Heat exchanger clogging detection

Abstract

This disclosure relates to heat exchanger blockage detection. A method for detecting heat exchanger blockage in a cooling system may include determining expected operating parameters, detecting current operating parameters, confirming that the cooling system is operating in a steady state as a prerequisite for detecting the current operating parameters, comparing the expected operating parameters with the current operating parameters, identifying heat exchanger blockage at least in part based on the comparison, and providing an indication if heat exchanger blockage is detected. Determining the expected operating parameters may include operating the cooling system in a steady state and / or at a predetermined capacity, and recording the current operating parameters at this time as expected operating parameters and / or calculating the expected operating parameters.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 739,449, filed December 27, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to cooling systems, and more specifically to monitoring data center cooling systems. Background Technology

[0004] Data center operators typically want their systems, including their cooling systems, to operate as efficiently as possible while still meeting demand. Cooling system efficiency decreases if heat exchangers become clogged.

[0005] More specifically, the air flowing through fluid-to-air heat exchangers (especially external condensers) often carries dust, dirt, and other contaminants. These contaminants accumulate, blocking the airflow path through the heat exchanger and / or isolating the heat exchanger from the air flowing through it. Reduced airflow and / or such isolation decreases heat transfer, thus reducing efficiency. Fluid-to-fluid heat exchangers may encounter similar problems. Summary of the Invention

[0006] The applicant has created new and useful apparatus, systems, and methods for detecting blockages in heat exchangers (e.g., heat exchangers used in data center cooling systems). In at least one embodiment, the system for detecting blockages in heat exchangers in a cooling system according to this disclosure can automatically detect when a flow path (e.g., an airflow path and / or a fluid flow path) is blocked or when the flow rate in the flow path decreases (which may reduce the efficiency of the cooling system). In at least one embodiment, the system according to this disclosure can provide messages, warnings, alerts, or any combination thereof, wherein the message indicates a low confidence level of potential blockage in a path and / or heat exchanger blockage, the warning indicates a moderate confidence level of limited blockage in a path and / or heat exchanger blockage, and the alert indicates a high confidence level of significant blockage in a path and / or heat exchanger blockage.

[0007] In at least one embodiment, the method for detecting heat exchanger blockage in a cooling system according to this disclosure may include determining expected operating parameters, detecting current operating parameters, confirming that the cooling system is operating in a steady state as a prerequisite for detecting the current operating parameters, comparing the expected operating parameters with the current operating parameters, identifying heat exchanger blockage at least in part based on the comparison, providing an indication if heat exchanger blockage is detected, or any combination thereof. In at least one embodiment, determining the expected operating parameters may include operating the cooling system in a steady state and / or at a predetermined capacity, and recording the current operating parameters at this time as the expected operating parameters and / or calculating the expected operating parameters. In at least one embodiment, comparing the expected operating parameters with the current operating parameters may include calculating the difference between the expected operating parameters and the current operating parameters.

[0008] In at least one embodiment, the expected operating parameters may be calculated based on one or more speeds, such as one or more fan speeds, one or more pump speeds, or any combination thereof. In at least one embodiment, the expected operating parameters may be calculated based on one or more flow rates. In at least one embodiment, the expected operating parameters may be calculated based on one or more pressures, such as one or more suction pressures, one or more discharge pressures, one or more condensing pressures, one or more pressure differentials (e.g., pressure differential across a heat exchanger and / or filter), or any combination thereof. In at least one embodiment, the expected operating parameters may be calculated based on one or more temperatures, such as one or more cooling medium temperatures, one or more refrigerant temperatures, one or more air temperatures, or any combination thereof. In at least one embodiment, the expected operating parameters may be calculated based on one or more demand signals. In at least one embodiment, the expected operating parameters may be calculated based on one or more capacities, such as one or more pump capacities, one or more compressor capacities, one or more piping capacities, one or more cooling capacities (e.g., cooling capacity of one or more cooling loops, circuits, or units), or any combination thereof.

[0009] In at least one embodiment, calculating the expected operating parameters may include calculating one or more speeds, such as one or more fan speeds, one or more pump speeds, or any combination thereof. In at least one embodiment, calculating the expected operating parameters may include calculating one or more flow rates. In at least one embodiment, calculating the expected operating parameters may include calculating one or more pressures, such as one or more suction pressures, one or more discharge pressures, one or more condensing pressures, one or more pressure differentials (e.g., pressure differential across a heat exchanger and / or filter), or any combination thereof. In at least one embodiment, calculating the expected operating parameters may include calculating one or more temperatures, such as one or more cooling medium temperatures, one or more refrigerant temperatures, one or more air temperatures, or any combination thereof.

[0010] In at least one embodiment, providing an indication if heat exchanger blockage is detected may include: providing a warning, alarm, or other message if blockage is detected. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include: providing a message if the difference (between the current operating parameters and the expected operating parameters) exceeds a first threshold. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include: providing a warning if the difference exceeds a second threshold. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include: providing an alarm if the difference exceeds a third threshold. In at least one embodiment, the second threshold may be greater than the first threshold. In at least one embodiment, the third threshold may be greater than the first threshold and / or the second threshold.

[0011] In at least one embodiment, a method for detecting heat exchanger blockage in a cooling system having multiple cooling units according to the present disclosure may include: operating a first cooling unit of the cooling system at a predetermined capacity; detecting a first set of current operating parameters of the first cooling unit; recording the first set of current operating parameters of the first cooling unit as expected operating parameters; determining the current capacity of the cooling system; calculating the maximum capacity of the cooling system without the first cooling unit; waiting for a predetermined time period; and performing a check process if the maximum capacity is greater than the current capacity; or any combination thereof. In at least one embodiment, the check process may include: operating the first cooling unit at a predetermined capacity while using the cooling system (as a whole) to provide the current capacity; detecting a second set of current operating parameters of the first cooling unit; comparing the expected operating parameters with the second set of current operating parameters; identifying heat exchanger blockage at least in part based on the comparison; or any combination thereof.

[0012] In at least one embodiment, the current capacity may vary, for example, based on demand and / or demand signals. In at least one embodiment, the current capacity, as used herein, does not need to be a measurement of the maximum capacity. In at least one embodiment, the current capacity, as used herein, may be a measurement of the current cooling output of the cooling system, which may vary based on demand and / or demand signals. In at least one embodiment, the current capacity of the cooling system may change to meet the demand and / or demand signals when they change. In at least one embodiment, the current capacity of the cooling system may change proportionally when the demand and / or demand signals change.

[0013] In at least one embodiment, operating the first cooling unit at a predetermined capacity while using the cooling system to provide the current capacity may include: operating the first cooling unit at the predetermined capacity in a steady state, and proportionally changing the second capacity of a second cooling unit of the cooling system according to demand and / or demand signals. In at least one embodiment, operating the first cooling unit at a predetermined capacity while using the cooling system to provide the current capacity may include: operating the first cooling unit at the predetermined capacity in a steady state, and proportionally changing one or more other cooling units of the cooling system according to demand and / or demand signals, such as one or more speeds, one or more flow rates, one or more outputs, one or more capacities, or any combination thereof of one or more other cooling units.

[0014] In at least one embodiment, the check process can be performed periodically (e.g., daily, weekly, monthly, or any combination thereof). In at least one embodiment, the check process can be performed periodically if the maximum capacity is greater than the current capacity. In at least one embodiment, the check process can be performed periodically only if the maximum capacity is greater than the current capacity. In at least one embodiment, the check process can be performed after a time period has expired. In at least one embodiment, the check process can be performed if the maximum capacity is greater than the current capacity after a time period has expired. In at least one embodiment, the check process can be performed after a time period has expired and the current capacity has fallen below the maximum capacity.

[0015] In at least one embodiment, the maximum capacity as used herein does not need to be the maximum capacity of the entire cooling system. In at least one embodiment, the maximum capacity as used herein may be the maximum capacity of the cooling system in the absence of one or more cooling units of the cooling system.

[0016] In at least one embodiment, the method for detecting heat exchanger blockage according to this disclosure may include utilizing two or more detection techniques. In at least one embodiment, the method for detecting heat exchanger blockage according to this disclosure may include operating the cooling system in a steady state and recording a first set of current operating parameters of the cooling system as a first set of expected operating parameters; determining the current capacity of the cooling system; calculating a second set of expected operating parameters based at least partially on the current capacity; detecting the second set of current operating parameters of the cooling system; comparing the second set of current operating parameters with the first set of expected operating parameters and the second set of expected operating parameters; identifying heat exchanger blockage based at least partially on the comparison; or any combination thereof. In at least one embodiment, the first set of expected operating parameters may include an indication of a first capacity at the time the first set of current operating parameters was recorded. In at least one embodiment, the method may include, for example, creating a first set of extrapolated expected operating parameters by extrapolating the first set of expected operating parameters based at least partially on the difference between the current capacity and the first capacity. In at least one embodiment, comparing the second set of current operating parameters with the first set of expected operating parameters may include or include comparing the second set of current operating parameters with the first set of extrapolated expected operating parameters. In at least one embodiment, each set of current operating parameters and / or expected operating parameters may include one or more expected operating parameters, such as one or more speeds, one or more flow rates, one or more pressures, one or more temperatures, one or more capacities, or any combination thereof.

[0017] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds one or more of the expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: determining that a second set of current operating parameters exceeds a first threshold of extrapolated expected operating parameters from a first set; determining that a second set of current operating parameters exceeds a second threshold of expected operating parameters from a second set; determining that a second set of current operating parameters exceeds a first threshold of extrapolated expected operating parameters from a first set and / or a second threshold of expected operating parameters from a second set; or any combination thereof. In at least one embodiment, the first threshold may be the same as or different from the second threshold.

[0018] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds one or more thresholds from one or more sets of expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds one threshold from any set of expected operating parameters or exceeds other thresholds from the sets of expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include assigning a higher weight to one or more sets of expected operating parameters than to other sets of expected operating parameters. In at least one embodiment, the method for detecting heat exchanger blockage according to this disclosure may provide an indication of heat exchanger blockage, an indication of the severity of heat exchanger blockage, an indication of the confidence level of heat exchanger blockage, or any combination thereof.

[0019] In at least one embodiment, identifying heat exchanger blockage based at least in part on comparison may include determining that a second set of current operating parameters exceeds a first set of extrapolated expected operating parameters and a first threshold of the second set of expected operating parameters, that the second set of current operating parameters exceeds a second threshold of the first set of extrapolated expected operating parameters, that the second set of current operating parameters exceeds a third threshold of the second set of expected operating parameters, or any combination thereof. In at least one embodiment, the second threshold may be greater than the first threshold. In at least one embodiment, the third threshold may be greater than the second threshold and / or the first threshold.

[0020] In at least one embodiment, the method may include operating a first cooling unit of the cooling system at a predetermined capacity, detecting a third set of current operating parameters of the first cooling unit, recording the third set of current operating parameters of the first cooling unit as a third set of expected operating parameters, calculating the maximum capacity of the cooling system without the first cooling unit, waiting for a predetermined time period, performing a check process if the maximum capacity is greater than the current capacity (and performing the check process only if the maximum capacity is greater than the current capacity), or any combination thereof. In at least one embodiment, the check process may include: operating the first cooling unit at a predetermined capacity while using the cooling system to provide the current capacity; detecting a fourth set of current operating parameters of the first cooling unit; or any combination thereof. In at least one embodiment, comparing the current operating parameters with the expected operating parameters may include comparing the third set of expected operating parameters with the fourth set of current operating parameters.

[0021] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds a first threshold of extrapolated expected operating parameters, that the second set of current operating parameters exceeds a second threshold of expected operating parameters, and that a fourth set of current operating parameters exceeds a third threshold of expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds both the first and second thresholds of extrapolated expected operating parameters, that the second set of current operating parameters exceeds both the first and third thresholds of extrapolated expected operating parameters, that the fourth set of current operating parameters exceeds both the second and third thresholds of expected operating parameters, or any combination thereof. In at least one embodiment, the second threshold may be less than, greater than, or equal to the first threshold. In at least one embodiment, the third threshold may be less than, greater than, or equal to the second threshold and / or the first threshold. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of one embodiment of a cooling system according to the present disclosure.

[0023] Figure 2 This is a schematic diagram of another embodiment of the cooling system according to the present disclosure.

[0024] Figure 3 It is a graph showing the operating parameters versus cooling capacity with and without heat exchanger blockage.

[0025] Figure 4 This is a graph showing another operating parameter versus cooling capacity with and without heat exchanger blockage.

[0026] Figure 5 This is a simplified diagram of one embodiment of a heat exchanger in a cooling system according to the present disclosure.

[0027] Figure 6 It is a pressure versus flow rate graph, showing the measurement results indicating heat exchanger blockage.

[0028] Figure 7 This is a flowchart of one embodiment of a method for detecting blockage in a heat exchanger according to the present disclosure.

[0029] Figure 8 This is a flowchart of another embodiment of a method for detecting blockage in a heat exchanger according to the present disclosure.

[0030] Figure 9 This is a flowchart, which is part of yet another embodiment of a method for detecting blockage in a heat exchanger according to the present disclosure.

[0031] Figure 10 yes Figure 9 The flowchart for another part of the method.

[0032] Figure 11 This is a simplified flowchart of one embodiment of a heat exchanger for a cooling system according to the present disclosure.

[0033] Figure 12 This is a simplified flowchart of another embodiment of the heat exchanger of the cooling system according to the present disclosure. Detailed Implementation

[0034] The accompanying drawings described above and the written description of specific structures and functions below are not intended to limit the scope of the applicant's invention or the scope of the appended claims. Rather, these drawings and written descriptions are provided to teach any person skilled in the art to make and use the patent-seeking invention. Those skilled in the art will understand that not all features of a commercial implementation of the invention are described or shown for clarity and understanding purposes. Those skilled in the art will also understand that the development of a practical commercial implementation incorporating various aspects of the invention will require numerous implementation-specific decisions to achieve the developer's ultimate goals for the commercial implementation. Such implementation-specific decisions may include, but are not limited to, compliance with system-related, business-related, governmental-related constraints, and other constraints that may vary depending on the specific implementation, location, and timeframe. While the developer's efforts may be complex and time-consuming in an absolute sense, such efforts will be routine for those skilled in the art who benefit from this disclosure. It must be understood that the invention disclosed and taught herein is susceptible to many and various modifications and alternatives.

[0035] The use of singular terms such as, but not limited to, “a” is not intended as a limitation on the number of items. Furthermore, the use of relational terms such as, but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “downward,” “upward,” and “side” in the written description is for clarity when specifically referring to the accompanying drawings and is not intended to limit the scope of the invention or the appended claims. The terms “comprising” and “e.g.” are illustrative and not restrictive. The terms “coupled,” “coupled,” “coupled,” “coupler,” and similar terms are used extensively herein and may include any method or means for fixing, joining, bonding, fastening, attaching, engaging, inserting, forming thereon or therein, connecting one or more components, or otherwise associating one or more components together, for example mechanically, magnetically, electrically, chemically, operatively, directly, or indirectly through intermediate elements, and may also include, but is not limited to, integrally forming one functional component with another functional component in a monolithic manner. Coupling can occur in any direction, including in the direction of rotation. Furthermore, all parts and components that can be physically inherently implemented in this disclosure include both virtual and real features, whether such features are explicitly described herein or not. These features include, but are not limited to, features such as shafts, ends, inner and outer surfaces, internal spaces, tops, bottoms, sides, boundaries, dimensions (e.g., height, length, width, thickness), mass, weight, volume, and density.

[0036] Any process flowcharts discussed herein illustrate the operation of possible implementations of systems, methods, and computer program products according to various embodiments of this disclosure. In this regard, each box in the flowchart may represent a module, segment, or portion of code, which may include one or more executable instructions for implementing a specified logical function. It should also be noted that in some implementations, the functions indicated in the boxes may not occur in the order depicted in the figures. For example, boxes shown consecutively may actually be executed substantially simultaneously. It will also be noted that each box illustrated in the flowchart may be implemented by a system based on dedicated hardware or a combination of dedicated hardware and computer instructions that performs a specific function or action.

[0037] The applicant has created new and useful apparatus, systems, and methods for detecting blockages in heat exchangers (e.g., heat exchangers used in data center cooling systems). In at least one embodiment, the system for detecting heat exchanger blockages in a cooling system according to this disclosure can automatically detect when flow paths (e.g., airflow paths and / or fluid flow paths) are blocked or when the flow rate in the flow path is reduced (which may decrease the efficiency of the cooling system). In at least one embodiment, the system according to this disclosure can provide messages indicating potentially blocked paths and / or low-confidence heat exchanger blockages, alerts indicating paths experiencing limited blockages and / or medium-confidence heat exchanger blockages, alarms indicating significantly blocked paths and / or high-confidence heat exchanger blockages, or any combination thereof.

[0038] Figure 1 This is a schematic diagram of one embodiment of a cooling system according to the present disclosure. Figure 2 This is a schematic diagram of another embodiment of the cooling system according to the present disclosure. Figure 3 It is a graph showing the operating parameters versus cooling capacity under conditions of heat exchanger blockage and non-blockage. Figure 4 This is a graph showing another operating parameter versus cooling capacity under conditions of heat exchanger blockage and non-blockage. Figure 5 This is a simplified diagram of one embodiment of a heat exchanger in a cooling system according to the present disclosure. Figure 6 It is a pressure versus flow rate graph, showing the measurement results indicating heat exchanger blockage. Figure 7 This is a flowchart of one embodiment of a method for detecting blockage in a heat exchanger according to the present disclosure. Figure 8 This is a flowchart of another embodiment of a method for detecting blockage in a heat exchanger according to the present disclosure. Figure 9 This is a flowchart, which is part of yet another embodiment of a method for detecting blockage in a heat exchanger according to the present disclosure. Figure 10 yes Figure 9 The flowchart for another part of the method. Figure 11 This is a simplified flowchart of one embodiment of a heat exchanger for a cooling system according to the present disclosure. Figure 12 This is a simplified flowchart of another embodiment of the heat exchanger of the cooling system according to the present disclosure. Figures 1 to 12 They are described in combination.

[0039] In at least one embodiment, the cooling system 100 according to this disclosure may include one or more cooling units, loops or circuits 110, and / or one or more controllers 120 for controlling various components of the cooling system 100 and / or the cooling units 110. In at least one embodiment, any or all of the cooling units 110 may include one or more evaporators 130 for extracting heat, for example, from computer equipment in a data center; one or more condensers 140 for discharging that heat to the external environment and / or another cooling medium; one or more compressors or pumps 150 for circulating refrigerant or other cooling fluid through the evaporators 130 and / or condensers 140; one or more fans 160 for inducing airflow through the evaporators 130 and / or condensers 140; or any combination thereof. In at least one embodiment, any or all of the cooling units 110 may include one or more flow control valves 170 for controlling the flow of a cooling medium, refrigerant, other cooling fluid, or any combination thereof. In at least one embodiment, any or all of the cooling units 110 may include one or more sensors 180 for detecting one or more flow rates, one or more pressures, one or more temperatures, or any combination thereof. In at least one embodiment, any or all of the cooling units 110 may include one or more filters 190 for filtering contaminants from airflow, cooling medium, refrigerant, other cooling fluids, or any combination thereof.

[0040] In at least one embodiment, the method 200 for detecting heat exchanger blockage in a cooling system 100 according to the present disclosure may include: determining expected operating parameters; detecting current operating parameters (as shown in step 210); confirming that the cooling system 100 is operating in a steady state as a prerequisite for detecting the current operating parameters (as shown in step 220); comparing the expected operating parameters with the current operating parameters (as shown in step 230); identifying heat exchanger blockage at least in part based on the comparison; providing an indication if heat exchanger blockage is detected (as shown in step 240); or any combination thereof. In at least one embodiment, determining the expected operating parameters may include operating the cooling system 100 in a steady state and / or at a predetermined capacity, and recording the current operating parameters at this time as expected operating parameters (as shown in step 250) and / or calculating the expected operating parameters (as shown in step 260). In at least one embodiment, comparing the expected operating parameters with the current operating parameters may include calculating the difference between the expected operating parameters and the current operating parameters.

[0041] In at least one embodiment, when the current operating parameters are recorded as expected operating parameters (as shown in step 250), the cooling system 100 and / or cooling unit 110 can be operated without interference, and the operating parameters can be recorded. In at least one embodiment, once sufficient data is obtained for the operating range (which can be obtained, for example, through orthogonal space discretization), the current operation can be evaluated and / or compared with past operations of the cooling system 100 and / or cooling unit 110. In at least one embodiment, if the current operation and past operation (i.e., the current operating parameters and expected operating parameters) are similar (equal and / or within a threshold), the cooling system 100 can continue to operate without any changes or warnings. In at least one embodiment, if a difference exists, an alarm or other message can be provided to report a possible blockage. In at least one embodiment, method 200 can be implemented wholly or partially by controller 120, which can be part of a local controller and / or a remote monitoring system. In at least one embodiment, method 200 can include tracking the evolution of the cooling system 100 and / or each cooling unit 110 over time and / or can process each unit 110 individually. In at least one implementation, once a sufficient amount of data has been collected (which can be used for broader generalization), the threshold can be automatically updated based on cell type, configuration, coolant, etc.

[0042] In at least one embodiment, method 200 may include detecting blockages in the absence of historical data. In at least one embodiment, method 200 may include constructing and / or utilizing mathematical models of cooling system 100 and / or cooling unit 110. In at least one embodiment, the mathematical model may be as simple as calculating the energy consumption and / or capacity of pump or compressor 150 based on velocity (e.g., in RPM), suction pressure, condensing pressure, or any combination thereof. In at least one embodiment, the mathematical model may be or include different modeling techniques, such as white-box modeling, gray-box modeling, black-box modeling, or any combination thereof. In at least one embodiment, method 200 may include constructing and / or utilizing different mathematical models for different cooling units 110 of cooling system 100.

[0043] In at least one embodiment, the calculation of expected operating parameters may be based on one or more speeds, such as one or more fan speeds, one or more pump speeds, or any combination thereof. In at least one embodiment, the calculation of expected operating parameters may be based on one or more flow rates. In at least one embodiment, the calculation of expected operating parameters may be based on one or more pressures, such as one or more suction pressures, one or more discharge pressures, one or more condensing pressures, one or more pressure differentials (e.g., pressure differentials across the heat exchanger and / or filter), or any combination thereof. In at least one embodiment, the method 200 for detecting heat exchanger blockage according to this disclosure may include utilizing one or more pressure and / or one or more pressure differential readings across the condenser 140 and / or across the filter 190 serving the condenser 140, for example by utilizing... Figure 11 and / or Figure 12 The filter 190 is shown in the diagram. In at least one embodiment, the sensor 180 may operate as a differential pressure sensor and / or be used to check the pressure across the filter 190, across the condenser 140 without the filter 190, or across the condenser 140 with the filter 190. The pressure readings may be compared with the cooling capacity of unit 110 and valve opening / pump speed data.

[0044] In at least one embodiment, the calculation of expected operating parameters may be based on one or more temperatures, such as one or more cooling medium temperatures, one or more refrigerant temperatures, one or more air temperatures, or any combination thereof. In at least one embodiment, the calculation of expected operating parameters may be based on one or more demand signals. In at least one embodiment, the calculation of expected operating parameters may be based on one or more capacities, such as one or more pump capacities, one or more compressor capacities, one or more piping capacities, one or more cooling capacities (e.g., the cooling capacity of one or more cooling loops, circuits, or units), or any combination thereof.

[0045] In at least one embodiment, calculating the expected operating parameters may include calculating one or more speeds, such as one or more fan speeds, one or more pump speeds, or any combination thereof. In at least one embodiment, calculating the expected operating parameters may include calculating one or more flow rates. In at least one embodiment, calculating the expected operating parameters may include calculating one or more pressures, such as one or more suction pressures, one or more discharge pressures, one or more condensing pressures, one or more pressure differentials (e.g., pressure differential across a heat exchanger and / or filter), or any combination thereof. In at least one embodiment, calculating the expected operating parameters may include calculating one or more temperatures, such as one or more cooling medium temperatures, one or more refrigerant temperatures, one or more air temperatures, or any combination thereof.

[0046] In at least one embodiment, calculating the expected operating parameters may include calculating one or more speeds based on one or more capacities and / or one or more temperatures. In at least one embodiment, calculating the expected operating parameters may include calculating one or more temperatures based on one or more capacities and / or one or more speeds. In at least one embodiment, calculating the expected operating parameters may include calculating one or more capacities based on one or more speeds and / or one or more temperatures. In at least one embodiment, calculating the expected operating parameters may include calculating one or more speeds based on one or more pressures and / or one or more temperatures. In at least one embodiment, calculating the expected operating parameters may include calculating one or more pressures based on one or more speeds and / or one or more temperatures.

[0047] In at least one embodiment, method 200 may include confirming that cooling system 100 and / or cooling unit 110 is operating in a steady-state manner, and subsequently calculating the delivered cooling capacity. In at least one embodiment, method 200 may include, for example, calculating the expected pump speed or valve opening for delivering the required cooling to condenser 140 based on the cooling capacity and medium temperature, and knowing the geometric details of condenser 140. In at least one embodiment, method 200 may include continuing to operate cooling system 100 and / or cooling unit 110 if actual operation is within the expected range. In at least one embodiment, method 200 may include, for example, providing an alarm, a warning, or a message based on the magnitude of the difference.

[0048] In at least one embodiment, providing an indication if heat exchanger blockage is detected may include providing a warning, alarm, or other message if blockage is detected. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include providing a message if the difference between the current operating parameters and the expected operating parameters exceeds a first threshold. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include providing a warning if the difference exceeds a second threshold. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include providing an alarm if the difference exceeds a third threshold. In at least one embodiment, the second threshold may be greater than the first threshold. In at least one embodiment, the third threshold may be greater than the first threshold and / or the second threshold. In at least one embodiment, the message may be advisory in nature and may not trigger a corrective action. In at least one embodiment, a warning may trigger a basic corrective action. In at least one embodiment, a warning may trigger a corrective action that may be more urgent, more complex, more thorough, or any combination thereof.

[0049] In at least one embodiment, a method 200 for detecting heat exchanger blockage in a cooling system 100 having multiple cooling units 110, according to the present disclosure, may include: operating a first cooling unit 110 of the cooling system 100 at a predetermined capacity; detecting a first set of current operating parameters of the first cooling unit 110; recording the first set of current operating parameters of the first cooling unit 110 as expected operating parameters; determining the current capacity of the cooling system 100; calculating the maximum capacity of the cooling system 100 without the first cooling unit 110; waiting for a predetermined time period; performing a check process 270 if the maximum capacity is greater than the current capacity; or any combination thereof. In at least one embodiment, the check process 270 may include: operating the first cooling unit 110 at a predetermined capacity while using the cooling system 100 (as a whole) to provide the current capacity; detecting a second set of current operating parameters of the first cooling unit 110; comparing the expected operating parameters with the second set of current operating parameters; identifying heat exchanger blockage at least in part based on the comparison; or any combination thereof.

[0050] In at least one embodiment, a method 200 for detecting heat exchanger blockage in a cooling system 100 having multiple cooling units 110, according to the present disclosure, may include: forcing one or more cooling units 110 to operate at a specific cooling capacity (which may be referred to as a reference condition). In at least one embodiment, the reference condition and / or associated data may be obtained during unit startup or after cleaning, for example by forcing one or more cooling units 110 to operate in a steady state and recording data related to capacity, pump speed, valve opening, etc. In at least one embodiment, a checking procedure 270 may include: excluding one or more cooling units 110 from the cooling system 100 if the currently provided total cooling capacity is less than the maximum cooling capacity of the remaining units 110 of the system 100. In at least one embodiment, the inspection process 270 may include: operating the selected unit 110 at a previously specified cooling capacity (i.e., reference conditions), waiting for the selected unit 110 to reach a steady state, measuring the current data (capacity, pump speed, valve opening, etc.) of the selected unit 110, comparing these measurements with previously recorded data (under reference conditions), and providing an alarm, warning, or message, or any combination thereof, based on the magnitude of the difference between the measurement results and the previously recorded data (under reference conditions). In at least one embodiment, after performing the inspection process 270, the selected unit 110 may be reintroduced into the system 100 of unit 110 (operating in a collaborative working mode) and will continue its normal cooling delivery operation (i.e., collaborative working) as part of the system 100.

[0051] In at least one embodiment, the current capacity may vary, for example, based on demand and / or demand signals. In at least one embodiment, the current capacity, as used herein, need not be a measurement of the maximum capacity of the cooling system 100 or any of its components. In at least one embodiment, the current capacity, as used herein, may be a measurement of the current cooling output of the cooling system 100, which may vary based on demand and / or demand signals. In at least one embodiment, the current capacity of the cooling system 100 may change to meet a change in demand and / or demand signal. In at least one embodiment, the current capacity of the cooling system 100 may change proportionally to a change in demand and / or demand signal.

[0052] In at least one embodiment, operating the first cooling unit 110 at a predetermined capacity while using the cooling system 100 to provide the current capacity may include: operating the first cooling unit 110 at the predetermined capacity in a steady state, and proportionally changing the second capacity of the second cooling unit 110 of the cooling system 100 according to demand and / or demand signals. In at least one embodiment, operating the first cooling unit 110 at a predetermined capacity while using the cooling system 100 to provide the current capacity may include: operating the first cooling unit 110 at the predetermined capacity in a steady state, and proportionally changing one or more other cooling units 110 of the cooling system 100 according to demand and / or demand signals, for example, changing one or more speeds, one or more flow rates, one or more outputs, one or more capacities, or any combination thereof of one or more other cooling units 110.

[0053] In at least one embodiment, the check process 270 may be performed periodically (e.g., daily, weekly, monthly, or any combination thereof). In at least one embodiment, the check process 270 may be performed periodically if the maximum capacity is greater than the current capacity. In at least one embodiment, the check process 270 may be performed periodically only if the maximum capacity is greater than the current capacity. In at least one embodiment, the check process 270 may be performed after a time period has expired. In at least one embodiment, the check process 270 may be performed when the maximum capacity is greater than the current capacity after a time period has expired. In at least one embodiment, the check process 270 may be performed after a time period has expired and the current capacity has fallen below the maximum capacity.

[0054] In at least one embodiment, the maximum capacity as used herein does not need to be the maximum capacity of the entire cooling system 100. In at least one embodiment, the maximum capacity as used herein may be the maximum capacity of the cooling system 100 without one or more cooling units 110 of the cooling system 100. For example, if the cooling system 100 includes three cooling units, the maximum capacity as used herein may be the maximum capacity of two of the three cooling units 110 of the cooling system 100.

[0055] In at least one embodiment, the method 200 for detecting heat exchanger blockage according to this disclosure may include utilizing two or more detection techniques. In at least one embodiment, each of the above techniques may produce different confidence levels regarding whether the condenser 140 is blocked. In at least one embodiment, the method 200 may include providing a weighted sum of two or more of the above techniques. In at least one embodiment, each technique may have a specified weight "w", which may be based on the sensitivity and / or accuracy of each technique. In at least one embodiment, the weights may be summed to 1:

[0056]

[0057] In at least one embodiment, the output of the above technique can be a binary value, such that if a given technique detects the presence of a blockage, its output can be 1, otherwise 0. In at least one embodiment, the total detection confidence can be defined as follows:

[0058] Confidence threshold

[0059] As a numerical example, if three evaluation techniques (there can be more or fewer techniques) are used and they have equal weights (one or more techniques can have higher weights than others), then the weight value is 0.33. Different detection confidence levels can be defined as follows:

[0060]

[0061] Here, if only one of the various techniques provides a positive detection of a blockage, method 200 may include continuing to check system 100 without providing an alarm or other message.

[0062]

[0063] Here, if two of the various techniques provide that a blockage is detected, method 200 may include providing an alert or other message that can trigger a corrective action.

[0064]

[0065] Here, where the three technologies of the various techniques provide for detecting a blockage, method 200 may include providing an alarm and / or triggering a more urgent and / or thorough corrective action.

[0066] In at least one embodiment, the method 200 for detecting heat exchanger blockage according to this disclosure may include: operating a cooling system 100 in a steady state and recording a first set of current operating parameters of the cooling system 100 as a first set of expected operating parameters; determining the current capacity of the cooling system 100; calculating a second set of expected operating parameters based at least in part on the current capacity; detecting the second set of current operating parameters of the cooling system 100; comparing the second set of current operating parameters with the first set of expected operating parameters and the second set of expected operating parameters; identifying heat exchanger blockage based at least in part on the comparison; or any combination thereof. In at least one embodiment, the first set of expected operating parameters may include an indication of a first capacity at the time the first set of current operating parameters is recorded. In at least one embodiment, the method 200 may include, for example, creating a first set of extrapolated expected operating parameters by extrapolating the first set of expected operating parameters based at least in part on the difference between the current capacity and the first capacity. In at least one embodiment, comparing the second set of current operating parameters with the first set of expected operating parameters may include or include comparing the second set of current operating parameters with the first set of extrapolated expected operating parameters. In at least one embodiment, each set of current operating parameters and / or expected operating parameters may include one or more expected operating parameters, such as one or more speeds, one or more flow rates, one or more pressures, one or more temperatures, one or more capacities, or any combination thereof.

[0067] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: determining that a second set of current operating parameters exceeds one or more of the expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: determining that a second set of current operating parameters exceeds a first threshold of extrapolated expected operating parameters from a first set; determining that a second set of current operating parameters exceeds a second threshold of expected operating parameters from a second set; determining that a second set of current operating parameters exceeds the first threshold of extrapolated expected operating parameters from a first set and / or that a second set of current operating parameters exceeds the second threshold of expected operating parameters from a second set; or any combination thereof. In at least one embodiment, the first threshold may be the same as or different from the second threshold.

[0068] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: determining that a second set of current operating parameters exceeds one or more thresholds from one or more sets of expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: determining that a second set of current operating parameters exceeds one threshold from any set of expected operating parameters or exceeds other thresholds from the set of expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: assigning a higher weight to one or more sets of expected operating parameters than to other sets of expected operating parameters. In at least one embodiment, the method for detecting heat exchanger blockage according to this disclosure may provide an indication of heat exchanger blockage, an indication of the severity of heat exchanger blockage, an indication of the confidence level of heat exchanger blockage, or any combination thereof.

[0069] In at least one embodiment, identifying heat exchanger blockage based at least in part on comparison may include: determining that a second set of current operating parameters exceeds a first set of extrapolated expected operating parameters and a first threshold of the second set of expected operating parameters; that the second set of current operating parameters exceeds a second threshold of the first set of extrapolated expected operating parameters; that the second set of current operating parameters exceeds a third threshold of the second set of expected operating parameters; or any combination thereof. In at least one embodiment, the second threshold may be greater than the first threshold. In at least one embodiment, the third threshold may be greater than the second threshold and / or the first threshold.

[0070] In at least one embodiment, method 200 may include: operating a first cooling unit 110 of cooling system 100 at a predetermined capacity; detecting a third set of current operating parameters of the first cooling unit 110; recording the third set of current operating parameters of the first cooling unit 110 as a third set of expected operating parameters; calculating the maximum capacity of cooling system 100 without the first cooling unit 110; waiting for a predetermined time period; performing a check process 270 if the maximum capacity is greater than the current capacity (and performing the check process 270 only if the maximum capacity is greater than the current capacity); or any combination thereof. In at least one embodiment, check process 270 may include: operating the first cooling unit 110 at a predetermined capacity while using cooling system 100 to provide the current capacity; detecting a fourth set of current operating parameters of the first cooling unit 110; or any combination thereof. In at least one embodiment, comparing the current operating parameters with the expected operating parameters may include comparing the third set of expected operating parameters with the fourth set of current operating parameters.

[0071] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: determining that a second set of current operating parameters exceeds a first threshold of extrapolated expected operating parameters from a first set; that the second set of current operating parameters exceeds a second threshold of expected operating parameters from a second set; and that a fourth set of current operating parameters exceeds a third threshold of expected operating parameters from a third set. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: determining that a second set of current operating parameters exceeds both the first threshold of extrapolated expected operating parameters from a first set and the second threshold of expected operating parameters from a second set; that the second set of current operating parameters exceeds both the first threshold of extrapolated expected operating parameters from a first set and the fourth set of current operating parameters exceeds the third threshold of expected operating parameters from a third set; that the second set of current operating parameters exceeds both the second threshold of expected operating parameters from a second set and the fourth set of current operating parameters exceeds the third threshold of expected operating parameters from a third set; or any combination thereof. In at least one embodiment, the second threshold may be less than, greater than, or equal to the first threshold. In at least one embodiment, the third threshold may be less than, greater than, or equal to the second threshold and / or the first threshold.

[0072] As those skilled in the art who benefit from this disclosure will understand, aspects of one or more embodiments of this disclosure can be implemented as a system, method, or computer program product. Therefore, aspects of this disclosure can take the form of a completely hardware implementation, a completely software implementation (including firmware, resident software, microcode, etc.), or an implementation combining software and hardware aspects, all of which can be collectively referred to herein as “circuit,” “module,” or “system.” Furthermore, aspects of this disclosure can take the form of a computer program product contained in one or more non-transitory computer-readable media having computer-readable program code contained thereon. Any combination of one or more computer-readable media can be utilized. The computer-readable media can be a computer-readable signal medium or a computer-readable storage medium. The computer-readable storage medium can be, for example, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, device, or apparatus, or any suitable combination thereof. More specific examples of such computer-readable storage media include, but are not limited to, the following: an electrical connection having one or more wires, a portable computer disk, a hard disk, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable optical disc read-only memory (CD-ROM), optical storage device, magnetic storage device, or any suitable combination thereof. In the context of this document, a computer-readable storage medium can be any tangible medium that can contain or store a program used by or in conjunction with an instruction execution system, device, or apparatus.

[0073] The program code contained on a computer-readable medium may be transmitted using any suitable medium or medium, including but not limited to wireless, wired, fiber optic cable, radio frequency (RF), or any suitable combination of the foregoing. The computer program code used to perform the operations of various aspects of this disclosure may be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Java, Smalltalk, C++, etc., and conventional procedural programming languages ​​such as the "C" programming language or similar programming languages. The program code may be executed entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer via any type of network including a local area network (LAN) or a wide area network (WAN), or may be connected to an external computer (e.g., via the Internet provided by an Internet service provider or via short-range wireless interconnection such as Bluetooth).

[0074] Aspects of this disclosure may be described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (devices and systems), and computer program products according to embodiments of this disclosure. Each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, may be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general-purpose computer, special-purpose computer, or other programmable data processing apparatus to produce a machine, such that instructions executed via one or more processors create means for implementing the functions / actions specified in the flowchart illustrations and / or one or more block diagram blocks. The computer program instructions may be stored in a computer-readable medium that instructs a computer, other programmable data processing apparatus, or other apparatus to operate in a particular manner, such that the instructions stored in the computer-readable medium produce an article of writing including instructions for implementing the functions / actions specified in the flowchart illustrations and / or one or more block diagram blocks. The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other apparatus to cause a series of operational steps to be performed on the computer, other programmable apparatus, or other apparatus, thereby producing a computer-implemented process, such that instructions executing on the computer or other programmable apparatus provide a process for implementing the functions / actions specified in the flowchart illustrations and / or one or more block diagram blocks. Each box in a flowchart and / or block diagram can be divided into multiple boxes and / or combined with other boxes to form a single box.

[0075] In at least one embodiment, a method for detecting heat exchanger blockage in a cooling system according to the present disclosure may include: determining expected operating parameters; detecting current operating parameters; confirming that the cooling system is operating in a steady state as a prerequisite for detecting the current operating parameters; comparing the expected operating parameters with the current operating parameters; identifying heat exchanger blockage at least in part based on the comparison; providing an indication if heat exchanger blockage is detected; or any combination thereof. In at least one embodiment, determining the expected operating parameters may include operating the cooling system in a steady state and / or at a predetermined capacity, and recording the current operating parameters at this time as the expected operating parameters and / or calculating the expected operating parameters. In at least one embodiment, comparing the expected operating parameters with the current operating parameters may include calculating the difference between the expected operating parameters and the current operating parameters.

[0076] In at least one embodiment, the expected operating parameters may be calculated based on one or more speeds, such as one or more fan speeds, one or more pump speeds, or any combination thereof. In at least one embodiment, the expected operating parameters may be calculated based on one or more flow rates. In at least one embodiment, the expected operating parameters may be calculated based on one or more pressures, such as one or more suction pressures, one or more discharge pressures, one or more condensing pressures, one or more pressure differentials (e.g., pressure differential across a heat exchanger and / or filter), or any combination thereof. In at least one embodiment, the expected operating parameters may be calculated based on one or more temperatures, such as one or more cooling medium temperatures, one or more refrigerant temperatures, one or more air temperatures, or any combination thereof. In at least one embodiment, the expected operating parameters may be calculated based on one or more demand signals. In at least one embodiment, the expected operating parameters may be calculated based on one or more capacities, such as one or more pump capacities, one or more compressor capacities, one or more piping capacities, one or more cooling capacities (e.g., cooling capacity of one or more cooling loops, circuits, or units), or any combination thereof.

[0077] In at least one embodiment, calculating the expected operating parameters may include calculating one or more speeds, such as one or more fan speeds, one or more pump speeds, or any combination thereof. In at least one embodiment, calculating the expected operating parameters may include calculating one or more flow rates. In at least one embodiment, calculating the expected operating parameters may include calculating one or more pressures, such as one or more suction pressures, one or more discharge pressures, one or more condensing pressures, one or more pressure differentials (e.g., pressure differential across a heat exchanger and / or filter), or any combination thereof. In at least one embodiment, calculating the expected operating parameters may include calculating one or more temperatures, such as one or more cooling medium temperatures, one or more refrigerant temperatures, one or more air temperatures, or any combination thereof.

[0078] In at least one embodiment, providing an indication if heat exchanger blockage is detected may include: providing a warning, alarm, or other message if blockage is detected. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include: providing a message if the difference (between the current operating parameters and the expected operating parameters) exceeds a first threshold. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include: providing a warning if the difference exceeds a second threshold. In at least one embodiment, providing an indication if heat exchanger blockage is detected may include: providing an alarm if the difference exceeds a third threshold. In at least one embodiment, the second threshold may be greater than the first threshold. In at least one embodiment, the third threshold may be greater than the first threshold and / or the second threshold.

[0079] In at least one embodiment, a method for detecting heat exchanger blockage in a cooling system having multiple cooling units according to the present disclosure may include: operating a first cooling unit of the cooling system at a predetermined capacity; detecting a first set of current operating parameters of the first cooling unit; recording the first set of current operating parameters of the first cooling unit as expected operating parameters; determining the current capacity of the cooling system; calculating the maximum capacity of the cooling system without the first cooling unit; waiting for a predetermined time period; and performing a check process if the maximum capacity is greater than the current capacity; or any combination thereof. In at least one embodiment, the check process may include: operating the first cooling unit at a predetermined capacity while using the cooling system (as a whole) to provide the current capacity; detecting a second set of current operating parameters of the first cooling unit; comparing the expected operating parameters with the second set of current operating parameters; identifying heat exchanger blockage at least in part based on the comparison; or any combination thereof.

[0080] In at least one embodiment, the current capacity may vary, for example, based on demand and / or demand signals. In at least one embodiment, the current capacity, as used herein, does not need to be a measurement of the maximum capacity. In at least one embodiment, the current capacity, as used herein, may be a measurement of the current cooling output of the cooling system, which may vary based on demand and / or demand signals. In at least one embodiment, the current capacity of the cooling system may change to meet the demand and / or demand signals when they change. In at least one embodiment, the current capacity of the cooling system may change proportionally when the demand and / or demand signals change.

[0081] In at least one embodiment, operating the first cooling unit at a predetermined capacity while using the cooling system to provide the current capacity may include: operating the first cooling unit at the predetermined capacity in a steady state, and proportionally changing the second capacity of a second cooling unit of the cooling system according to demand and / or demand signals. In at least one embodiment, operating the first cooling unit at a predetermined capacity while using the cooling system to provide the current capacity may include: operating the first cooling unit at the predetermined capacity in a steady state, and proportionally changing one or more other cooling units of the cooling system according to demand and / or demand signals, such as one or more speeds, one or more flow rates, one or more outputs, one or more capacities, or any combination thereof of one or more other cooling units.

[0082] In at least one embodiment, the check process can be performed periodically (e.g., daily, weekly, monthly, or any combination thereof). In at least one embodiment, the check process can be performed periodically if the maximum capacity is greater than the current capacity. In at least one embodiment, the check process can be performed periodically only if the maximum capacity is greater than the current capacity. In at least one embodiment, the check process can be performed after a time period has expired. In at least one embodiment, the check process can be performed if the maximum capacity is greater than the current capacity after a time period has expired. In at least one embodiment, the check process can be performed after a time period has expired and the current capacity has fallen below the maximum capacity.

[0083] In at least one embodiment, the maximum capacity as used herein does not need to be the maximum capacity of the entire cooling system. In at least one embodiment, the maximum capacity as used herein may be the maximum capacity of the cooling system in the absence of one or more cooling units of the cooling system.

[0084] In at least one embodiment, the method for detecting heat exchanger blockage according to this disclosure may include utilizing two or more detection techniques. In at least one embodiment, the method for detecting heat exchanger blockage according to this disclosure may include: operating the cooling system in a steady state and recording a first set of current operating parameters of the cooling system as a first set of expected operating parameters; determining the current capacity of the cooling system; calculating a second set of expected operating parameters based at least in part on the current capacity; detecting the second set of current operating parameters of the cooling system; comparing the second set of current operating parameters with the first set of expected operating parameters and the second set of expected operating parameters; identifying heat exchanger blockage based at least in part on the comparison; or any combination thereof. In at least one embodiment, the first set of expected operating parameters may include an indication of a first capacity at the time the first set of current operating parameters was recorded. In at least one embodiment, the method may include, for example, creating a first set of extrapolated expected operating parameters by extrapolating the first set of expected operating parameters based at least in part on the difference between the current capacity and the first capacity. In at least one embodiment, comparing the second set of current operating parameters with the first set of expected operating parameters may include or include comparing the second set of current operating parameters with the first set of extrapolated expected operating parameters. In at least one embodiment, each set of current operating parameters and / or expected operating parameters may include one or more expected operating parameters, such as one or more speeds, one or more flow rates, one or more pressures, one or more temperatures, one or more capacities, or any combination thereof.

[0085] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds one or more of the expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds a first threshold of extrapolated expected operating parameters from a first set, determining that a second set of current operating parameters exceeds a second threshold of expected operating parameters from a second set, determining that a second set of current operating parameters exceeds a first threshold of extrapolated expected operating parameters from a first set and / or a second threshold of expected operating parameters from a second set, or any combination thereof. In at least one embodiment, the first threshold may be the same as or different from the second threshold.

[0086] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds one or more thresholds from one or more sets of expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds one threshold from any set of expected operating parameters or exceeds other thresholds from the sets of expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include assigning a higher weight to one or more sets of expected operating parameters than to other sets of expected operating parameters. In at least one embodiment, the method for detecting heat exchanger blockage according to this disclosure may provide an indication of heat exchanger blockage, an indication of the severity of heat exchanger blockage, an indication of the confidence level of heat exchanger blockage, or any combination thereof.

[0087] In at least one embodiment, identifying heat exchanger blockage based at least in part on comparison may include determining that a second set of current operating parameters exceeds a first set of extrapolated expected operating parameters and a first threshold of the second set of expected operating parameters, that the second set of current operating parameters exceeds a second threshold of the first set of extrapolated expected operating parameters, that the second set of current operating parameters exceeds a third threshold of the second set of expected operating parameters, or any combination thereof. In at least one embodiment, the second threshold may be greater than the first threshold. In at least one embodiment, the third threshold may be greater than the second threshold and / or the first threshold.

[0088] In at least one embodiment, the method may include operating a first cooling unit of the cooling system at a predetermined capacity, detecting a third set of current operating parameters of the first cooling unit, recording the third set of current operating parameters of the first cooling unit as a third set of expected operating parameters, calculating the maximum capacity of the cooling system without the first cooling unit, waiting for a predetermined time period, performing a check process when (and only when) the maximum capacity is greater than the current capacity, or any combination thereof. In at least one embodiment, the check process may include: operating the first cooling unit at a predetermined capacity while using the cooling system to provide the current capacity; detecting a fourth set of current operating parameters of the first cooling unit; or any combination thereof. In at least one embodiment, comparing the current operating parameters with the expected operating parameters may include comparing the third set of expected operating parameters with the fourth set of current operating parameters.

[0089] In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include determining that a second set of current operating parameters exceeds a first threshold of extrapolated expected operating parameters, that the second set of current operating parameters exceeds a second threshold of expected operating parameters, and that a fourth set of current operating parameters exceeds a third threshold of expected operating parameters. In at least one embodiment, identifying heat exchanger blockage at least partially based on comparison may include: determining that a second set of current operating parameters exceeds both the first and second thresholds of extrapolated expected operating parameters; that the second set of current operating parameters exceeds both the first and third thresholds of extrapolated expected operating parameters; that the second set of current operating parameters exceeds both the second and third thresholds of expected operating parameters; that the second set of current operating parameters exceeds both the second and third thresholds of expected operating parameters; or any combination thereof. In at least one embodiment, the second threshold may be less than, greater than, or equal to the first threshold. In at least one embodiment, the third threshold may be less than, greater than, or equal to the second threshold and / or the first threshold.

[0090] Without departing from the spirit of the applicant's disclosure, other and additional implementations utilizing one or more aspects of this disclosure are conceivable. For example, apparatus, systems, and methods can be implemented for many different types and sizes across many different industries. Furthermore, various methods and implementations of apparatus, systems, and methods can be combined with each other to produce variations of the disclosed methods and implementations. Discussion of singular elements can include plural elements, and vice versa. Unless otherwise specifically limited, the order of steps can occur in various sequences. The individual steps described herein can be combined with other steps, interspersed with described steps, and / or broken down into multiple steps. Similarly, elements have been functionally described and can be implemented as individual components or combined into components having multiple functions.

[0091] This invention has been described in the context of preferred and other embodiments, and not every embodiment of the invention has been described. Obvious modifications and alterations to the described embodiments will be available to those skilled in the art who will benefit from this disclosure. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention as envisioned by the applicant, but rather, in accordance with patent law, the applicant intends to fully protect all such modifications and improvements that fall within the scope or equivalent of the appended claims.

Claims

1. A method for detecting blockage in a heat exchanger, the method comprising: Determine the expected operating parameters of the cooling system; The current operating parameters of the cooling system are detected at least in part based on signals from one or more sensors configured to communicate with the cooling system. Compare the expected operating parameters with the current operating parameters; and Heat exchanger blockage is identified at least in part based on the comparison.

2. The method according to claim 1, wherein, The determination includes operating the cooling system in a stable state and recording the current operating parameters as the expected operating parameters.

3. The method according to claim 1, wherein, The determination includes calculating the expected operating parameters.

4. The method according to claim 3, wherein, The calculations are based, at least in part, on velocity, pressure, and temperature.

5. The method according to claim 3, wherein, The calculations are based, at least in part, on the temperature of the cooling medium.

6. The method according to claim 3, wherein, The calculations are based, at least in part, on demand signals.

7. The method according to claim 3, wherein, The calculation includes calculating at least one of the expected speed and the expected valve position.

8. The method according to claim 1, wherein, The determination includes operating the cooling system at a predetermined capacity and recording the current operating parameters as the expected operating parameters.

9. The method of claim 1, further comprising confirming that the cooling system is operating in a stable state as a prerequisite for detecting the current operating parameters.

10. The method according to claim 1, wherein, The comparison includes calculating the difference between the expected operating parameters and the current operating parameters.

11. The method of claim 10, further comprising: If the difference exceeds a first threshold, a message is provided; If the difference exceeds the second threshold, a warning is issued; And if the difference exceeds a third threshold, an alert is provided; wherein the second threshold is greater than the first threshold; wherein the third threshold is greater than the second threshold; wherein the message is different from the warning; and wherein the alert is different from both the message and the warning.

12. A method for detecting blockage in a heat exchanger of a cooling system having multiple cooling units, the method comprising: The first cooling unit of the cooling system is operated at a predetermined capacity. Detect the first set of current operating parameters of the first cooling unit; Record the first set of current operating parameters of the first cooling unit as expected operating parameters; Determine the current capacity of the cooling system; Calculate the maximum capacity of the cooling system without the first cooling unit; as well as If the maximum capacity is greater than the current capacity, then a check process is performed; The inspection process includes: While using the cooling system to provide the current capacity, the first cooling unit is operated at the predetermined capacity; Detect the second set of current operating parameters of the first cooling unit; Compare the expected operating parameters with the second set of current operating parameters; and Heat exchanger blockage is identified at least in part based on the comparison.

13. The method according to claim 12, wherein, The current capacity changes based on demand signals.

14. The method according to claim 13, wherein, While using the cooling system to provide the current capacity, operating the first cooling unit at the predetermined capacity includes: operating the first cooling unit at the predetermined capacity in a stable state, and proportionally changing the second capacity of the second cooling unit of the cooling system in accordance with the demand signal.

15. The method according to claim 12, wherein, If the maximum capacity is greater than the current capacity, the check process is performed periodically; and the check process is performed periodically only when the maximum capacity is greater than the current capacity.

16. The method according to claim 12, wherein, The check process is performed when the maximum capacity exceeds the current capacity after a certain period expires.

17. A method for detecting blockage in a heat exchanger, the method comprising: The cooling system is operated in a stable state, and a first set of current operating parameters of the cooling system is recorded as a first set of expected operating parameters, wherein the first set of expected operating parameters includes an indication of a first capacity when the first set of current operating parameters is recorded. Determine the current capacity of the cooling system; The second set of expected operating parameters is calculated at least in part based on the current capacity; A first set of extrapolated expected operating parameters is created by extrapolating the first set of expected operating parameters based at least in part on the difference between the current capacity and the first capacity. Detect the second set of current operating parameters of the cooling system; Compare the second set of current operating parameters with the first set of extrapolated expected operating parameters and the second set of expected operating parameters; and Heat exchanger blockage is identified at least in part based on the comparison.

18. The method according to claim 17, wherein, The identification includes: determining that the second group of current operating parameters exceeds a first threshold of the first group of extrapolated expected operating parameters, or determining that the second group of current operating parameters exceeds a second threshold of the second group of expected operating parameters.

19. The method of claim 17, wherein, The identification includes: determining that the second group of current operating parameters exceeds a first threshold of the first group of extrapolated expected operating parameters, and determining that the second group of current operating parameters exceeds a second threshold of the second group of expected operating parameters.

20. The method of claim 17, wherein, The identification includes: determining that the second group of current operating parameters exceeds the first group of extrapolated expected operating parameters and the first threshold of the second group of expected operating parameters; determining that the second group of current operating parameters exceeds the second threshold of the first group of extrapolated expected operating parameters; or determining that the second group of current operating parameters exceeds the third threshold of the second group of expected operating parameters, wherein the second threshold is greater than the first threshold and the third threshold is greater than the first threshold.

Images