsuccessful, and an alarm is sent in step 710. In some examples not shown, when a flushing failure is detected, a second flush (as shown in step 706) may be performed one or two more times. If the calculation falls within the threshold difference, the flushing is successful, and at step 702, the heat exchanger 118 and pumps 102, 122 operate as usual to supply loads 110a, 110b, 110c, 110d. Based on this calculation, the controller 116 can output a notification related to the success or failure of the flushing of the scale on the heat exchanger to a display screen or another device.

[0237] Figure 7A Method 700 can be applied to: a heat exchanger module with a single heat exchanger 118; a heat exchanger module 220 with two heat exchangers 118a, 118b. Figure 2B ); and a heat exchange module 230 with three heat exchangers 118, 118b, 118c ( Figure 2C This can be a heat exchanger module 220 or 230, or a heat exchanger module 118 with three or more heat exchangers 118. In some examples, method 700 may use the heat transfer coefficient (U) of the entire heat exchanger module 220, 230, instead of individual heat exchangers 118. In other examples, method 700 may use the heat transfer coefficient (U) of individual heat exchangers 118a, 118b, 118c. By monitoring individual heat exchangers 118a, 118b, 118c, controller 116 can determine that only one of the individual heat exchangers 118a, 118b, 118c in heat exchanger module 230 requires automatic maintenance (flushing). Controller 116 can also determine whether only one individual heat exchanger 118a, 118b, 118c in heat exchanger module 230 requires manual repair, replacement, maintenance, chemical flushing, etc.

[0238] For example, when performing step 706 (automatic maintenance of heat exchanger 118), flushing can be performed on individual heat exchangers 118a, 118b, 118c, for example, by opening or closing applicable valves 224 via controller 116 (or HX card 222). In one example, fewer than all of the individual heat exchangers 118a, 118b, 118c may be fouled, and only heat exchangers 118a, 118b, 118c require flushing. In other examples, when the entire heat exchanger module 230 requires flushing, each individual heat exchanger 118a, 118b, 118c can be flushed one at a time (or fewer than all at a time). By opening fewer than all of the individual heat exchangers 118a, 118b, 118c, this partial operation of heat exchanger module 230 can bias the increased flow rate of pumps 102, 122 to full flow rate (which is typically a partial load and does not require full flow rate) when supplying variable loads in real time.

[0239] Figure 8 Graph 800 shows simulation results of the braking horsepower of control pumps 102, 122 operating through various heat exchangers with varying fouling factors as a function of time. The y-axis is braking horsepower (or watts). The x-axis is time. Plot line 802 represents the braking horsepower for a clean, ideal configuration and remains horizontal over time as shown in graph 800. Plot line 804 represents the braking horsepower of a heat exchanger 118 with automatic maintenance according to an example embodiment. Plot line 804 shows a fouling factor (FF) of 0.0001 after a period of time. Other plotted lines are shown for scenarios without automatic maintenance. Plot lines 806, 808, and 810 show the higher fouling factor of the heat exchanger and the higher braking horsepower of control pumps 102, 122 when operating at higher demand pressures (in PSI or Pa) and flow rates (in gallons per minute (GPM) or liters per minute) without automatic maintenance. Circle 812 is a detailed view of curve diagram 800, which shows in line 804 that when automatic flushing is present, vertex 814 occurs, and thus the required braking power is reduced after each flush.

[0240] In the example, a plotted line on graph 800 is drawn based on actual measurements from one or more sensors. In some examples, any or all of the following are used: actual measurements; first-principles considerations of the physical properties of the device; test data from test equipment, sensor data from actual operation, or other previously stored data from one or more actual heat exchangers with the same or different physical properties; and / or machine learning. The plotted line can be predicted by controller 116 to determine future parameters of the heat exchanger over time (or at a specific future time). These parameters may include, for example, flow capacity, fouling factor (FF), heat transfer capacity (Qc), and heat transfer coefficient (U). In the example, functions such as polynomial equations, such as quadratic polynomials or higher-order polynomials, can be used to determine and represent the plotted line.

[0241] For example, controller 116 can be configured to calculate and predict parameters of the heat exchanger, such as current flow capacity, fouling factor (FF), heat transfer capacity (Qc), and heat transfer coefficient (U). Given a fouling rate or amount, controller 116 can be configured to calculate and predict future parameters of the heat exchanger. Controller 116 can be configured to calculate and predict heat exchanger parameters to further account for accumulated fouling, instances of flushing (as described herein, manually or automatically), instances of chemical washing, etc. For example, line 408 illustrates that even with automatic flushing, a small amount of fouling can still occur. Historical information and historical performance responses of the heat exchanger or other heat exchangers can be used for prediction. In some examples, controller 116 can compare actual sensor information and calculated parameters of the heat exchanger with predicted parameters to provide a data training set for future predictions by controller 116.

[0242] In some examples, controller 116 may be configured to predict and recommend when (which day) maintenance of heat exchanger 118 is required based on trend lines or other analyses. This prediction and recommendation may be based on a user-defined percentage of useful heat transfer capacity or remaining heat transfer coefficient, a specified percentage of heat transfer capacity or remaining heat transfer coefficient, or other predictive calculations.

[0243] Figure 9A graph 900 shows the test results of the heat transfer coefficient (U-value) versus the flow rate of the clean heat exchanger 118. This test is performed before the transport and / or installation of the heat exchanger 118. The solid line 902 represents the measured U-value. The dashed line 904 represents a polynomial fit of the measured U-value. In this example, the coefficients of the solid line 902 can be stored in memory and can be directly compared to real-time measurements (at the same or interpolated flow rate). In this example, the polynomial fit of the dashed line 904 is a quadratic polynomial, but it could also be a higher-order polynomial, depending on the desired amount of fit, or other equations or models. Another example variable that can be tested and determined is the heat transfer capacity of the clean heat exchanger 118, and the heat transfer capacity of the heat exchanger 118 subsequently determined during use.

[0244] To determine the measured U-value of solid line 902, performance mapping was performed using test equipment under the operating conditions and an alternative condition with a different temperature. Supply flow rate (F) 供应 ) and load flow (F 载荷 The values ​​are varied proportionally to operate at 100%, 90%, 80%, 70%, 60%, 50%, 40%, and 30% of the total operating flow to determine the U value.

[0245] Performance is mapped for each heat exchanger 118, and the data is stored on HX card 222 and cloud 308, with the stored data linked to the unique serial numbers of heat exchangers 118a, 118b, and 118c. When heat exchangers 118a, 118b, and 118c are installed or assembled onto heat transfer module 230, the performance mapping for each heat exchanger 118a, 118b, and 118c is uploaded to the cloud server and stored in HX card 222. This testing is performed at the factory on test equipment prior to the transport and / or installation of heat transfer module 230. In other examples, this test equipment is performed at a third-party testing facility. The required capacity for the test equipment can be up to 600 gpm (or liters per minute) and up to 15,000,000 Btu / hr (or kW) at a liquid temperature difference of 20°F (or equivalent Celsius).

[0246] Then, at various flow rates, the clean U-value can be compared using heat exchanger 118 and control pumps 102, 122 with the real-time calculated U-value determined during real-time supply of loads 110a, 110b, 110c, 110d. Polynomial fitting, based on first principles of the heat exchanger's physical characteristics and / or predicted future performance, can be used to determine the expected U-value of the heat exchanger during real-time operation and variable load supply. Interpolation can also be performed between specially tested flow rate values.

[0247] In some examples, controller 116 may be configured to predict and recommend the heat transfer capacity or coefficient of heat exchanger 118 after performing automatic maintenance based on trend lines or other analyses.

[0248] The heat transfer coefficient U of the clean heat exchanger 118 can be calculated as follows: U 清洁 = Q 平均 / (A × LMTD) Among them, Q 平均 This is the average value of the heat transfer measured across the load fluid path and the supply fluid path, as shown below: Q 平均 =(Q 载荷 + Q 供应 ) / 2 Q can be calculated based on the measurements from the flow sensor and temperature sensor. 载荷 As shown below (for Q) 供应 Perform similar calculations). Q 载荷 = C × m × abs(T 进 –T 出 ) = C 载荷 × ρ 载荷 × F 载荷、测量值 × abs(T 载荷、出、测量值 –T 载荷、进、测量值 ), in, C is the specific heat capacity based on pressure and temperature. m is the mass flow rate. F 载荷 It is the load flow rate. ρ 载荷 It is T 载荷、出、测量值 –T 载荷、进、测量值 Fluid density at average value, C 载荷 It is T 载荷、出、测量值 –T 载荷、进、测量值 The specific heat capacity of the fluid on the load side at the average value.

[0249] Heat transfer capacity (Qc) is the amount of heat energy that can be transferred across heat exchanger 118 under design conditions. As the heat transfer coefficient (U) decreases, the heat transfer capacity Qc also decreases. In system design, a minimum threshold of acceptable heat transfer capacity Qm is required. When Qc becomes less than Qm, cleaning, automatic maintenance (e.g., flushing), manual servicing, or replacement can be performed, and / or a warning can be issued.

[0250] In some examples, test equipment simulating flow and temperature conditions can be used to determine the heat transfer coefficient U. 清洁 Or heat transfer capacity (Qc). In some examples, when heat exchanger 118 is initially installed to serve system loads 110a, 110b, 110c, 110d, the heat transfer coefficient U can also be determined and calculated using real-time operation. 清洁 Or heat transfer capacity (Qc).

[0251] One or more operating points under operating conditions can be tested and then stored to the HX card 222. Such operating points include F... 供应、设计值 ;T 供应、进、设计值 ;T 供应、出、设计值 ;F 载荷、设计值 ;T 载荷、出、设计值 and T 载荷、进、设计值 Q 载荷、设计值 Fluid type supply; Fluid type load; P 供应、设计值 and P 载荷、设计值 It provides a specification for storing multiple sets of working conditions on the HX card 222, which can be edited.

[0252] Still referencing Figure 9 Instead of testing, in other examples, curve 900 can be determined by first-principles calculations, for example, based on the known dimensions of heat exchanger 118 (and brazing plate 202) and the fluid characteristics of the circulating medium.

[0253] Refer to step 724 ( Figure 7B ) and step 744 ( Figure 7C The calculation of the heat transfer coefficient (U) of heat exchanger 118 when the real-time supply system loads 110a, 110b, 110c, and 110d will now be described in more detail. A similar process can be performed when determining the clean heat transfer coefficient (U) of heat exchanger 118. Another example variable or coefficient of heat exchanger 118 that can be determined and analyzed according to the example embodiment is heat transfer capacity.

[0254] The amount of fouling in heat exchanger 118 can be output to a screen or transmitted to another device for displaying heat transfer performance. Performance can be represented by color coding, where green indicates a clean exchanger, yellow indicates some fouling, and red indicates the need for maintenance and cleaning. In this example, the handling of the heat exchanger fouling is completed by HX card 222 and sent to cloud 308 for output to the screen of smart device 304, or to BAS 302. The displayed data can be in imperial units (F, ft, gpm, BTU / h) and metric units (C, m, l / s, kW).

[0255] Heat exchange in fluids including water and up to 60% ethylene / propylene glycol mixtures can be calculated. Thermodynamic data for these fluids are available on the HX card 222, with a minimum increment of 5% for the ethylene glycol mixture.

[0256] The heat transfer calculation is as follows.

[0257] Q = m × C × (T) 进 –T 出 ), in, Q represents the heat transferred. C is the specific heat capacity as a function of pressure and temperature. m is the mass flow rate. Tin is the inlet temperature of the fluid flow. Tout is the outlet temperature of the fluid flow.

[0258] For heat exchangers: Q HX = U × A × (LMTD), in, Q HX The heat is transferred through a heat exchanger. U is the overall heat transfer coefficient of a specific heat exchanger. A is the heat transfer surface area (usually constant).

[0259] LMTD (Counterflow Layout) is defined by the following logarithmic mean temperature difference (sometimes the supply side is referred to as the hot side, and the load side as the cold side): LMTD = [(T 供应、进 – T 载荷、出 ) – (T 供应、出 – T 载荷、进 )] / ln[(T 供应、进 – T 载荷、出 ) / (T 供应、出 – T 载荷、进 )], in, T 供应、进 It is the inlet (to the heat exchanger) fluid temperature on the supply side. T 供应、出 It is the outlet fluid temperature (from the heat exchanger) on the supply side. T 载荷、进 It is the inlet (to the heat exchanger) fluid temperature on the load side. T 载荷、出 It is the outlet fluid temperature (from the heat exchanger) on the load side.

[0260] U 清洁 It is the overall heat transfer coefficient of an ideal heat exchanger with cleanliness, U污垢 This is the total heat transfer coefficient at a specific time during operation. The U-value can be adjusted during factory testing (under clean conditions) and mapped to the HX card 222. 清洁 (F) 供应 F 载荷 T 供应、进 T 供应、出 T 载荷、进 T 载荷、出 ) is a function specific to the selection and geometry of each heat exchanger, which is a mathematical formula and can be verified and mapped onto the HX card 222 during factory testing.

[0261] To determine the current value of U, U 污垢 : U 污垢 = Q 平均 / (A × LMTD) Among them, Q 平均 This is the average value of the heat transfer measured across the load fluid path and the supply fluid path, as shown below: Q 平均 =(Q 载荷 + Q 供应 ) / 2 Q has already been provided in the equation above. 载荷 and Q 供应 The calculation.

[0262] If U 污垢 Than U 清洁 If the value is more than 20% lower (or other suitable threshold), the HX card 222 will output a warning to devices such as BAS 302, cloud 308, and smart device 304.

[0263] In some examples, U should only be compared for a certain range of flow from 100% to 50% of the operating point. 清洁 and U 污垢 .

[0264] An example comparison for calculating heat transfer coefficients is the fouling factor (FF): FF = 1 / U 污垢 –1 / U 清洁 .

[0265] A lower FF is expected. In the example, when the FF is at least 0.00025, it is concluded that heat exchanger 118 should be maintained (flushed). An FF of 0.0001 can be considered acceptable and no maintenance is required. A baseline FF can also be calculated for cleaning heat exchanger 118.

[0266] Refer to step 724 ( Figure 7B ) and step 744 ( Figure 7C As an alternative to calculating the heat transfer coefficient (U), it is understood that other parameters or coefficients may be calculated by the controller 116 to determine whether maintenance of the heat exchanger 118 is required due to scaling and whether flushing maintenance is necessary.

[0267] In this example, the heat load (Q) or associated heat transfer capacity (Qc) can be used to determine the need for maintenance. Flow measurements can be received from a first flow sensor in the supply fluid path and a second flow sensor in the load fluid path. The flow measurement information from the flow sensors is used to determine that heat exchanger 118 requires maintenance due to fouling. The heat load (Q) can be calculated for each fluid path based on the corresponding flow rate and temperature. First, the clean heat load (Q) of each of the supply fluid path and load fluid path of heat exchanger 118 when it is in a clean state can be determined as a baseline. During the real-time supply of loads 110a, 110b, 110c, and 110d, real-time flow rate and temperature measurements can be determined from each of the supply fluid path and load fluid path of heat exchanger 118. The real-time heat load (Q) can be calculated from the real-time measurements. When the calculated difference exceeds a threshold, the comparison between the calculated baseline and the actual heat load (Q) can be used to determine the need for maintenance.

[0268] For example, if Q 供应 The change is greater than Q 载荷 If the change is greater than 10%, a warning will be issued to the user. In other words, if: Abs (Q) 供应 –Q 载荷 ) / max(Q 供应 –Q 载荷 > 0.10 This change can be taken from the running average of 100 consecutive readings. Any peaks can be filtered to avoid unstable control. Differences exceeding 3 standard deviations can be excluded.

[0269] In this example, pressure measurements can be used to determine when maintenance is required. A first differential pressure sensor detects the differential pressure across the supply fluid path. A second differential pressure sensor detects the differential pressure across the load fluid path. When heat exchanger 118 is in a clean state, a clean differential pressure value across each fluid path of heat exchanger 118 is determined as a baseline. When loads 110a, 110b, 110c, and 110d are supplied, the controller 116 determines the real-time measured differential pressure and calculates a comparison between the real-time measured value and the baseline. If the comparison exceeds a threshold difference, maintenance is required.

[0270] For example, if the pressure differential is 20% higher than the pressure drop curve across the clean heat exchanger, a warning is issued to indicate some scaling (yellow). If the pressure differential is 30% higher than the pressure drop curve across the clean heat exchanger, a warning is issued to indicate scaling (red).

[0271] In this example, temperature measurements can be used to determine if heat exchanger 118 requires maintenance. When in a clean state, the clean temperature difference across each of the supply fluid path and the second fluid path of heat exchanger 118 is established as a baseline. Controller 116 can determine the real-time temperature measurements and calculate a comparison between the actual temperature difference of heat exchanger 118 and the baseline temperature difference of heat exchanger 118. If the comparison exceeds a threshold difference, maintenance is required.

[0272] When there is more than one heat exchanger 118a, 118b, 118c within the heat transfer module 230, a temperature sensor on each heat exchanger 118a, 118b, 118c is used to monitor fouling on each heat exchanger. For each heat exchanger, the inlet and outlet fluid flow temperatures are measured. If the fluid flow temperature difference on a particular heat exchanger differs from the average fluid flow temperature difference across all heat exchangers by more than 1°F (or equivalent Celsius), a warning is issued to indicate fouling on that particular heat exchanger 118a, 118b, 118c, and it needs to be inspected or automatically flushed. In this example, more than 1000 consecutive readings must exist before a warning is issued.

[0273] Now for reference Figure 6 This illustration shows an example embodiment of a control system 600 for coordinating two or more control devices (shown as two), specifically a first control device 108a controlling pump 102 and a second control device 108b controlling pump 122. The same reference numerals are used for ease of reference. As shown, each control device 108a, 108b may each include controllers 506a, 506b, input subsystems 522a, 522b, and output subsystems 520a, 520b, for example, to control at least one or more operable device components (not shown here), such as the variable motors controlling pumps 102, 122.

[0274] A coordination module 602 is shown, which may be part of at least one of the control devices 108a, 108b, or may be such as controller 116. Figure 1B This is part of a separate external device such as . Similarly, it is inferred that applications 514a, 514b may be part of at least one of control devices 108a, 108b, or such as controller 116 ( Figure 1B It is part of a separate device, such as a coordination module 602. In the example, the coordination module 602 is in the HX card 222.

[0275] In operation, coordination module 602 coordinates control devices 108a, 108b to produce coordinated outputs. In the illustrated example embodiment, control devices 108a, 108b work together to meet certain requirements or share loads (e.g., one or more output attributes 114), and they infer values ​​for one or more of each device's output attributes by indirectly inferring them from other measured input variables and / or device attributes. This coordination is achieved using inference applications 514a, 514b that receive measured inputs to calculate or infer corresponding individual output characteristics (e.g., temperature, head load, head, and / or flow rate at each device) at each device 102, 122. From those individual output characteristics, individual contributions from each device 102, 122 to the load (individually to output characteristic 114) can be calculated based on system / building settings. From those individual contributions, coordination module 602 estimates the aggregate or combined attributes of one or more of the output characteristics 114 at the system loads of all control devices 108a, 108b. The coordination module 602 compares the setpoint of the combined output characteristics (typically temperature or pressure variables) and then determines how and by what intensity the operable elements of each control device 108a, 108b should be controlled.

[0276] It should be understood that, where appropriate, depending on the specific output attribute being calculated and taking into account the losses in the system, the total or combined output characteristic 114 can be calculated as a nonlinear combination of individual output characteristics.

[0277] In some example embodiments, when the coordination module 602 is part of the first control device 108a, this can be considered a master-slave configuration, where the first control device 108a is the master device and the second control device 108b is the slave device. In another example embodiment, the coordination module 602 is embedded in more control devices 108a, 108b than actually needed for fail-safe redundancy.

[0278] Still referencing Figure 6 In another exemplary embodiment, each control pump 102, 122 can be controlled to optimally optimize the efficiency of the respective control pump 102, 122 under partial load, for example, to maintain their respective control curves or reach the optimal efficiency point on their respective control curves. In another exemplary embodiment, each control pump 102, 122 can be controlled to optimally optimize the entire building system 100 and the design daily load profile 400. Figure 4A ) or load profile 420 ( Figure 4B ) efficiency.

[0279] Refer again Figure 1AThe pump assembly 106a can employ various types of pumps with variable speed control. In some example embodiments, the pump assembly 106a includes at least one sealed housing that houses the pump assembly 106a, which at least defines an input element for receiving circulating media and an output element for discharging circulating media. The pump assembly 106a includes one or more operable elements, including a variable motor that can be variably controlled from the control unit 108a to rotate at a variable speed. The pump assembly 106a also includes an impeller operatively coupled to the motor and rotating based on the motor's speed to circulate the circulating media. Depending on the type of pump assembly 106a, the pump assembly 106a may also include additional suitable operable elements or features. Some device characteristics of the pump assembly 106a, such as motor speed and power, can be detected automatically by internal sensors of the control unit 108a.

[0280] Refer again Figure 1A The control devices 108a, 108b for each control pump 102, 122 may include internal detectors or sensors, commonly referred to in the art as “sensorless” control pumps because no external sensors are required. The internal detectors may be configured to self-detect, for example, device characteristics, such as the power and speed of pump device 106a. Other input variables may be detected. Depending on the internal detectors, the pump speed of pump devices 106a, 106b may be varied to achieve pressure and flow setpoints, or temperature and thermal load setpoints, for pump device 106a. Program mapping may be used by the control devices 108a, 108b to map the detected power and speed to final output characteristics, such as head output and flow output, or temperature output and thermal load output.

[0281] The relationship between parameters can be approximated by specific similarity laws, which can be influenced by volume, pressure, and braking horsepower (BHP) (hp / kW). For example, for a change in impeller diameter at a constant speed: D1 / D2 = Q1 / Q2; H1 / H2 = D1 2 / D2 2 BHP1 / BHP2 = D1 3 / D2 3 For example, with a constant impeller diameter for changes in velocity: S1 / S2 = Q1 / Q2; H1 / H2 = S1 2 / S2 2 BHP1 / BHP2 = S1 3 / S2 3Where: D = impeller diameter (Ins / mm); H = pump head (Ft / m); Q = pump capacity (gpm / lps); S = speed (rpm / rps); BHP = brake horsepower (shaft power – hp / kW).

[0282] Variations may be made in the exemplary embodiments disclosed herein. Some exemplary embodiments can be applied to any variable speed device and are not limited to variable speed controlled pumps. For example, some other embodiments may use different parameters or variables, and may use more than two parameters (e.g., three parameters on a three-dimensional map, or N parameters on an N-dimensional map). Some exemplary embodiments can be applied to any device that depends on two or more related parameters. Some exemplary embodiments may include variables that depend on parameters or variables such as liquid, temperature, viscosity, suction pressure, site height, and the number of operations of the device or pump.

[0283] Figure 10 A graph 1000 shows an example operating range and selection range (design point region 1040) for variable speed control pumps 102 and 122 used in a heat transfer system. The following discussion pertains to control pump 102, and a similar process can be applied to control pump 122. Efficiency curves (expressed as percentages) are shown from the lower left to the upper right, and in this example, a peak efficiency curve of 78% is shown.

[0284] Operating range 1002 is shown as a polygonal region or area on graph 1000, wherein the region is defined by a boundary representing a suitable operating range 1002. Design point region 1040 is within operating range 1002 and includes a boundary representing a suitable range of selections for design points of a particular control pump 102, 122. Design point region 1040 may be referred to as a “range of selection,” “compound curve,” or “design envelope” for a particular control pump 102, 122. In some example embodiments, design point region 1040 may be used to select an appropriate model or type of control pump 102, 122, which is optimized for partial load operation based on a particular design point. For example, a design point may be, for example, the maximum expected system load, such as the full load operating flow rate shown by point A (1010), which is the flow rate of a system such as building 104 ( Figure 1B This is required by systems such as [system name missing]. With the help of a graphical user interface, the user can select (e.g., click) design points of building 104 on graph 1000, and any control pumps 102 that overlap with the design point area 1040 are output to the graphical user interface because these control pumps are considered to be suitable for the specific design points of building 104.

[0285] The design point can be estimated by the system designer based on the maximum flow rate (operating flow rate) required for efficient operation and the head / pressure loss required to pump the design flow rate through the system piping and fittings. Note that because pump head estimates can be overestimated, most systems will never reach the design pressure and will exceed the design flow rate and power. Other systems where the designer underestimates the required head will operate at pressures higher than the design point. For such cases, a key feature of appropriately selecting a smart variable speed pump is that it can be appropriately adjusted to deliver more flow rate and head into the system than the designer specified.

[0286] Graph 1000 includes axes that incorporate relevant parameters. For example, head squared is proportional to flow rate, and flow rate is proportional to velocity. In the example shown, the horizontal axis or x-axis 1004 represents flow rate in US gallons per minute (GPM) (or liters per minute), while the vertical axis or y-axis 1006 represents head (H) in feet (or pounds per square inch (psi) or meters). Operating range 1002 is a superimposed representation of the control pumps 102, 122 relative to those parameters on graph 1000.

[0287] like Figure 10 As shown, one or more control curves 1008 (one shown) can be defined and programmed for intelligent variable speed devices such as control pump 102. Depending on changes in detected parameters (e.g., externally or internally detected changes in flow / load), the operation of control pumps 102, 122 can be maintained on the same control curve 1008 based on instructions from control devices 108a, 108b (e.g., at higher or lower flow points). This control mode can also be referred to as secondary pressure control (QPC) because control curve 1008 is a quadratic curve between two operating points (e.g., point A (1010): maximum head and point C (1014): minimum head that can be calculated as 40% of the maximum head). References to "intelligent" devices herein include the ability of control pumps 102, 122 to self-regulate their operation along control curve 1008 according to specific requirements or detected loads. The thicker areas on control curve 1008 represent the average load when operating to supply building 104.

[0288] Design point area 1040 can be optimized for selecting appropriate control pumps 102, 122 via a graphical user interface, taking into account the heat exchanger 118 in system 100. Given... Figure 10An example embodiment is a method executed by controller 116 for selecting a variable speed device from a plurality of such variable speed devices, such as one or two controlled pumps 102, 122, which have variable controllable motors to supply system loads. The control curve information of the variable speed device depends at least on a first parameter (e.g., head) and a second parameter (e.g., flow rate), which are correlated. The method may include displaying a graphical user interface on a display screen. The method includes: determining a design point for the rated total system load for the first parameter and for the rated total system load for the second parameter; determining the additional capacity required for the rated total system load of the first or second parameter to account for changes in system resistance of the system load caused by heat exchanger 118; and outputting (e.g., displaying) one or more variable speed devices, taking into account heat exchanger 118, that minimally meet the additional capacity required to supply the system load. The method may include selecting one of the variable speed devices via a graphical user interface or receiving a selection of one of the variable speed devices. The method may include installing and operating the selected variable speed device in building system 100.

[0289] In some examples, additional capabilities include power capacity available from the variable speed device to account for the pressure increase caused by the heat exchanger 118. Determining the design point may include receiving the design point via a graphical user interface. In some examples, additional capabilities include heat transfer capacity.

[0290] Now for reference Figure 11A , 11B Figures 11 and 11C show different design envelopes (selection ranges) for selecting candidate heat exchangers 118 to be installed in system 100 from multiple heat exchanger models. Figure 11A , 11B Figure 11C illustrates an interactive graphical user interface, including corresponding graphics, in which the user can select (e.g., click) a design point (e.g., operating load) of building system 100. Specific heat exchangers overlapping with the design point are candidates for installation in the building system.

[0291] Figure 11A A graph 110 showing the system head versus flow rate is presented, providing a selection range for one or more candidate heat exchangers 118 for selecting building system 100. Figure 11A There are four heat exchangers to choose from: HX1, HX2, HX3, and HX4. Figure 11B A graph 1120 showing cooling capacity versus flow rate is presented, providing a range of options for selecting one or more candidate heat exchangers 118 for building system 100. Figure 11B In the range shown, there are two selectable heat exchangers, HX3 and HX4. Figure 11CA graph 1140 showing heating capacity versus flow rate is presented, providing a selection range for one or more candidate heat exchangers 118 for selecting building system 100. Figure 11C In the range shown, there are two selectable heat exchangers, HX3 and HX4.

[0292] For example, in Figure 11A In this configuration, the user can select a design point of 35 psi (24.6 m) and 300 US GPM (1136 L / min) on graph 1100. In this case, the processor can output all four heat exchangers HX1, HX2, HX3, and HX4 as candidate devices for installation and operation in building system 100. If the user selects a design point of 35 psi (24.6 m) and 1700 US GPM (6435 L / min) on graph 1100, the processor will output only heat exchanger HX4 as a candidate device for installation and operation in building system 100. In some examples, the user can also select one of the candidate heat exchangers 118 for installation and operation in building system 100.

[0293] Similarly, when the known design point of building system 100 is cooling capacity, then Figure 11B The curve 1120 can be used to select candidate heat exchangers. When the known design point of building system 100 is heating capacity, then... Figure 11C The curve 1140 can be used to select candidate devices.

[0294] In some examples, once one or more candidate control pumps 102, 122 and heat exchanger 118 have been identified by the processor, at least one processor can be used to optimize the total cost of selecting, installing and operating these and other components of the building system 100.

[0295] Now for reference Figure 12A and 12B One or more processors can be used, each through... Figure 12A and 12B The graphical interface screens 1200 and 1220 shown determine candidate models for control pumps 102 and 122 and heat exchanger 118. In some examples, one or more processors can provide specific recommendations for the optimal combination of control pumps 102 and 122 and heat exchanger 118 for a particular building system 100. In the example, Figure 12A and 12B The fields can include manually inserted fields or drop-down selectable fields, as shown in the figure.

[0296] Reference Figure 12AThe graphical interface screen 1200 includes a pre-selection screen that allows the user to view the model numbers of components for the entire heat transfer system using specified parameters specific to the pumps and heat exchangers. Default units are displayed on the screen. A feature is the option to select the building type and location, which defines the building's operational profile. This profile allows the processor to optimize the selection of heat exchangers and pumps. Load profiles can be defined for different building types and converted according to the American Society of Heating, Refrigerating and Air-Conditioning Engineers (RTM) procedures for different locations.

[0297] In some examples, the allowed pump and heat exchanger redundancy is optional and can be 0% or from 50% to 100%.

[0298] In some examples, the fluid may be selected from water and a water-glycol mixture. If the user hovers their mouse over "System head without heat exchanger," a comment will pop up providing further explanation.

[0299] Reference Figure 12B The graphical interface screen 1220 allows users to modify the load profile according to their requirements. Discount periods and rates can also be customized for each project. Users can also simulate different operational scenarios using rating options.

[0300] Once the graphical user screens 1200 and 1220 are complete, the total cost of selecting, installing, and operating the control pumps 102 and 122, heat exchanger 118, and other components of the building system 100 can be optimized. Specific models of the control pumps 102 and 122 and heat exchanger 118 can be recommended via one or more processors.

[0301] The total cost of building system 100 includes initial installation costs and operating costs. Initial installation costs include the costs of heat exchangers, pumps, valves, extraction conductors, piping (including any pressure heads), and installation. Operating costs include pumping energy. The total cost is compared to other options using a net present value (NPV) method based on the user-defined discount period and discount rate. The default number of years is, for example, 10 years, and the default discount rate is, for example, 5%.

[0302] The pressure drop across heat exchanger 118 varies in increments of 0.5 psi, and the lifecycle cost for each scenario is obtained and stored in memory. The units are then ranked according to the lowest lifecycle cost.

[0303] Net Present Value (NPV) is calculated as follows:

[0304] in: Rt is the cost t in a specific year. N is the number of years. i is the discount rate. t represents a specific year.

[0305] Based on user application and location, one or more processors are used to select the building load profile. In the example, NPV is optimized to minimize cost. The building load profile can be extracted from the parallel redundancy specification. The load profile curve 400 (…) Figure 4A ) or load profile curve 420 ( Figure 4B Extract the building load profile. Calculate the total pumping energy by integrating the pump energy with the selected load profile.

[0306] In the example embodiments, each illustrated block or module may represent software, hardware, or a combination of hardware and software, where appropriate. Furthermore, some blocks or modules may be combined in other example embodiments, and more or fewer blocks or modules may exist in other example embodiments. Additionally, in other embodiments, some blocks or modules may be divided into multiple sub-blocks or sub-modules.

[0307] While some current embodiments have been described in terms of method, those skilled in the art will understand that the current embodiments also relate to various devices, such as server devices that include components for performing at least some aspects and features of the described methods, which may be implemented by means of hardware components, software, or any combination of both or in any other way. Furthermore, articles of art used with devices such as pre-recorded storage devices or other similar non-transitory computer-readable media including program instructions recorded thereon, or computer data signals carrying computer-readable program instructions, can instruct the devices to facilitate the practice of the described methods. It should be understood that such devices, articles of art, and computer design signals are also within the scope of the current exemplary embodiments.

[0308] While some of the examples described above have been presented in a specific order, those skilled in the art will understand that some messages, steps, or processes may be performed in a different order, as long as changing the order of any given step does not prevent or impair the occurrence of subsequent steps. Furthermore, in other embodiments, some of the above-described messages or steps may be removed or combined, and in other embodiments, some of the above-described messages or steps may be divided into many sub-messages or sub-steps. Moreover, some or all of the steps of a dialogue may be repeated when needed. Elements described as methods or steps are similarly applicable to systems or subcomponents, and vice versa.

[0309] In example embodiments, one or more controllers may be implemented or executed by one or more of the following systems: personal computer (PC), programmable logic controller (PLC), microprocessor, Internet, cloud computing, mainframe (local or remote), mobile phone or mobile communication device.

[0310] As used herein, the term "computer-readable medium" includes any medium that can store instructions, program steps, or the like for use by or execution by a computer or other computing device, including, but not limited to: magnetic media such as magnetic disks, disk drives, magnetic drums, magneto-optical disks, magnetic tapes, magnetic core memory, or the like; electronic storage such as any type of random access memory (RAM), including static RAM, dynamic RAM, synchronous dynamic RAM (SDRAM), read-only memory (ROM), any type of programmable read-only memory, including PROM, EPROM, EEPROM, FLASH, EAROM, so-called "solid-state disks"; any other type of electronic storage, including charge-connected devices (CCDs) or bubble memory; any type of portable electronic data carrying card, including compact flash memory, secure digital card (SD-CARD), memory stick, and the like; and optical media such as optical discs (CDs), digital versatile optical discs (DVDs), or Blu-ray discs (RTMs).

[0311] An example embodiment is a heat transfer system for supplying a variable load, comprising: a heat exchanger defining a first fluid path and a second fluid path; a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; and at least one controller configured to: control the first variable control pump to control the first circulating medium through the heat exchanger to supply the variable load, determine, based on real-time operational measurements, that the heat exchanger requires maintenance due to fouling during the supply of the variable load, and, in response to the determination, control the first flow rate of the first variable control pump to the first circulating medium to flush the fouling of the heat exchanger.

[0312] In any of the above example embodiments, control of the first variable control pump to the first flow rate is performed during the real-time supply of the variable load in order to flush the scale on the heat exchanger.

[0313] In any of the above example embodiments, the system further includes a second variable control pump for providing a variable flow rate of the second circulating medium through a second fluid path of the heat exchanger.

[0314] In any of the above example embodiments, the first fluid path is between the heat exchanger and the variable load, and the second fluid path is between the temperature source and the heat exchanger.

[0315] In any of the above example embodiments, the first fluid path is between the temperature source and the heat exchanger, and the second fluid path is between the heat exchanger and the variable load.

[0316] In any of the above example embodiments, at least one controller is configured to control a second flow rate of the second variable control pump to the second circulating medium in response to the determination, so as to flush out scale on the heat exchanger.

[0317] In any of the above example embodiments, the first flow rate or the second flow rate is the maximum flow rate setting.

[0318] In any of the above example embodiments, control of the first variable control pump to the first flow rate and control of the second variable control pump to the second flow rate are performed simultaneously.

[0319] In any of the above example embodiments, the control of the first variable control pump to the first flow rate and the control of the second variable control pump to the second flow rate are executed sequentially at different times.

[0320] In any of the above example embodiments, the system further includes a heat transfer module comprising a heat exchanger and at least one additional heat exchanger connected in parallel with the heat exchanger, wherein the first fluid path and the second fluid path are further defined by the at least one additional heat exchanger.

[0321] In any of the above example embodiments, the system further includes a corresponding valve for each heat exchanger, which can be controlled by at least one controller, wherein one or more of the corresponding valves are controlled to close when flushing the scale on each heat exchanger, and less than all heat exchangers are flushed at a time.

[0322] In any of the above example embodiments, the system further includes: a first pressure sensor configured to detect a pressure measurement input to a first fluid path of the heat transfer module; a second pressure sensor configured to detect a pressure measurement input to a second fluid path of the heat transfer module; a first differential pressure sensor spanning the input to the output of the first fluid path of the heat transfer module; a second differential pressure sensor spanning the input to the output of the second fluid path of the heat transfer module; a first temperature sensor configured to detect a temperature measurement input to the first fluid path of the heat transfer module; a second temperature sensor configured to detect a temperature measurement output to the first fluid path of the heat transfer module; a third temperature sensor configured to detect a temperature measurement input to the second fluid path of the heat transfer module; a fourth temperature sensor configured to detect a temperature measurement output to the second fluid path of the heat transfer module; and corresponding temperature sensors to detect a temperature measurement output of each fluid path of each heat exchanger of the heat transfer module; wherein at least one controller is configured to receive data indicating the measurements from the pressure sensor, differential pressure sensor, and temperature sensor for the determination that the heat exchanger requires maintenance due to fouling of the heat exchanger.

[0323] In any of the above example embodiments, the system further includes: a first flow sensor configured to detect a first flow measurement of a first flow through a heat transfer module, the heat transfer module including a first fluid path and a corresponding first fluid path for at least one additional heat exchanger; a second flow sensor configured to detect a second flow measurement of a second flow through a heat transfer module, the heat transfer module including a second fluid path and a corresponding second fluid path for at least one additional heat exchanger; wherein the at least one controller is configured to: receive data indicating flow measurement values ​​from the first and second flow sensors, calculate corresponding heat loads (Q) of the first and second flow through the heat transfer module based on: the first flow measurement, the second flow measurement, a corresponding temperature measurement from a first temperature sensor, a corresponding temperature measurement from a third temperature sensor, and a corresponding temperature measurement from the output of a corresponding temperature sensor of each heat exchanger of the corresponding temperature sensor, and calculate a comparison between the heat load (Q) of the first flow and the heat load (Q) of the second flow for the determination that the heat exchanger requires maintenance due to fouling of the heat exchanger.

[0324] In any of the above example embodiments, the system further includes: at least one pressure sensor or temperature sensor configured to detect measurements at the heat exchanger, wherein at least one controller is configured to determine a heat exchanger cleanliness coefficient value when in a clean state; wherein the determination that the heat exchanger requires maintenance due to fouling further includes: calculating an actual coefficient value of the heat exchanger based on measurements from at least one pressure sensor or temperature sensor during real-time operation measurements when a variable load is supplied; and calculating a comparison between the actual coefficient value of the heat exchanger and the heat exchanger cleanliness coefficient value.

[0325] In any of the above example embodiments, at least one controller is configured to determine the clean heat transfer coefficient (U) of a heat exchanger when it is in a clean state; wherein the determination that the heat exchanger requires maintenance due to fouling of the heat exchanger further includes: calculating the actual heat transfer coefficient (U) of the heat exchanger based on measurements from at least one pressure sensor or temperature sensor during real-time operation measurement when a variable load is supplied; and calculating a comparison between the actual heat transfer coefficient (U) of the heat exchanger and the clean heat transfer coefficient (U) of the heat exchanger.

[0326] In any of the above example embodiments, the calculation comparison is based on the actual heat transfer coefficient (U) of the heat exchanger and the clean heat transfer coefficient (U) of the heat exchanger to calculate the scaling factor (FF).

[0327] In any of the above example embodiments, the scaling factor (FF) is calculated as follows: FF = 1 / U污垢 – 1 / U 清洁 , in, U 清洁 It is the clean heat transfer coefficient (U). U 污垢 It is the actual heat transfer coefficient (U).

[0328] In any of the above example embodiments, at least one controller is configured to determine a clean pressure differential value across a first fluid path of the heat exchanger when it is in a clean state; wherein, the determination that the heat exchanger requires maintenance due to fouling of the heat exchanger based on real-time operational measurements when a variable load is supplied further includes: calculating an actual pressure differential value across the first fluid path of the heat exchanger based on measurements from at least one pressure sensor during real-time operational measurements when a variable load is supplied; and calculating a comparison between the actual pressure differential value of the heat exchanger and the clean pressure differential value of the heat exchanger.

[0329] In any of the above example embodiments, at least one controller is configured to determine a clean temperature difference value across a first fluid path of the heat exchanger when it is in a clean state; wherein the determination that the heat exchanger requires maintenance due to fouling of the heat exchanger further includes: calculating an actual temperature difference value of the first fluid path of the heat exchanger based on measurements from a temperature sensor during real-time operation measurement when a variable load is supplied; and calculating a comparison between the actual temperature difference value of the heat exchanger and the temperature difference value of the heat exchanger.

[0330] In any of the above example embodiments, the cleanliness factor value of the heat exchanger in a clean state is predetermined by testing before the heat exchanger is transported or installed, and the cleanliness factor value is stored in memory. The cleanliness factor value of the heat exchanger in a clean state is determined by at least one controller, and the determination is performed by accessing the cleanliness factor value from memory.

[0331] In any of the above example embodiments, the system further includes at least one sensor configured to detect a measurement indicating the heat exchanger; wherein at least one controller is configured to determine a cleanliness coefficient value of the heat exchanger when it is in a clean state; wherein the determination that the heat exchanger requires maintenance due to fouling further includes: predicting an actual current coefficient value of the heat exchanger based on previous measurements of the at least one sensor during real-time operation measurements when a variable load is supplied; and calculating a comparison between the predicted actual coefficient value of the heat exchanger and the cleanliness coefficient value of the heat exchanger.

[0332] In any of the above example embodiments, the determination that the heat exchanger needs maintenance due to fouling of the heat exchanger further includes: determining, for a specified time period, a variable load continuously supplied by the heat exchanger at a maximum specified partial load.

[0333] In any of the above example embodiments, the maximum specified partial load is 90% of the full load of the variable load, and the specified time period is at least 7 days or about 7 days.

[0334] In any of the above example embodiments, at least one controller is configured to determine whether the flushing of scale on the heat exchanger is successful or unsuccessful by: determining the cleanliness coefficient value of the heat exchanger when it is in a clean state; calculating the actual coefficient value of the heat exchanger based on measured real-time operating values ​​when a variable load is supplied; and calculating a comparison between the actual coefficient value of the heat exchanger and the cleanliness coefficient value of the heat exchanger, wherein, based on the calculation of this comparison, at least one controller is configured to output a notification regarding whether the flushing of scale on the heat exchanger is successful or unsuccessful.

[0335] In any of the exemplary embodiments above, the first flow rate is: the maximum flow rate setting of the first variable control pump; or the maximum operating flow rate of the variable load; or the maximum flow capacity of the heat exchanger.

[0336] In any of the above example embodiments, the first flow rate includes the return flow of the first variable control pump.

[0337] In any of the above example embodiments, the heat exchanger is a plate-and-frame countercurrent heat exchanger that includes multiple brazed plates for inducing turbulence when facilitating heat transfer between a first fluid path and a second fluid path.

[0338] In any of the above example embodiments, the heat exchanger is a shell-and-tube heat exchanger or a plate heat exchanger.

[0339] In any of the above example embodiments, at least one controller is integrated with the heat exchanger.

[0340] An example embodiment is a method for supplying a variable load using a heat transfer system including a heat exchanger defining a first fluid path and a second fluid path. The heat transfer system includes a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger. The method is performed by at least one controller and includes: controlling the first variable control pump to control the first circulating medium through the heat exchanger to supply the variable load; determining, based on real-time operational measurements, that the heat exchanger requires maintenance due to fouling during the supply of the variable load; and, in response to the determination, controlling a first flow rate of the first variable control pump to the first circulating medium to flush the fouling of the heat exchanger.

[0341] An example embodiment is a heat transfer module, comprising: a sealed housing defining a first port, a second port, a third port, and a fourth port; a plurality of parallel heat exchangers within the sealed housing defining a first fluid path between the first and second ports and a second fluid path between the third and fourth ports; a first pressure sensor within the sealed housing configured to detect a pressure measurement input to the first fluid path of the heat transfer module; a second pressure sensor within the sealed housing configured to detect a pressure measurement input to the second fluid path of the heat transfer module; a first differential pressure sensor within the sealed housing and traversing the input to output of the first fluid path of the heat transfer module; and a second differential pressure sensor within the sealed housing and traversing the second fluid path of the heat transfer module. The heat transfer module includes: an input to an output path; a first temperature sensor within a sealed housing configured to detect the temperature measurement of the output of the first fluid path; a second temperature sensor within a sealed housing configured to detect the temperature measurement of the output of the first fluid path; a third temperature sensor within a sealed housing configured to detect the temperature measurement of the input of the second fluid path; a fourth temperature sensor within a sealed housing configured to detect the temperature measurement of the output of the second fluid path; corresponding temperature sensors within a sealed housing to detect the temperature measurement of the output of each fluid path of each heat exchanger in the heat transfer module; and at least one controller configured to receive data indicating the measured values ​​from the pressure sensor, differential pressure sensor, and temperature sensor.

[0342] In any of the above example embodiments, at least one controller is configured to instruct one or more variable control pumps to operate the flow through the heat exchanger.

[0343] In any of the above example embodiments, at least one controller is configured to: determine a cleanliness coefficient value for the heat exchanger when it is in a clean state; determine that the heat exchanger requires maintenance due to fouling, including: when a variable load is supplied, during real-time operation, calculating an actual coefficient value for the heat exchanger based on measurements from a pressure sensor, a differential pressure sensor, a temperature sensor, or an external flow sensor; calculating a comparison between the actual coefficient value and the cleanliness coefficient value of the heat exchanger to conclude that the heat exchanger requires maintenance due to fouling; and instructing one or more variable control pumps to operate at a maximum flow rate setting through the heat exchanger to flush away the fouling.

[0344] In any of the above example embodiments, instructions to one or more variable control pumps are executed during the real-time supply of variable loads.

[0345] In any of the above example embodiments, one of the variable control pumps is attached to the first port, while the other of the variable control pumps is attached to the third port.

[0346] In any of the above example embodiments, at least one controller is located in a sealed housing.

[0347] In any of the above example embodiments, each of the plurality of parallel heat exchangers is a plate heat exchanger.

[0348] In any of the above example embodiments, each of the plurality of parallel heat exchangers is a shell-and-tube heat exchanger or a plate heat exchanger.

[0349] An example embodiment is a system for tracking the performance of a heat exchanger, comprising: a heat exchanger for installation in a system with a load; an output subsystem; and at least one controller configured to: determine a cleanliness factor value of the heat exchanger when it is in a clean state; calculate an actual factor value of the heat exchanger based on real-time operational measurements taken when the load is supplied; calculate a comparison between the actual factor value of the heat exchanger and the cleanliness factor value of the heat exchanger; and output to the output subsystem when the comparison meets a criterion.

[0350] In any of the above example embodiments, the output includes sending a signal to control one or more variable control pumps to maximum flow rate in order to flush the heat exchanger.

[0351] In any of the above example embodiments, the output includes outputting an alarm to an output subsystem, wherein the output subsystem includes a display screen or a communication subsystem.

[0352] In any of the above example embodiments, an alarm indicates that the heat exchanger needs to be flushed or maintained.

[0353] In any of the exemplary embodiments described above, an alarm indicates a performance degradation of the heat exchanger.

[0354] In any of the above example embodiments, the coefficient value is the heat transfer coefficient (U).

[0355] In any of the above example embodiments, at least one controller is integrated with the heat exchanger.

[0356] An example embodiment is a method for tracking the performance of a heat exchanger used in a system under load. The method is executed by at least one controller and includes: determining a cleanliness factor value of the heat exchanger when it is in a clean state; calculating an actual factor value of the heat exchanger based on measured real-time operational measurements when a load is supplied; calculating a comparison between the actual factor value and the cleanliness factor value of the heat exchanger; and outputting the result to an output subsystem when the comparison meets a criterion.

[0357] An example embodiment is a heat transfer system for supplying a variable load, comprising: a heat exchanger defining a first fluid path and a second fluid path; a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; a variable flow control mechanism for providing a variable flow rate of a second circulating medium through the second fluid path of the heat exchanger; a sensor for detecting a variable, the sensor comprising: a first at least one sensor for sensing at least one variable indicating the first circulating medium; and a second at least one sensor for sensing at least one variable indicating the second circulating medium; and at least one controller configured to control at least one parameter of the first or second circulating medium by detecting the variable using the first at least one sensor and the second at least one sensor, and controlling the flow rate of one or both of the first variable control pump or the variable flow control mechanism based on the detected variable of the first and second circulating media, the feedforward control loop to achieve control of at least one parameter.

[0358] In an example embodiment, the feedforward control loop is based on a mathematical model between at least one parameter to be controlled and a detected variable.

[0359] In an example embodiment, the system further includes a memory for storing, for at least one or both of the first or second circulating medium: specific heat capacity as a function of pressure and temperature; and fluid density for use in a mathematical model by at least one controller.

[0360] In an example embodiment, at least one controller is configured to determine the heat transfer coefficient (U) of a heat exchanger, wherein the heat transfer coefficient (U) is used in a mathematical model.

[0361] In an example embodiment, when a variable load is supplied, the heat transfer coefficient (U) of the heat exchanger is determined based on real-time operational measurements from sensors.

[0362] In an example embodiment, determining the heat transfer coefficient (U) of a heat exchanger includes predicting the heat transfer coefficient (U) based on variables previously detected by sensors during real-time operational measurements when a variable load is supplied.

[0363] In an example embodiment, determining the heat transfer coefficient (U) of a heat exchanger includes calculating the heat transfer coefficient (U) based on the variables currently detected by the sensors during real-time operational measurements when a variable load is supplied.

[0364] In an example embodiment, the heat transfer coefficient (U) of the heat exchanger is determined based on tests prior to the installation and / or transportation of the heat exchanger.

[0365] In the example embodiment, at least one parameter being controlled is a parameter that is different from the variable detected in the feedforward control loop.

[0366] In an example embodiment, a first fluid path is between a heat exchanger and a variable load, a first variable control pump is between a heat exchanger and a variable load, a second fluid path is between a temperature source and a heat exchanger, and a variable flow control mechanism is between a temperature source and a heat exchanger.

[0367] In an example embodiment, at least one variable flow control mechanism between the temperature source and the heat exchanger is controlled by at least one controller to achieve control of at least one parameter.

[0368] In example embodiments, the temperature source includes a boiler, cooler, regional source, waste temperature source, or geothermal source.

[0369] In an example embodiment, at least one parameter controlled by at least one controller is the output temperature from the heat exchanger to the temperature source.

[0370] In the example embodiment, the temperature source includes a geothermal source.

[0371] In an example embodiment, at least one parameter controlled by at least one controller maximizes the temperature difference across the heat exchanger to the temperature source.

[0372] In an example embodiment, when at least one controller maximizes the temperature difference across the heat exchanger to the temperature source, the temperature difference is controlled to be constant across the heat exchanger to the variable load, and the temperature difference is controlled to be constant across the heat exchanger between the input temperature from the temperature source and the input temperature from the variable load.

[0373] In an example embodiment, when at least one controller maximizes the temperature difference across the heat exchanger to the temperature source, the temperature difference is controlled to be variable across the heat exchanger to the variable load, and the temperature difference is controlled to be variable across the heat exchanger between the input temperature from the temperature source and the input temperature from the variable load.

[0374] In the example embodiment, the temperature source includes a cooling tower.

[0375] In an example embodiment, the system also includes a cooler connected in parallel with the heat exchanger for supplying variable loads from the cooling tower.

[0376] In an example embodiment, the system also includes a cooler connected in series between the heat exchanger and the variable load.

[0377] In example embodiments, the temperature source includes a boiler, cooler, regional source, or waste temperature source.

[0378] In an example embodiment, at least one parameter controlled by at least one controller is the output temperature from the heat exchanger to the variable load.

[0379] In an example embodiment, the system also includes a hot water heater connected in series between the heat exchanger and the variable load.

[0380] In an example embodiment, at least one parameter controlled by at least one controller maintains a specified fixed ratio of the flow rate of the first fluid path to the flow rate of the second fluid path.

[0381] In the example embodiment, at least one parameter is controlled by at least one controller to a specified value.

[0382] In the example embodiment, at least one parameter is controlled by at least one controller to be optimized or maximized.

[0383] In an example embodiment, the system further includes a heat transfer module comprising a heat exchanger and at least one additional heat exchanger connected in parallel with and to the heat exchanger, wherein a first fluid path and a second fluid path are further defined by the at least one additional heat exchanger.

[0384] In an example embodiment, the sensors include: a first pressure sensor configured to detect a pressure measurement input to a first fluid path of the heat transfer module; a second pressure sensor configured to detect a pressure measurement input to a second fluid path of the heat transfer module; a first differential pressure sensor spanning the input to the output of the first fluid path of the heat transfer module; a second differential pressure sensor spanning the input to the output of the second fluid path of the heat transfer module; a first temperature sensor configured to detect a temperature measurement input to the first fluid path of the heat transfer module; a second temperature sensor configured to detect a temperature measurement output of the first fluid path of the heat transfer module; a third temperature sensor configured to detect a temperature measurement input to the second fluid path of the heat transfer module; a fourth temperature sensor configured to detect a temperature measurement output of the second fluid path of the heat transfer module; and corresponding temperature sensors to detect a temperature measurement output of each fluid path of each heat exchanger of the heat transfer module.

[0385] In an example embodiment, the sensor includes: a first flow sensor configured to detect a flow measurement of a first fluid path of the heat exchanger; and a second flow sensor configured to detect a flow measurement of a second fluid path of the heat exchanger. In an example embodiment, the sensor includes at least one pressure sensor configured to detect pressure measurements at the heat exchanger.

[0386] In an example embodiment, the first at least one sensor includes a first at least one temperature sensor, and the second at least one sensor includes a second at least one temperature sensor.

[0387] In an example embodiment, the sensor includes a flow sensor to detect flow measurements of a first or second fluid path of a heat exchanger having at least one controlled parameter.

[0388] In an example embodiment, the sensor includes a flow sensor to detect flow measurements of a first or second fluid path of a heat exchanger having at least one controlled parameter.

[0389] In an example embodiment, the heat exchanger is a plate counterflow heat exchanger that includes multiple brazed plates for inducing turbulence when facilitating heat transfer between a first fluid path and a second fluid path.

[0390] In the example embodiment, the heat exchanger is a shell-and-tube heat exchanger or a plate heat exchanger.

[0391] In the example embodiment, the variable flow control mechanism is a second variable control pump.

[0392] In an example embodiment, the system further includes at least one processor configured to facilitate the selection of one or both of a first variable control pump or a second variable control pump from a plurality of variable control pumps for installation to supply the variable load. The at least one processor is configured to: generate a graphical user interface for display on a screen; receive a design setpoint for the variable load via the graphical user interface; determine additional capacity required for the rated total value of a first parameter or a second parameter to account for variations in system resistance of the variable load caused by the heat exchanger; and display one or more variable control pumps that take into account the heat exchanger to minimize the additional capacity required to supply the variable load, wherein one or more variable speed devices are selected as one or both of the first variable control pump or the second variable control pump for installation.

[0393] In an example embodiment, at least one processor is configured to facilitate the selection of a heat exchanger from a plurality of heat exchangers for installation to supply a variable load. The at least one processor is configured to display one or more heat exchangers that meet the design setpoint for the variable load when operating at partial load, wherein the heat exchanger is selected from the one or more heat exchangers for installation to supply the variable load.

[0394] In the example embodiment, a first variable control pump, a second variable control pump, and a heat exchanger are selected, which together optimize the cost of partial load operation of the variable load over a specified number of years.

[0395] In the example embodiment, capability is power capability.

[0396] In the example embodiment, the capability is heat transfer capability.

[0397] In an example embodiment, the variable flow control mechanism is a variable control valve.

[0398] In the example embodiment, the sensor is integrated with the heat exchanger.

[0399] In an example embodiment, at least one controller is integrated with the heat exchanger.

[0400] An example embodiment is a method for supplying a variable load using a heat transfer system including a heat exchanger defining a first fluid path and a second fluid path. The heat transfer system includes: i) a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; ii) a variable flow control mechanism for providing a variable flow rate of a second circulating medium through the second fluid path of the heat exchanger; and iii) a sensor for detecting variables, the sensor including: a first at least one sensor for sensing at least one variable indicating the first circulating medium; and a second at least one sensor for sensing at least one variable indicating the second circulating medium. The method is performed by at least one controller and includes: detecting variables using the first at least one sensor and the second at least one sensor; and, based on the detected variables of the first and second circulating media, using a feedforward control loop to control one or both of the first variable control pump or the variable flow control mechanism to achieve control of at least one parameter of the first or second circulating medium.

[0401] An example embodiment is a heat transfer system comprising: a heat exchanger defining a first fluid path and a second fluid path; a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; a variable flow control mechanism for providing a variable flow rate of a second circulating medium through the second fluid path of the heat exchanger; a sensor for detecting variables, the sensor comprising: a first at least one sensor for sensing at least one variable indicating the first circulating medium, and a second at least one sensor for sensing at least one variable indicating the second circulating medium; and at least one controller configured to control the first variable control pump in a first type of flow control mode and switch control of the first variable control pump to a second type of flow control mode different from the first type of control mode.

[0402] In an example embodiment, the first type of flow control mode or the second control mode uses a feedforward control loop based on the detected variables of the first circulating medium and the second fluid circulating medium.

[0403] In an example embodiment, the first type of flow control mode or the second control mode uses a feedforward control loop based on the detected variables of the first circulating medium and the second fluid circulating medium.

[0404] In an example embodiment, the controller is configured to automatically perform switching based on variables detected from sensors.

[0405] An example embodiment is a heat transfer system for supplying a variable load, comprising: a heat exchanger defining a first fluid path and a second fluid path; a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; at least one pressure sensor or temperature sensor configured to detect a measurement at the heat exchanger; and at least one controller configured to: calculate an actual heat transfer coefficient or heat transfer capacity of the heat exchanger based on the measurement values ​​of the at least one pressure sensor or temperature sensor during real-time operation measurements while supplying a variable load, repeat the calculation of the actual coefficient value of the heat exchanger at different time points, and predict, based on the calculation, when the heat exchanger will require maintenance due to fouling of the heat exchanger.

[0406] In an example embodiment, the controller is also configured to predict when the heat exchanger will reach a specified heat transfer capacity or heat transfer coefficient value based on measurements from at least one pressure sensor or temperature sensor during real-time operation measurements while supplying a variable load.

[0407] In an example embodiment, the controller is also configured to control the first variable control pump to a first flow rate of the first circulating medium to flush out scale on the heat exchanger and to estimate the heat transfer capacity or heat transfer coefficient of the heat exchanger after scale flushing based on historical data.

[0408] In an example embodiment, a sensor for detecting a variable used by the controller is also included, the sensor including at least one sensor for sensing at least one variable indicating the first circulating medium.

[0409] In an example embodiment, the system also includes an output interface for outputting data related to the prediction.

[0410] An example embodiment is a heat transfer system for supplying a load, comprising: a heat exchanger defining a first fluid path and a second fluid path; a first variable control pump for providing a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; and at least one controller configured to: control the first variable control pump to control the first circulating medium through the heat exchanger to supply the load, and to control the first variable control pump to achieve a pulsed flow of the first circulating medium to flush out scale buildup in the heat exchanger.

[0411] In an example embodiment, the first variable control pump is controlled as a pulsed flow to flush scale from the heat exchanger, configured to be performed during real-time supply of load.

[0412] In an example embodiment, the system further includes a second variable control pump for providing a variable flow rate of the second circulating medium through a second fluid path of the heat exchanger, wherein the at least one controller is configured to control the second variable control pump in response to the determination to achieve a second pulsed flow of the second circulating medium to flush out scale on the heat exchanger.

[0413] In an example embodiment, the pulse flow includes increasing the flow rate of the first circulating medium from a specified flow rate level to an increased flow rate level, restoring the first circulating medium to a specified flow rate level, and repeating the increase and restoration.

[0414] In an example embodiment, at least one controller is configured to determine that rinsing from the pulsed flow is unsuccessful, and in response, to control the first variable control pump to the maximum flow setting.

[0415] In an example embodiment, at least one controller is configured to determine whether a flush from a pulsed flow is successful or unsuccessful, wherein success is determined based on a heat exchanger variable exceeding a threshold, the variable being the heat transfer coefficient (U) of the heat exchanger, the pressure difference across the heat exchanger, or the heat transfer capacity of the heat exchanger.

[0416] Variations can be made to some of the example embodiments, which may include any of the above combinations and sub-combinations. The embodiments shown above are merely examples and are by no means intended to limit the scope of this disclosure. Variations of the innovations described herein will be apparent to those skilled in the art who will benefit from this disclosure, and these variations are within the scope of this disclosure. Specifically, one or more features of the above embodiments can be selected to produce alternative embodiments including combinations of features that may not have been described in detail above. Additionally, one or more features of the above embodiments can be selected and combined to produce alternative embodiments including combinations of features that may not have been described in detail above. After reading this disclosure in its entirety, features suitable for such combinations and sub-combinations will be apparent to those skilled in the art. The subject matter described herein is intended to cover and encompass all suitable technical variations.

[0417] Certain adaptations and modifications can be made to the described embodiments. Therefore, the embodiments discussed above are considered illustrative rather than restrictive.

Claims

1. A heat transfer system for supplying variable loads, comprising: A heat exchanger that defines a first fluid path and a second fluid path, wherein the heat exchanger is a liquid-to-liquid heat exchanger; A first variable control pump is used to provide a variable flow rate of a first circulating medium through the first fluid path of the heat exchanger; At least one pressure sensor or temperature sensor, said pressure sensor or temperature sensor being configured to detect a measured value at the heat exchanger; and At least one controller, said at least one controller being configured to: When supplying a variable load, the actual coefficient value or heat transfer capacity of the heat exchanger is calculated based on the measurements from the at least one pressure sensor or temperature sensor during real-time operation measurement. The calculation of the actual coefficient values ​​of the heat exchanger is repeated at different time points; Based on the calculations, it is predicted when the heat exchanger will require maintenance due to scaling. The first variable control pump is controlled to a first flow rate of the first circulating medium in order to flush out scale buildup in the heat exchanger; and Based on historical data, estimate the heat transfer capacity or heat transfer coefficient of the heat exchanger after scale flushing.

2. The heat transfer system according to claim 1, characterized in that, The controller is also configured to predict when the heat exchanger will reach a specified heat transfer capacity or heat transfer coefficient value based on measurements taken by the at least one pressure sensor or temperature sensor during real-time operation measurements while the variable load is supplied.

3. The heat transfer system according to claim 1, characterized in that, It also includes sensors for detecting variables used by the controller, the sensors including at least one sensor for sensing at least one variable indicating the first circulating medium.

4. The heat transfer system according to claim 1, characterized in that, It also includes an output interface for outputting data related to the prediction.

5. The heat transfer system according to claim 1, characterized in that, The prediction of when the heat exchanger will require maintenance is based on previous measurements from at least one pressure sensor or temperature sensor during real-time operation when the variable load is supplied.

6. A heat transfer system for supplying a load, comprising: A heat exchanger that defines a first fluid path and a second fluid path; A first variable control pump is used to provide a variable flow rate of a first circulating medium through a first fluid path of the heat exchanger; as well as At least one controller, said at least one controller being configured to: The first variable control pump is controlled to control the first circulating medium through the heat exchanger in order to supply the load; It was determined that the heat exchanger required maintenance due to scaling. as well as The first variable control pump is controlled to achieve a pulsed flow of the first circulating medium in order to flush out the scale on the heat exchanger.

7. The heat transfer system according to claim 6, characterized in that, The first variable control pump is controlled to flush the scale on the heat exchanger with the pulsed flow, configured to perform this action during the real-time supply of the load.

8. The heat transfer system according to claim 6, characterized in that, It also includes a second variable control pump for providing a variable flow rate of the second circulating medium through a second fluid path of the heat exchanger, wherein the at least one controller is configured to control the second variable control pump in response to the determination to achieve a second pulse flow of the second circulating medium in order to flush out scale on the heat exchanger.

9. The heat transfer system according to claim 6, characterized in that, The pulse flow includes: increasing the flow rate of the first circulating medium from a specified flow rate level to an increased flow rate level, restoring the first circulating medium to the specified flow rate level, and repeating the increase and restoration.

10. The heat transfer system according to claim 6, characterized in that, The at least one controller is configured to determine that the flushing from the pulsed flow was unsuccessful, and in response, to control the first variable control pump to a maximum flow setting.

11. The heat transfer system according to claim 6, characterized in that, The at least one controller is configured to determine whether the flushing from the pulsed flow is successful or unsuccessful, wherein success is determined based on a variable of the heat exchanger exceeding a threshold, the variable being the heat transfer coefficient (U) of the heat exchanger, the pressure difference across the heat exchanger, or the heat transfer capacity of the heat exchanger.

12. The heat transfer system according to claim 6, characterized in that, The determination of the heat exchanger's maintenance requirements includes prediction based on previous measurements taken when the load was supplied.

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