Method for managing a process engineering facility
Patent Information
- Application Number
- EP2023754705
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-08-19
- Filing Date
- 2023-08-08
- Publication Date
- 2025-06-25
- Estimated Expiration
- 2043-08-08
AI Technical Summary
Process engineering systems, particularly those utilizing heat exchangers, face challenges in effectively managing and monitoring the operation and service life of heat exchanger blocks due to temperature differences, which can lead to mechanical stresses, wear, and reduced service life, lacking comprehensive monitoring and predictive maintenance tools.
A method and graphical user interface that utilize sensor data to determine key parameters like temperature differences between heat exchanger blocks, providing a graphical representation of service life and operational state, enabling predictive maintenance and optimization of heat exchanger performance and lifespan.
The solution allows for real-time monitoring and management of heat exchanger operation, predicting service life, reducing wear, and optimizing performance by providing actionable insights for maintenance and operational adjustments, thereby extending the lifespan and improving efficiency of heat exchangers.
Smart Images

Figure 1.1
Abstract
Description
[0001] Description
[0002] PROCEDURE FOR MANAGING A PROCESS PLANT
[0003] The invention relates to a method for managing a process engineering plant and a graphical user interface for managing a process engineering plant as well as a computing system, a computer program and a machine-readable storage medium.
[0004] Background of the invention
[0005] Process engineering plants are typically understood to be systems for carrying out material changes and / or transformations using targeted physical and / or chemical and / or biological and / or nuclear processes. Such changes and transformations typically include crushing, screening, mixing, heat transfer, rectification, crystallization, drying, cooling, filling, and superimposed material transformations such as chemical, biological, or nuclear reactions.
[0006] Heat exchangers, such as vacuum-brazed (aluminum) plate fin heat exchangers (PFHE) or coil-wound heat exchangers (CWHE), are often used in process plants due to a variety of advantages (heat integration, compactness, cost). For example, such a (plate) heat exchanger can comprise a plurality of parallel-arranged separating plates or baffles.
[0007] "separator plates") and a plurality of fins or structured plates with fins, with one fin arranged between each two adjacent separator plates, forming a plurality of parallel channels through which a medium can flow. The fins are delimited at the sides by so-called sidebars (edge strips) that are soldered to the adjacent plates. The interconnected structured plates, sidebars, separator plates, and cover plates form a heat exchanger block. In this way, a heat exchanger block is formed with a plurality of parallel heat transfer passages, allowing media to be passed past each other, for example, in countercurrent, to achieve indirect heat exchange. A heat exchanger, in particular a plate heat exchanger (PFHE), can comprise a plurality of such heat exchanger blocks.
[0008] The aim is to be able to manage such a process plant, for example in order to be able to operate the plant effectively.
[0009] Disclosure of the invention
[0010] Against this background, a method for managing a process plant and a graphical user interface for managing a process plant, as well as a computing system, a computer program, and a machine-readable storage medium having the features of the independent patent claims, are proposed. Advantageous embodiments are the subject of the dependent claims and the following description.
[0011] The process plant comprises at least one heat exchanger. Each of these heat exchangers is designed as a plate heat exchanger, e.g., a vacuum-brazed (aluminum) plate heat exchanger (PFHE). Furthermore, each of these heat exchangers comprises a plurality of heat exchanger blocks. These individual heat exchangers are provided in the process plant, in particular, for heating or cooling a specific fluid or fluid stream. In addition to the plate heat exchangers, the process plant may comprise other components, for example, other, differently designed heat exchangers (e.g., spiral-wound heat exchangers, CWHE), columns (hollow, slender columns with internals), phase separation devices (vessels with internals), vessels for phase separation, etc.For example, the process plant can be a plant for the separation and / or liquefaction of gases, for example an air separation plant, or generally a plant for the separation of mixtures of substances based on physical properties, a natural gas plant, a hydrogen and synthesis gas plant, an adsorption and membrane plant, e.g. a pressure swing adsorption plant, or a cryogenic plant, e.g. for cooling superconductors and cold neutron sources, MRIs, fusion and fission applications or in the liquefaction of helium and hydrogen.
[0012] Within the scope of the present method, sensor values, measured values, or current actual values are received from sensors arranged on or in the at least one heat exchanger. These sensors can be installed, for example, on a surface of the respective heat exchanger or within the heat exchanger or protruding into the heat exchanger. The sensor values can, in particular, characterize physical / chemical properties of the heat exchanger itself or its operation, e.g., its material or a fluid flowing through the heat exchanger. The sensor values expediently describe current temperature values of individual or all heat exchanger blocks of the respective heat exchanger.
[0013] Based on these received sensor values, parameters (or key figures) are determined that identify or characterize the operation of the at least one heat exchanger. These parameters can, for example, directly describe the current state or current physical conditions of the at least one heat exchanger or at least allow conclusions to be drawn about such properties. Such a parameter can, for example, be a so-called key performance indicator (KPI), which can be used to evaluate, for example, progress or the degree of fulfillment of specified goals.
[0014] As such a characteristic, a temperature difference between heat exchanger blocks of the at least one heat exchanger is determined. For example, measured temperature values on the surface of the individual heat exchanger blocks or measured temperature values within the individual heat exchanger blocks can be taken into account for this purpose. Temperature differences between directly adjacent heat exchanger blocks that are mechanically connected to one another and / or in fluid communication with one another are expediently determined.
[0015] It is also possible to conveniently determine several temperature differences between several adjacent heat exchanger blocks as a characteristic. Furthermore, additional characteristic values can be conveniently determined from additional sensor values.
[0016] The received sensor values and / or the determined parameters are processed for a graphical representation of a state of the at least one heat exchanger. This state can, in particular, characterize the operation of the at least one heat exchanger, e.g., effectiveness, performance, etc. For example, the state can be a current state and thus, in particular, characterize the current operation of the respective heat exchanger. Furthermore, the state can also be a past state and, in particular, characterize the operation of the at least one heat exchanger in the past. Furthermore, the state can also be a future state, for example, extrapolated from the current and / or past state.
[0017] The sensor values or parameters are processed in particular in such a way that (operationally) relevant information regarding the condition, which is important for the operation of the respective heat exchanger and also for the operation of the entire system, can be extracted or recognized in a simple and clear manner. The representation of the condition can be an audiovisual representation of the respective condition, in particular a graphical or visual and / or an acoustic representation. For example, the representation can comprise a visual representation of individual sensor values and / or parameters in a two- or multi-dimensional graph, e.g. as an image file or as an interactive, editable graphic. Furthermore, the representation can comprise, for example, an acoustic representation, e.g. with the aid of audio files, e.g. an acoustic output of individual sensor values or parameters, an output of warning tones, etc.
[0018] At least one service life or a remaining service life is determined as the condition of the at least one heat exchanger depending on the specific temperature difference between the heat exchanger blocks of the at least one heat exchanger. Furthermore, a graphical representation of this service life of the at least one heat exchanger is determined. For example, the service life can be determined or extrapolated from the sensor values or parameters using analytical, numerical or statistical methods, e.g. with the help of theoretical simulations. Temperature differences between heat exchanger blocks can have direct, immediate but also indirect effects on the service life of the respective heat exchanger. Large temperature differences between the individual heat exchanger blocks can lead to considerable loads on the material of the blocks, in particular to considerable mechanical stresses.For example, large temperature differences can place high stresses on connecting lines or connecting elements between individual heat exchanger blocks. Such high stresses can lead to deformation, wear, fatigue, and weakening of the block material. Persistently high temperature differences and frequently changing temperature differences can further increase such stresses. Large or changing temperature differences between heat exchanger blocks within a single heat exchanger can therefore negatively impact the service life of the heat exchanger.
[0019] To determine the service life, for example, an original service life can be considered, which was determined, estimated, or estimated after the heat exchanger was manufactured or initially commissioned, as well as the operating period that has already elapsed since the initial commissioning. Depending on the current temperature differences between heat exchanger blocks, corresponding mechanical stresses and loads on the heat exchanger material can be determined, and corresponding effects on the service life or a corresponding reduction in the service life can be extrapolated, estimated, or calculated. For this purpose, analytical, numerical, or statistical calculations and / or simulations can be performed, for example.In this way, the current remaining service life of the heat exchanger can be determined as the condition of the respective heat exchanger, expediently depending on the original service life, the total operating time to date and the effects of temperature differences.
[0020] The estimated service life can be conveniently prepared for graphical representation in such a way that the remaining service life can be easily identified and understood. For example, in addition to the current estimated service life, a service life history can also be displayed. This makes it particularly easy to understand how the estimated remaining service life has developed or changed during previous operation. This makes it particularly easy to understand which events, operating conditions, and temperature differences have a significant impact on the remaining service life.
[0021] This graphical representation of the service life can, for example, provide a service life tracker or monitor, which displays the service life consumption based on the system's operating conditions and predicts the remaining service life. Furthermore, it can also display a histogram of the thermal and / or mechanical cycles and thermal fatigue of the individual heat exchangers. For example, such a service life monitor can be used to provide recommendations for maintenance and / or replacement measures, taking into account, for example, delivery times for components to be replaced or installed.
[0022] The processed sensor values and / or parameters are output or displayed in a graphical user interface. In the course of this, the graphical representation of the service life of at least one heat exchanger is output in the graphical user interface. This graphical user interface represents, in particular, a human-machine interface, an input / output interface, a user interface, or an (information management) dashboard. In particular, this user interface represents a software tool or software tool for interacting with the system in order to output information relevant to the operation and management of the system and to further enable the operation of the system to be influenced.
[0023] For example, the graphical user interface can be output by a computing unit, e.g., a PC, a laptop, a tablet, a control unit, etc. A central, uniform interface is particularly advantageous for the graphical user interface. The graphical user interface, or the software underlying the graphical user interface, is particularly advantageously executed by a central computing unit or a central computing system, e.g., by a server or a computing system in the context of so-called "cloud computing." Thus, the underlying software does not have to be executed on the computing unit itself from which the graphical user interface is displayed or output, but can be executed centrally by a remote computing unit.The graphical user interface can thus be displayed uniformly and independently on a variety of different computing units. For example, the graphical user interface can be streamed from the central processing unit by the respective computing unit or displayed in a browser-based manner, e.g., as a (web) dashboard.
[0024] Depending on these output, processed sensor values and / or parameters, the operation of at least one heat exchanger is managed, monitored or controlled in the graphical user interface.
[0025] Relevant information characterizing the operation of the respective heat exchanger can be read in the user interface and based on this information, the current operation can be monitored and changes can be developed and implemented to improve the operation.
[0026] During this management, the determined (in particular remaining) service life of at least one heat exchanger is monitored or analyzed. The graphical representation of the service life output in the graphical user interface can expediently be used to detect and monitor effects or changes in the service life. A detected, in particular non-linear (e.g. exponential) reduction in the service life, e.g. due to large temperature differences between the heat exchanger blocks, can expediently be counteracted, e.g. by adjusting operating parameters or operating points of the heat exchanger or the entire system. For example, the service life consumption of the heat exchangers during past operating states can be tracked in the graphical user interface, and operational improvements can be developed to increase the remaining service life.
[0027] The invention further relates to a corresponding graphical user interface, wherein advantages and advantageous embodiments of this graphical user interface according to the invention and of the method according to the invention arise accordingly from the present description. The graphical user interface has at least one display area that is configured to output sensor values and / or parameters that were received or determined and processed according to the present method. The display area is configured to output the graphical representation of the service life of the at least one heat exchanger. These display areas or display panels make it possible to present the information relevant to the operation of the respective heat exchanger in an intuitive and clear manner. For example, one or more such display areas can be provided for each heat exchanger.Alternatively or additionally, one or more such display areas can be provided for each of the processed sensor values and / or parameters.
[0028] The present invention provides a way to visualize, monitor, and manage the operation of individual heat exchangers in a process plant online. For this purpose, the graphical user interface provides a central, uniform interface for displaying information regarding the operation or properties of the heat exchangers and, based on this information, influencing the plant and its operation, in particular to improve the operation, effectiveness, or performance of the plant and to reduce wear and tear on the plant. Furthermore, based on the displayed information, recommendations for maintenance work, e.g., repairs, cleaning, component replacement, etc., can be made, and optimal maintenance work can be predicted ("predictive maintenance").Particularly advantageously, the invention makes it possible to monitor the remaining service life and in particular to increase it or at least not to reduce it unnecessarily or to counteract potential reductions in the service life.
[0029] The graphical user interface enables a combination, consolidation, or synthesis of hardware installed in the plant, particularly in the form of sensors or measuring devices, and management, analysis, simulation, and / or control software. The corresponding operationally relevant information can be conveniently made available in the graphical user interface as a central (web) dashboard to individual or all parties involved in the operation of the plant, for example, a manufacturer, owner, operator, plant manager, supervisory board, external experts, technical consultants, etc. With the help of the user interface and its functionalities, plant operators, for example, have the opportunity to evaluate and improve the performance and service life of the heat exchangers.For example, the graphical user interface can enable a heat exchanger manufacturer to provide various product concepts, e.g. leasing contracts, performance guarantee contracts, heat transfer contracts, deliveries with extended warranties, free trial periods and data recorders using the heat exchanger as a recording device that automatically transmits data to the manufacturer.
[0030] The central, graphical user interface makes it possible, in particular, to provide operationally relevant information to parties that are geographically dispersed and spread across large distances. For example, the relevant information can be provided via the user interface both to the operator or owner of the process plant, who may be located in the plant itself or in close proximity to it, and to parties located far away from the plant, such as the manufacturer or owner of the plant, who may be located at a great distance from the plant, perhaps at a distant company headquarters.
[0031] The corresponding information or data can, for example, be transmitted or exchanged between both locally networked and distant units. For example, the recorded sensor values of the sensors installed in or on the heat exchangers can be transmitted via a local network in the process plant to a local, central processing unit, e.g., a server of the plant, from which the user interface is also executed or which is directly networked via the local network with a processing unit executing the user interface. Furthermore, the sensor values of the sensors can, for example, also be transmitted to a remote processing unit, e.g., a (company) server, or a remote computing system, such as a distributed computing system in the context of so-called "cloud computing," in which the user interface itself is executed or to whichto which, in turn, a computing unit executing the user interface is connected. For example, the sensor values can be transmitted directly from the sensors to such a remote computing unit or such a remote computing system, or indirectly, by first transmitting the values to a local computing unit of the system, which then transmits the sensor values to the remote computing unit or the remote computing system. Furthermore, such a local computing unit can also perform calculations, for example determining the parameters and / or processing the sensor values or parameters. The corresponding data can then be transmitted from the local computing unit to the cloud system, and output by it in the graphical user interface. By one or more computing units, each of which is connected to the computing unit executing the user interface, e.g.The graphical user interface can then be output and displayed on a screen via a local (plant) network or the Internet. The centrally executed graphical user interface can thus be displayed uniformly by a multitude of different, possibly geographically distributed, processing units.
[0032] The graphical user interface can, for example, enable the visualization and tracking of the history, particularly the service life history, and / or the performance of the individual heat exchangers in the system. Furthermore, the operation of the individual heat exchangers can be made transparent and improved. In particular, the user interface can enable the consolidation of all relevant information and the history of the individual heat exchangers, the tracking of the history, and easy remote access to information.Furthermore, predictive maintenance based on information about the service life of the heat exchangers, an assessment of risks to continued operation based on such service life information, and improvements to plant operation can be made to avoid critical (operating) conditions that can cause high service life consumption, particularly high temperature differences and frequently changing temperature differences between the heat exchanger blocks, and to maximize heat exchanger performance. For example, automatic measures, control loops, control loop tuning, plant automation, automation of start-up, restart, load changes, etc. can be implemented. Furthermore, the plant performance and opportunities for performance improvement can be visualized and evaluated.
[0033] According to one embodiment, the state of the at least one heat exchanger is further determined as a change in the service life of the at least one heat exchanger depending on the determined temperature difference between the heat exchanger blocks. Furthermore, a graphical representation of this change in service life is determined, and the graphical representation of the change in service life is output in the graphical user interface. In particular, a relationship can thus be established and visualized as to how temperature differences affect the remaining service life. For example, for this purpose, the mechanical stresses and strains on the heat exchanger material caused by the temperature differences can be determined, and the effects of these stresses and strains on the service life can be determined.Furthermore, for example, the graphical representation can be used to graphically illustrate how past temperature differences have affected and changed the respective remaining service life at that time. The graphical user interface can be used to conveniently monitor and investigate over the long term how temperature differences between individual heat exchanger blocks affect the remaining service life of the heat exchanger. In particular, the graphical user interface can be used to develop an (operating) strategy to avoid service-reducing temperature differences and to increase the service life of the heat exchanger or decrease it as slowly as possible to achieve the best possible service life for the heat exchanger.
[0034] According to one embodiment, managing the operation of the at least one heat exchanger further comprises determining a maintenance interval of the at least one heat exchanger and / or a maintenance task to be performed on the at least one heat exchanger depending on the graphical representation of the service life output in the graphical user interface. For example, such maintenance or a repair or replacement of individual components can be scheduled depending on the service life consumption, expediently in order to increase the remaining service life as much as possible. For example, such maintenance intervals and maintenance tasks can be determined for components of the heat exchanger that are subject to high loads due to temperature differences between the heat exchanger blocks.
[0035] According to one embodiment, managing the operation of the at least one heat exchanger further comprises determining risks to the operation or the service life of the at least one heat exchanger based on the graphical representation of the service life output in the graphical user interface. For example, by analyzing the current and past states and the corresponding service life consumption in the user interface, it is possible to identify which specific operating states or which specific temperature differences lead to increased loads, increased wear, and increased service life consumption. Such states can then be avoided or counteracted.
[0036] According to one embodiment, managing the operation of the at least one heat exchanger further comprises determining control values or operating conditions or operating parameters of the at least one heat exchanger, depending on the graphical representation of the service life output in the graphical user interface, in order to avoid critical conditions that lead to a shortening of the service life. By monitoring and analyzing the conditions, service life, etc. displayed in the user interface, for example, the most optimized control values can be developed in order to operate the heat exchangers in the most optimized operating conditions possible, so that the most maximized service life can be achieved.
[0037] According to one embodiment, the state of the at least one heat exchanger is further determined as a power or current power of the at least one heat exchanger and / or a history or a temporal progression of the at least one heat exchanger. The current power of the respective heat exchanger can, for example, be determined analytically or numerically from the sensor values and / or parameters using physical equations. Alternatively or additionally, the parameters can also directly characterize the current power. The corresponding sensor values and / or parameters can, in particular, be processed such that the current power can be visually and / or acoustically displayed in an intuitive and clear manner. The history of the at least one heat exchanger can, in particular, comprise a history or a temporal progression of the sensor values and / or the parameters and / or the power.The graphical user interface, for example, allows for flexible switching between current and past values, or for flexible comparison of current and past values. For example, the graphical user interface can include a start or overview page in which the performance, service life, and history, or the corresponding sensor values and / or parameters, are displayed and / or can be selected for display. For example, this overview page can include a list or buttons to quickly display relevant information about heat exchanger operation and to track or visualize the heat exchanger's history.
[0038] According to one embodiment, the sensors arranged on or in the at least one heat exchanger are each designed as a temperature sensor and / or pressure sensor and / or flow sensor and / or sound sensor or acoustic sensor and / or vibration sensor. The measured values recorded by these sensors relate in particular to physical properties of the material of the heat exchanger and / or the fluid flows conducted through the heat exchanger. With the help of the temperature sensors, for example, the temperatures of the fluid flows and the heat exchanger walls can be measured. With the help of the pressure and flow sensors, for example, the pressure and flow of the individual fluid flows can be recorded. With the help of the sound and vibration sensors, in particular, vibrations in the heat exchanger walls can be monitored. Furthermore, with the help of the sensors and their sensor values, mechanical stresses in the heat exchanger can be directly recorded or indirectly derived.Furthermore, other suitable sensors can also be used, e.g. optical sensors such as cameras, etc.
[0039] According to one embodiment, one or more of the following variables are further determined as a characteristic variable: a temperature difference within the at least one heat exchanger, a temperature difference between fluid flows of the at least one heat exchanger, a temperature difference between fluid flows and heat exchanger blocks of the at least one heat exchanger, a rate of cooling processes and / or warm-up processes of the at least one heat exchanger ("cooldown" rate / "warmup" rate), a local temperature profile within the at least one heat exchanger, a temporal temperature profile within the at least one heat exchanger, a mechanical stress level of the at least one heat exchanger, and / or a thermal stress level of the at least one heat exchanger. In particular, such characteristic variables can be determined from temperature sensor values recorded at various locations in the heat exchangers.With the help of such parameters, in particular, temperature profiles of the heat exchangers can be described, which allow conclusions to be drawn about the operation and effectiveness of the heat exchangers and which also characterize the loads acting on the heat exchangers during their operation, which in turn allow conclusions to be drawn about the remaining service life or service life consumption.
[0040] Alternatively or additionally, according to one embodiment, a deviation of the operation of the at least one heat exchanger from a predetermined (safety) guideline for the operation of the at least one heat exchanger and / or a deviation from a (safety) specification for the at least one heat exchanger is determined as a characteristic variable. For example, such deviations can include sensor values and / or characteristic variables leaving predetermined, permissible ranges or reaching, exceeding, or falling below predetermined, permissible limit or threshold values. The occurrence of such deviations from (safety) guidelines or specifications can often trigger the output of alarm messages. For example, such alarm messages can also be taken into account as a characteristic variable, e.g. a frequency or specific times with which or at which such alarm messages are output.
[0041] According to one embodiment, the processing of the sensor values and / or the parameters further comprises determining a graphical representation of a temporal progression of individual sensor values and / or individual parameters depending on the points in time at which the respective sensor values were determined. In particular, changes or trends in the individual sensor values or parameters during operation of the heat exchangers can thus be tracked. For example, the processing can comprise a visualization of relevant time series data, e.g., process-related data or data regarding properties of the heat exchangers. Furthermore, the processing can comprise, for example, determining relationships or correlations between data or trends, as well as, for example, determining a correlation matrix, an indicator for fluctuations and outliers, etc.
[0042] According to one embodiment, the processing of the sensor values and / or the characteristic variables further comprises determining a graphical representation of a local profile of individual sensor values and / or individual characteristic variables within the at least one heat exchanger depending on positions within the at least one heat exchanger at which the respective sensor values were determined. In particular, the processing comprises a visualization of a local profile of the respective data, furthermore in particular of predetermined, intended or specified operating conditions. This can in particular enable a comparison between the actual operation and the predetermined operating conditions. For example, it can be explicitly displayed if the current operation lies outside the specified operating conditions. For example, the processing or visualization can comprise the provision of a slider function.For example, the processing may include determining a temperature range representation, e.g. a visualization of a local temperature profile of the individual heat exchangers and the specified operating conditions.
[0043] According to one embodiment, the processing of the sensor values and / or the characteristic variables further comprises determining a graphical representation of a multi-dimensional profile of individual sensor values and / or individual characteristic variables depending on the times at which the respective sensor values were determined and depending on the positions within the at least one heat exchanger at which the respective sensor values were determined. In particular, the temporal and spatial profiles of individual sensor values or characteristic variables are each visualized as a three-dimensional plot depending on time and location. For example, the temperature profile and the temperature gradient of a respective heat exchanger can each be visualized as a three-dimensional plot along the length of the heat exchanger and over time. For example, mechanical and / or thermal stress levels orMechanical and / or thermal loads during heat exchanger operation can be tracked. Furthermore, deviations from specified or recommended guidelines or specifications can be visualized in these multidimensional graphs, e.g., deviations from guidelines according to an operating manual or specified standards. Such multidimensional graphs can be used, for example, to evaluate and improve heat exchanger operation with regard to service life and performance. Furthermore, a reporting functionality for retrospective evaluation for a specific period can be enabled.
[0044] According to one embodiment, processing the sensor values and / or the parameters further comprises determining a graphical representation of the performance of the at least one heat exchanger. For example, individual parameters can be displayed that characterize the current performance and current operation of the individual heat exchangers, as well as, in particular, issued alarm messages, so that (operationally) relevant information can be quickly identified. For example, parameters can be appropriately processed and displayed for this purpose that describe heat transferability (e.g., depending on a heat transfer coefficient, on an area at which heat exchange takes place, and on thermal conductivity), as well as, for example, contamination, pressure drops, temperature bottlenecks, opportunities for performance improvement, etc.
[0045] According to one embodiment, processing the sensor values and / or the parameters further comprises determining a graphical representation of a hazard analysis of the at least one heat exchanger. For example, such a hazard analysis (HAZAN) can be performed to minimize risks for thermal conditions of the heat exchangers. Risk mitigation measures, e.g., alarms, control loops, etc., are expediently provided in the system. The graphical representation of the hazard analysis can, for example, provide a HAZAN overview dashboard in which alarm messages and measures implemented in the system to minimize risks for thermal stress can be summarized. Furthermore, a reporting functionality for retrospective evaluation for a specific period of time can be enabled, for example.
[0046] According to one embodiment, processing the sensor values and / or the parameters further comprises determining a graphical representation of cooling processes ("cooldown") and / or warm-up processes ("warmup", "startup") of the at least one heat exchanger. In this way, an overview dashboard for cooling and warm-up processes can be provided in the graphical user interface. For example, such a graphical representation can provide a comprehensive overview of the individual heat exchangers, so that cooling processes and cooling rates can be easily tracked. Furthermore, this graphical representation can be used, for example, to improve the operation of the heat exchangers, to create a reporting functionality for retrospectively evaluating the cooling process, and to add information regarding the start-up process to an operating manual.
[0047] According to one embodiment, processing the sensor values and / or the parameters further comprises determining a graphical representation of a thermal expansion of heat exchanger blocks of the at least one heat exchanger. For example, a local or spatial profile of a temperature gradient of the respective block along the three spatial directions can be displayed. In particular, an overview of block expansions and thermal states can thus be displayed in the graphical user interface. For example, a live view and video functionality can be enabled.
[0048] According to one embodiment, managing the operation of the at least one heat exchanger further comprises monitoring or analyzing a current state and / or a future state and / or a past state of the at least one heat exchanger. For example, the state displayed in the graphical user interface, its displayed history and the displayed extrapolated state can be compared with predetermined safety or operating guidelines. Thus, the graphical user interface can be used to assess whether the operation of the individual heat exchangers is within permissible specifications or whether there is potential for improvement. According to one embodiment, managing the operation of the at least one heat exchanger further comprises determining control values orof operating conditions or operating parameters of the at least one heat exchanger in order to increase the performance of the at least one heat exchanger. By monitoring and analyzing the conditions, service life, etc. displayed in the user interface, for example, the most optimized control values can be developed to operate the heat exchangers in the most optimized operating states possible, thus achieving the greatest possible performance and effectiveness.
[0049] According to one embodiment, inputs are received in the user interface and the at least one heat exchanger is controlled depending on the received inputs. According to one embodiment, the graphical user interface has at least one control surface or at least one control panel for this purpose, which is set up to receive inputs. The graphical user interface is set up to control the at least one heat exchanger depending on these received inputs. In particular, the inputs can be manual inputs from the system operator or system owner. The user interface thus provides the option of making manual inputs and directly influencing the heat exchangers. For example, control values orSetpoints can be entered, which can then be transferred from the user interface, for example, to a controller, which implements these control or setpoint values and controls the heat exchangers accordingly. For example, the user interface can have functionality to visualize and track the effects of the inputs made or the corresponding changes to the control values on the condition, effectiveness, and / or service life of the respective heat exchanger.
[0050] According to one embodiment, each heat exchanger block comprises interconnected structural plates and / or sidebars and / or separating plates and / or cover plates. For example, such a heat exchanger block can comprise a plurality of parallel separating plates or separating plates (so-called "separator plates") and a plurality of structural plates or structural plates with fins (so-called fins), with one structural plate being arranged between each adjacent separating plate, so that a plurality of parallel channels are formed between adjacent plates through which a medium can flow. The fins are delimited at the sides by sidebars (edge strips) that are soldered to the adjacent plates. The interconnected structural plates, sidebars, separating plates, and cover plates form a heat exchanger block.
[0051] A computing system according to the invention, e.g., a server of a process plant or a remote, distributed computing system in the context of so-called "cloud computing," is configured, particularly in terms of programming, to carry out a method according to the invention. For this purpose, the computing system has, in particular, a graphical user interface according to the invention, particularly centrally and uniformly.
[0052] The implementation of a method according to the invention in the form of a computer program or computer program product with program code for carrying out all method steps is also advantageous, since this entails particularly low costs, in particular if an executing control unit is also used for other tasks and is therefore already present. Finally, a machine-readable storage medium is provided with a computer program stored thereon, as described above. Suitable storage media or data carriers for providing the computer program are, in particular, magnetic, optical and electrical memories, such as hard disks, flash memories, EEPROMs, DVDs, and others. Downloading a program via computer networks (Internet, intranet, etc.) is also possible. Such a download can be wired or cable-based or wireless (e.g. via a WLAN network, a 3G, 4G, 5G or 6G connection, etc.).
[0053] Further advantages and embodiments of the invention will become apparent from the description and the accompanying drawings.
[0054] The invention is illustrated schematically in the drawing using exemplary embodiments and is described below with reference to the drawing.
[0055] Brief description of the drawings Figure 1 shows schematically and in perspective a heat exchanger for a process plant that can be managed according to an embodiment of the present invention.
[0056] Figure 2 schematically shows a process plant that can be managed according to an embodiment of the present invention.
[0057] Figure 3 schematically shows a graphical user interface according to an embodiment of the invention.
[0058] Embodiment(s) of the invention
[0059] Figure 1 schematically shows a heat exchanger designated 100 which can be used in a process plant that can be managed according to an embodiment of the present invention.
[0060] The heat exchanger 100 shown in Figure 1 is a brazed aluminum plate-fin heat exchanger (PFHE; designations according to the German and English editions of ISO 15547-2:3005), which can be used in a wide variety of systems at a wide range of pressures and temperatures. Such heat exchangers are used, for example, in the cryogenic separation of air, in the liquefaction of natural gas, or in plants for the production of ethylene. It is understood that "aluminum" can also refer to an aluminum alloy.
[0061] Brazed aluminum plate-fin heat exchangers are shown and described in Figure 2 of the aforementioned ISO 15547-2:3005 and on page 5 of the ALPEMA publication "The Standards of the Brazed Aluminum Plate-Fin Heat Exchanger Manufacturers' Association," 3rd edition 2010. Figure 1 essentially corresponds to the illustrations in the aforementioned ISO standard and will be explained below.
[0062] The plate heat exchanger 100, shown partially opened in Figure 1, is used for the heat exchange of, in the example shown, five different process media A to E. For the heat exchange between the process media A to E, the plate heat exchanger 100 comprises a plurality of partition plates 4 arranged parallel to one another (referred to as parting sheets in the aforementioned publications, to which the following information in brackets also refers), between which heat exchange passages 1 are formed, each for one of the process media A to E, which can thereby enter into heat exchange with one another.
[0063] The structured plates with the fins 3 are typically folded or corrugated, with the folds or corrugations forming flow channels, as shown in Figure 1 of ISO 15547-2:3005. Compared to plate heat exchangers without fins, the provision of the structured plates with fins 3 offers the advantage of improved heat transfer, more targeted fluid guidance, and increased mechanical (tensile) strength. In the heat exchange passages 1, the process media A to E flow separately from one another, particularly through the separating plates 4, but can possibly pass through the latter in the case of perforated structured plates with fins 3.
[0064] The individual passages 1 or the structural plates with the slats 3 are each surrounded laterally by so-called sidebars 8, which, however, leave open feed and discharge openings 9. The sidebars 8 keep the separating plates 4 at a distance and provide mechanical reinforcement for the printing chamber. Reinforced cover plates 5 (cap sheets), arranged parallel to the separating plates 4, serve as the closure on at least two sides.
[0065] By means of so-called headers 7, which are equipped with nozzles 6, the process media A to E are fed in and out via feed and discharge openings 9. In the inlet area of the passages 1, there are further structured plates with so-called distributor fins 2, which ensure even distribution across the entire width of the passages 1. At the end of the passage 1, viewed in the direction of flow, there may be further structured plates with distributor fins 2, which guide the process media A to E from the passages 1 into the headers 7, where they are collected and withdrawn via the corresponding nozzles 6.The structural plates with the fins 3, the additional structural plates with the distributor fins 2, the sidebars 8, the separating plates 4, and the cover plates 5 form a cuboid-shaped heat exchanger block 20. A "heat exchanger block" is understood here to mean the aforementioned elements without the headers 7 and nozzles 6 in an interconnected state. As not illustrated in Figure 1, the plate heat exchanger 100 can be formed from several corresponding cuboid-shaped and interconnected heat exchanger blocks 20, particularly for manufacturing reasons.
[0066] Corresponding plate heat exchangers 100 are brazed from aluminum. The individual passages 1, comprising the structural sheets with the fins 3, the additional structural sheets with the distributor fins 2, the cover sheets 5, and the sidebars 8, are each coated with solder, stacked one on top of the other or arranged accordingly, and heated in a furnace. The headers 7 and the nozzles 6 are welded onto the heat exchanger block 20 produced in this way. The headers 7 are manufactured using semi-cylindrical extruded profiles, which are cut to the required length and then welded onto the heat exchanger block 20.
[0067] Figure 2 schematically shows a process plant 200 that can be managed according to an embodiment of the present invention.
[0068] The process plant 200 can be designed, for example, as an air separation plant or a plant for separating mixtures of substances based on physical properties. The process plant 200 has a plurality of heat exchangers 210, each of which is designed, for example, as an aluminum plate heat exchanger PFHE 100 shown in Figure 1 and each having a plurality of heat exchanger blocks 20. Furthermore, the plant 200 can, for example, also have further heat exchangers, each of which can, for example, also be designed as spiral-wound heat exchangers. The process plant 200 further has further components, e.g., a column 230. For reasons of clarity, only one such further component 230 is shown in Figure 2, but it is understood that the plant 200 can also have a plurality of other different components.Furthermore, it is understood that the system 200 may also have a larger or smaller number of heat exchangers 210.
[0069] A plurality of sensors 220 are arranged in and on each of the individual plate heat exchangers 210, for example, temperature sensors, pressure sensors, and flow sensors, to detect corresponding physical properties of the respective heat exchanger material and the respective process media. For reasons of clarity, Figure 2 shows three sensors 220 for each heat exchanger 210. However, it is understood that each heat exchanger 210 can also have a larger or smaller number of sensors 220, as well as other types of sensors, e.g., sound sensors, vibration sensors, etc.
[0070] The sensors 220 arranged in and on the heat exchangers 210 are connected to a local network 201 of the system 200, which is indicated by dashed lines in Figure 2. A central controller 240 for controlling and regulating the system 200 is connected to the individual system components via the local network 201. The measured values recorded by the sensors 220 are transmitted via the network 201 to the controller 240 and stored there. Furthermore, a computer 250 is connected to the network 201, by means of which an operator or user, who may be located in the system 200 or in the immediate vicinity thereof, can manage the system 200.
[0071] The controller 240 and the computer 250 are connected via the internet 205 to a remote computing system 260 in what is known as "cloud computing." A computer 270 is also connected to this cloud 260 via the internet 205. A computer 270, via which, for example, a manufacturer or owner of the system 200, who may be located a great distance from the system 200, can also manage the system 200. Such internet connections are indicated in Figure 2 as dashed lines.
[0072] In order to manage the system with the aid of computers 250, 270, a graphical user interface is provided according to one embodiment of the present invention. For this purpose, the computing system 260 is configured, in particular by programming, to carry out an embodiment of a method according to the invention. In the course of this, the sensor values acquired by the sensors 220 and stored in the controller 240 are transmitted from the controller 240 to the computing system 260 via the Internet 205. These sensor values include, for example, temperature values of fluid flows within the heat exchanger blocks of the individual heat exchangers 210 as well as temperature values of the walls of the heat exchanger blocks of the individual heat exchangers 210.
[0073] Depending on these received sensor values, the computing system 260 determines parameters that identify or characterize the operation of the heat exchangers 210. At least a temperature difference between the heat exchanger blocks of the individual heat exchangers 210 is determined as such parameters. Furthermore, such parameters can include, for example, a temperature difference within the individual heat exchangers 210, a temperature difference between fluid flows within the individual heat exchangers 210, a temperature difference between the fluid flows and heat exchanger blocks of the individual heat exchangers 210, a rate of cooling and warming processes of the individual heat exchangers 210, a local temperature profile and a temporal temperature profile within the individual heat exchangers 210, and a mechanical stress level and a thermal stress level of the individual heat exchangers 210.Furthermore, parameters such as whether the operation of the individual heat exchangers 210 deviates from specified guidelines can be determined.
[0074] The sensor values and parameters are graphically processed by the computing system 260 to represent the condition of the heat exchangers 210. As such a condition, the service life of the individual heat exchangers 210 is determined depending on the determined temperature difference between the respective heat exchanger blocks of the individual heat exchangers 210. The computing system 260 further determines a graphical representation of this service life of the individual heat exchangers 210.
[0075] Furthermore, the computing system 260 can determine, as a state, a change or consumption in the service life of the individual heat exchangers 210 depending on the respective temperature differences. For example, during the processing, a graphical representation of this change in the remaining service life of the individual heat exchangers 210 can be determined depending on the temperature differences of the respective heat exchanger blocks, and in particular depending on the operating conditions of the respective heat exchanger 210. Thus, for example, a service life monitor can be set up.
[0076] Furthermore, the computing system 260 can determine, as such a state, for example, a current performance of the individual heat exchangers 210 as well as a history or a temporal progression of the performance and service life of the individual heat exchangers 210.
[0077] For example, during this processing, a graphical representation of the temporal progression of individual sensor values and parameters can be determined, depending on the times at which the respective sensor values were determined. For this purpose, two-dimensional diagrams can be generated in which the respective sensor value or parameter is plotted against time. For example, diagrams of the temperature values recorded as sensor values and the temperature differences determined as parameters, each plotted against time, can be determined.
[0078] Furthermore, during processing, a graphical representation of a local progression of individual sensor values and individual parameters can be determined, depending on the positions within the respective heat exchanger 210 at which the respective sensor values were determined. For example, two-dimensional diagrams can be generated for this purpose in which the respective sensor value or parameter is plotted against the length of the respective heat exchanger. For example, such two-dimensional graphs of the recorded temperature values and the determined temperature differences can be determined, each plotted against the length of the respective heat exchanger.
[0079] Furthermore, during processing, a multidimensional curve of individual sensor values and parameters can be determined, depending on the time at which the respective sensor values were determined and the position within the respective heat exchanger at which the respective sensor values were determined. For example, three-dimensional diagrams can be generated in which the recorded temperatures or the determined temperature differences are plotted against time and against the length of the respective heat exchanger.
[0080] Furthermore, during the processing, a graphical representation of the performance of the individual heat exchangers 210 can be determined. For example, current sensor values and parameters that characterize the performance or effectiveness of the individual heat exchangers 210 can be displayed for this purpose.
[0081] Furthermore, during the processing process, a graphical representation of a hazard analysis of the individual heat exchangers can be generated. This can, for example, display alarm messages issued and the circumstances that led to these alarms being issued.
[0082] Furthermore, during the processing, a graphical representation of the cooling processes ("cooldown") and warm-up processes ("warmup", "startup") of the individual heat exchangers 210 can be determined. For example, cooling rates of the individual heat exchangers 210 can be displayed in the course of this.
[0083] Furthermore, during the processing, a graphical representation of the thermal expansion of the individual heat exchanger blocks can be determined. For example, each heat exchanger block can be graphically displayed in a regular resting state, and it can be shown how the respective heat exchanger block thermally deforms during operation compared to this resting state. For example, a local, spatial profile of a temperature gradient of the respective heat exchanger block can be displayed along the three spatial directions.
[0084] The sensor values and parameters processed in this way are output by the computing system 260 in a graphical user interface. In the process, at least the graphical representation of the service life of the individual heat exchangers 210 is output in the graphical user interface. For this purpose, the computing system 260 centrally and uniformly generates a graphical user interface, and corresponding data is transmitted via the internet 205 to the computers 250, 270 so that this user interface can be uniformly displayed on the screens of the computers 250, 270.
[0085] This graphical user interface manages the operation of the individual heat exchangers 210, monitoring at least the service life of each heat exchanger 210. For this purpose, the appropriately prepared sensor values and parameters, i.e., the two- and multi-dimensional diagrams described above, etc., are output in the user interface. Based on this prepared and displayed information, the system operator and the system manufacturer can monitor and analyze the individual heat exchangers 210, e.g., with regard to their condition, performance, effectiveness, service life, etc.
[0086] Based on these analyses, improved operating conditions or control values can be determined, for example, according to which the heat exchangers should be operated in the future to increase their service life and performance. These new control values, e.g., new setpoints, can be entered by the system operator and system manufacturer in the user interface displayed on the respective computer 250, 270. These inputs are transmitted from the user interface or from the computer system 260 executing the user interface to the controller 240, so that this controller 240 controls the individual heat exchangers 210 accordingly.
[0087] Figure 3 schematically shows a graphical user interface 300 according to an embodiment of the invention, as it can be executed centrally by the computing system 260 and uniformly displayed on the computers 250, 270.
[0088] For example, the current status of the system 200 can be displayed on a start or overview page 310 in the user interface 300. This overview page 310 can have a plurality of display areas or display panels 311, 312, 313, 314, in which the remaining service life of the individual heat exchangers 210 and also, for example, a current overall status of the system 200, a current operating temperature of the system 200, a temporal temperature difference, and a local temperature difference can be displayed. Furthermore, switches 320 are displayed in the user interface 300. By pressing or clicking individual ones of these switches, for example, further display areas are opened, in which individual processed sensor values or parameters are then displayed.
[0089] For example, by operating the switch 321, the two-dimensional diagrams of the recorded temperature values and the determined temperature differences of the individual heat exchanger blocks can be displayed, each plotted against time.
[0090] By operating the switch 322, for example, the two-dimensional diagrams of the recorded temperature values and the determined temperature differences of the individual heat exchanger blocks can be displayed, each plotted against the length of the respective heat exchanger.
[0091] By operating the switch 323, for example, the three-dimensional diagrams of the recorded temperatures and the determined temperature differences of the individual heat exchanger blocks can be displayed, each plotted against time and against the length of the respective heat exchanger.
[0092] Furthermore, by actuating the switch 324, for example, an input field or input panel can be opened in which inputs can be made, which are then passed on to the controller 240 for controlling the system 200.
[0093] The invention thus provides a central, uniform user interface 300 for monitoring and managing the operation of the individual heat exchangers 210 of the process plant 200 online, for displaying information regarding the operation and properties of the individual heat exchangers 210, for influencing the operation of the plant 200 depending on this information, and for increasing the effectiveness and service life of the individual heat exchangers 210.
Claims
Patent claims Method for managing a process plant (200) having at least one heat exchanger (100, 210), each of these heat exchangers (100, 210) being designed as a plate heat exchanger and each having a plurality of heat exchanger blocks (20), comprising: Receiving sensor values from sensors (220) arranged on or in the at least one heat exchanger (100, 210); Determining parameters that characterize an operation of the at least one heat exchanger (100, 210) as a function of the received sensor values, wherein a temperature difference between heat exchanger blocks (20) of the at least one heat exchanger (100, 210) is determined as a parameter; Preparing the sensor values and / or the characteristic variables for a graphical representation of a state of the at least one heat exchanger (100, 210), wherein a service life of the at least one heat exchanger (100, 210) is determined as the state depending on the determined temperature difference between the heat exchanger blocks (20) of the at least one heat exchanger (100, 210), and wherein a graphical representation of the service life of the at least one heat exchanger (100, 210) is determined; Outputting the processed sensor values and / or parameters in a graphical user interface (300), wherein the graphical representation of the service life of the at least one heat exchanger (100, 210) is output in the graphical user interface (300); Managing the operation of the at least one heat exchanger (100, 210) depending on the output, processed sensor values and / or parameters in the graphical user interface (300), wherein the service life of the at least one heat exchanger (100, 210) is monitored. Method according to claim 1, wherein a change in the service life of the at least one heat exchanger (100, 210) is further determined as the state of the at least one heat exchanger (100, 210) depending on the determined temperature difference between the heat exchanger blocks (20) of the at least one heat exchanger (100, 210), wherein a graphical representation of the change in the service life of the at least one heat exchanger (100, 210) is determined and wherein the graphical representation of the change in the service life of the at least one heat exchanger (100, 210) is output in the graphical user interface (300).
3. The method of claim 1 or 2, wherein managing the operation of the at least one heat exchanger (100, 210) further comprises one or more of the following steps: Determining a maintenance interval of the at least one heat exchanger (100, 210) depending on the graphical representation of the service life of the at least one heat exchanger (100, 210) output in the graphical user interface; Determining a maintenance task to be performed on the at least one heat exchanger (100, 210) depending on the graphical representation of the service life of the at least one heat exchanger (100, 210) output in the graphical user interface; Determining risks for operation of the at least one heat exchanger (100, 210) depending on the graphical representation of the service life of the at least one heat exchanger (100, 210) output in the graphical user interface; Determining control values of the at least one heat exchanger (100, 210) depending on the graphical representation of the service life of the at least one heat exchanger (100, 210) output in the graphical user interface in order to avoid critical conditions which lead to a shortening of the service life.
4. Method according to one of the preceding claims, wherein a performance of the at least one heat exchanger (100, 210) and / or a history of the at least one heat exchanger (100, 210) is further determined as the state of the at least one heat exchanger (100, 210).
5. Method according to one of the preceding claims, wherein the sensors (220) arranged on or in the at least one heat exchanger (100, 210) are each designed as a temperature sensor and / or pressure sensor and / or flow sensor and / or sound sensor and / or vibration sensor.
6. Method according to one of the preceding claims, wherein one or more of the following variables are further determined as parameters: a temperature difference within the at least one heat exchanger (100, 210); a temperature difference between fluid flows of the at least one heat exchanger (100, 210); a temperature difference between fluid flows and heat exchanger blocks (20) of the at least one heat exchanger (100, 210); a rate of cooling processes and / or warming processes of the at least one heat exchanger (100, 210); a local temperature profile within the at least one heat exchanger (100, 210); a temporal temperature profile within the at least one heat exchanger (100, 210); a mechanical stress level of the at least one heat exchanger (100, 210); a thermal stress level of the at least one heat exchanger (100, 210); a deviation from a guideline for the operation of the at least one heat exchanger (100, 210);a deviation from a specification for the at least one heat exchanger (100, 210); 7. Method according to one of the preceding claims, wherein the processing of the sensor values and / or the parameters further comprises one or more of the following steps: Determining a graphical representation of a temporal progression of individual sensor values and / or individual parameters depending on the points in time at which the respective sensor values were determined; Determining a graphical representation of a local course of individual sensor values and / or individual parameters within the at least one heat exchanger (100, 210) depending on positions within the at least one heat exchanger (100, 210) at which the respective sensor values were determined; Determining a graphical representation of a multi-dimensional course of individual sensor values and / or individual characteristic variables depending on the times at which the respective sensor values were determined and depending on the positions within the at least one heat exchanger (100, 210) at which the respective sensor values were determined; Determining a graphical representation of a performance of the at least one heat exchanger (100, 210); Determining a graphical representation of a hazard analysis of the at least one heat exchanger (100, 210); Determining a graphical representation of cooling processes and / or warming processes of the at least one heat exchanger (100, 210); Determining a graphical representation of a thermal expansion of heat exchanger blocks (20) of the at least one heat exchanger (100, 210).
8. The method according to any one of the preceding claims, wherein managing the operation of the at least one heat exchanger (100, 210) further comprises one or more of the following steps: Monitoring a current state of the at least one heat exchanger (100, 210); Monitoring a future state of the at least one heat exchanger (100, 210); Monitoring a past state of the at least one heat exchanger (100, 210); Determining control values of the at least one heat exchanger (100, 210) in order to increase a power of the at least one heat exchanger (100, 210).
9. Method according to one of the preceding claims, further comprising: Receiving inputs in the user interface (300); Controlling the at least one heat exchanger (100, 210) depending on the received inputs.
10. Method according to one of the preceding claims, wherein each heat exchanger block (20) has interconnected structural plates (2, 3) and / or sidebars (8) and / or separating plates (4) and / or cover plates (5).
11. A graphical user interface (300) for managing a process plant (200) having at least one heat exchanger (100, 210), each of said heat exchangers (100, 210) being designed as a plate heat exchanger and each having a plurality of heat exchanger blocks (20), the graphical user interface having at least one display area (310) configured to output sensor values received and processed according to a method according to one of the preceding claims and / or parameters determined and processed according to a method according to one of the preceding claims, the display area (310) being configured to output the graphical representation of the service life of the at least one heat exchanger (100, 210).
12. Graphical user interface (300) according to claim 11, further comprising at least one control surface configured to receive inputs, wherein the graphical user interface (300) is configured to control the at least one heat exchanger (100, 210) depending on these received inputs.
13. A computing system (260) configured to perform all method steps of a method according to any one of claims 1 to 10.
14. A computing system (260) according to claim 13 having a graphical user interface (300) according to claim 11 or 12.
15. A computer program which causes a computing system (260), in particular the computing system (260) according to claim 13 or 14, to carry out all method steps of a method according to one of claims 1 to 10 when it is executed on the computing system (260).
16. A machine-readable storage medium having a computer program according to claim 15 stored thereon.