Wireless shell-and-tube heat exchanger fouling prediction system

Abstract

The system may include a shell-and-tube heat exchanger, which has temperature sensors mounted on the outer surfaces of the shell inlet and outlet ports and the tube inlet and outlet ports, flow sensors mounted on the outer surfaces of the shell inlet and tube inlet ports, and pressure sensors in T-fittings connected to the shell inlet and outlet ports and the tube inlet and outlet ports. A wireless transmitter can transmit sensor data from the sensors to a computing device. Based on the sensor data, the computing device can determine one or more fouling indicators that indicate the possibility of fouling occurring in the shell-and-tube heat exchanger.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Application No. 63 / 495,916, filed on April 13, 2023, the content of which is incorporated herein by reference in its entirety.

[0002] (Field of the Invention) This specification relates to the monitoring of heat exchangers, and more particularly to a wireless shell - and - tube heat exchanger fouling prediction system.

Background Art

[0003] A shell - and - tube heat exchanger comprises a shell having one or more tubes inside the shell. One fluid flows through the tubes and another fluid flows through the shell over the tubes. Thus, heat can be exchanged between the two fluids. Shell - and - tube heat exchangers are used in various manufacturing processes. In particular, they can remove heat from process fluids to maintain operating conditions within safe limits.

[0004] However, shell - and - tube heat exchangers are susceptible to fouling and overheating of the cooling medium. These effects can disrupt manufacturing processes that utilize shell - and - tube heat exchangers, resulting in production losses. Early recognition of fouling and other detrimental conditions can enable corrective measures to be taken to minimize subsequent production losses. However, the installation of conventional instrumentation for continuously monitoring the operation of shell - and - tube heat exchangers can be costly, time - consuming, and can lead to environmental health and safety concerns. Therefore, an improved method for predicting fouling in shell - and - tube heat exchangers is needed.

Summary of the Invention

[0005] In one embodiment, the system may include a shell-and-tube heat exchanger, a plurality of sensors, a plurality of wireless transmitters, and a computing device. The shell-and-tube heat exchanger may include a shell inlet port, a shell outlet port, a tube inlet port, a tube outlet port, a first T-fitting connected to the shell inlet port, a second T-fitting connected to the shell outlet port, a third T-fitting connected to the tube inlet port, and a fourth T-fitting connected to the tube outlet port. A first temperature sensor may be mounted on the outer surface of the shell inlet port and can measure a first temperature of the fluid inside the shell inlet port. A second temperature sensor may be mounted on the outer surface of the shell outlet port and can measure a second temperature of the fluid inside the shell outlet port. A third temperature sensor may be mounted on the outer surface of the tube inlet port and can measure a third temperature of the fluid inside the tube inlet port. A fourth temperature sensor may be mounted on the outer surface of the tube outlet port and can measure a fourth temperature of the fluid inside the tube outlet port. A first flow sensor may be mounted on the outer surface of the shell inlet port and can measure the flow rate of the fluid inside the shell inlet port. A second flow sensor may be mounted on the outer surface of the shell outlet port and can measure a second flow rate of fluid inside the shell outlet port. A first pressure sensor may be located inside the first T-fitting and can measure a first pressure of fluid inside the shell inlet port. A second pressure sensor may be located inside the second T-fitting and can measure a second pressure of fluid inside the shell outlet port. A third pressure sensor may be located inside the third T-fitting and can measure a third pressure of fluid inside the tube inlet port. A fourth pressure sensor may be located inside the fourth T-fitting and can measure a fourth pressure of fluid inside the tube outlet port. Each wireless transmitter may be connected to one of the sensors and can transmit data captured by the connected sensor to a computing device. The computing device can determine one or more fouling indicators based on the data received from the wireless transmitters.One or more fouling indicators can indicate the possibility of fouling occurring within a shell-and-tube heat exchanger.

[0006] In another embodiment, one method involves receiving first temperature data from a first wireless transmitter coupled to a first temperature sensor mounted on the outer surface of the shell inlet port of a shell-and-tube heat exchanger; receiving second temperature data from a second wireless transmitter coupled to a second temperature sensor mounted on the outer surface of the shell outlet port of a shell-and-tube heat exchanger; receiving third temperature data from a third wireless transmitter coupled to a third temperature sensor mounted on the outer surface of the tube inlet port of a shell-and-tube heat exchanger; receiving fourth temperature data from a fourth wireless transmitter coupled to a fourth temperature sensor mounted on the outer surface of the tube outlet port of a shell-and-tube heat exchanger; receiving first flow rate data from a fifth wireless transmitter coupled to a first flow rate sensor mounted on the outer surface of the shell inlet port of a shell-and-tube heat exchanger; and receiving second flow rate data from a sixth wireless transmitter coupled to a second flow rate sensor mounted on the outer surface of the shell outlet port of a shell-and-tube heat exchanger. This may include receiving first pressure data from a ninth wireless transmitter coupled to a first pressure sensor located inside a first T-fitting connected to the shell inlet port of a shell-and-tube heat exchanger; receiving second pressure data from a tenth wireless transmitter coupled to a second pressure sensor located inside a second T-fitting connected to the shell outlet port of a shell-and-tube heat exchanger; receiving third pressure data from an eleventh wireless transmitter coupled to a third pressure sensor located inside a third T-fitting connected to the tube inlet port of a shell-and-tube heat exchanger; receiving fourth pressure data from a twelfth wireless transmitter coupled to a fourth pressure sensor located inside a fourth T-fitting connected to the tube outlet port of a shell-and-tube heat exchanger; and determining one or more fouling indicators based on first temperature data, second temperature data, third temperature data, fourth temperature data, first flow rate data, second flow rate data, first pressure data, second pressure data, third pressure data, and fourth pressure data. The first temperature data may indicate the first temperature of the fluid inside the shell inlet port.The second temperature data may indicate the second temperature of the fluid inside the shell outlet port. The third temperature data may indicate the third temperature of the fluid inside the tube inlet port. The fourth temperature data may indicate the fourth temperature of the fluid inside the tube outlet port. The first flow rate data may indicate the first flow rate of the fluid inside the shell inlet port. The second flow rate data may indicate the second flow rate of the fluid inside the shell outlet port. The first pressure data may indicate the first pressure of the fluid inside the shell inlet port. The second pressure data may indicate the second pressure of the fluid inside the shell outlet port. The third pressure data may indicate the third pressure of the fluid inside the tube inlet port. The fourth pressure data may indicate the fourth pressure of the fluid inside the tube outlet port. A fouling indicator can indicate the possibility of fouling occurring in the shell-and-tube heat exchanger.

[0007] In another embodiment, one method involves attaching a first temperature sensor to the outer surface of the shell inlet port of a shell-and-tube heat exchanger, a second temperature sensor to the outer surface of the shell outlet port of a shell-and-tube heat exchanger, a third temperature sensor to the outer surface of the tube inlet port of a shell-and-tube heat exchanger, a fourth temperature sensor to the outer surface of the tube inlet port of a shell-and-tube heat exchanger, a first flow sensor to the outer surface of the shell inlet port, a second flow sensor to the outer surface of the shell outlet port, and a third temperature sensor connected to the shell inlet port. This may include: placing a first pressure sensor inside a T-fitting; placing a second pressure sensor inside a second T-fitting connected to a shell outlet port; placing a third pressure sensor inside a third T-fitting connected to a tube inlet port; placing a fourth pressure sensor inside a fourth T-fitting connected to a tube outlet port; and connecting a corresponding wireless transmitter to each of the first, second, third, and fourth temperature sensors, first flow sensor, second flow sensor, first pressure sensor, second pressure sensor, third pressure sensor, and fourth pressure sensor. The first temperature sensor can measure a first temperature of the fluid inside the shell inlet port. The second temperature sensor can measure a second temperature of the fluid inside the shell outlet port. The third temperature sensor can measure a third temperature of the fluid inside the tube inlet port. The fourth temperature sensor can measure a fourth temperature of the fluid inside the tube outlet port. The first flow sensor can measure the flow rate of the fluid inside the shell inlet port. A second flow sensor can measure a second flow rate of fluid inside the shell outlet port. A first pressure sensor can measure a first pressure of fluid inside the shell inlet port. A second pressure sensor can measure a second pressure of fluid inside the shell outlet port. A third pressure sensor can measure a third pressure of fluid inside the tube inlet port. A fourth pressure sensor can measure a fourth pressure of fluid inside the tube outlet port.Each wireless transmitter can transmit data captured by connected sensors to a computing device. [Brief explanation of the drawing]

[0008] The embodiments described in the drawings are for illustrative purposes only and are not intended to limit the disclosure. A detailed description of the following exemplary embodiments can be understood in conjunction with the following drawings, in which similar structures are shown with similar reference numerals. [Figure 1] This figure schematically illustrates a wireless shell-and-tube heat exchanger fouling prediction system according to one or more embodiments shown and described herein. [Figure 2] This figure schematically illustrates a flow sensor according to one or more embodiments shown and described herein. [Figure 3] Figure 1 is a schematic diagram of a computing device according to one or more embodiments shown and described herein. [Figure 4] This figure schematically shows multiple memory modules of the computing device shown in Figure 3, according to one or more embodiments described herein. [Figure 5] This figure schematically illustrates a portion of another wireless shell-and-tube heat exchanger fouling prediction system according to one or more embodiments shown and described herein. [Figure 6] This figure schematically illustrates a portion of another wireless shell-and-tube heat exchanger fouling prediction system according to one or more embodiments shown and described herein. [Figure 7] This is a flowchart illustrating an exemplary method for operating the wireless shell-and-tube heat exchanger fouling prediction system of Figure 1, according to one or more embodiments shown and described herein. [Modes for carrying out the invention]

[0009] Embodiments disclosed herein describe systems and methods for predicting fouling in shell-and-tube heat exchangers. In particular, embodiments disclosed herein describe a wireless shell-and-tube heat exchanger fouling prediction system. In embodiments disclosed herein, a shell-and-tube heat exchanger may be referred to as a heat exchanger.

[0010] In embodiments disclosed herein, a system for monitoring the performance of a heat exchanger comprises a plurality of clamp-on sensors that can be non-invasively installed on an existing heat exchanger. In particular, the sensors may be clamped to the outer surface of the heat exchanger to measure data related to the heat exchanger (e.g., performance indicators). Since the sensors are clamped to the outer surface of the heat exchanger, they can be installed without interrupting the continuous operation of the heat exchanger. The sensors may measure temperature, pressure, and fluid flow rate using the heat exchanger, as disclosed herein.

[0011] The system may also include multiple wireless transmitters that can be connected to sensors. In particular, each sensor may be connected to a wireless transmitter that can wirelessly transmit data collected by the sensor to a remote computing device. Thus, data can be collected from sensors without requiring a wired connection to the computing device. The computing device can receive the sensor data and calculate a heat exchanger fouling indicator or fouling coefficient based on the sensor data. The calculated heat exchanger fouling indicator can predict heat exchanger fouling. Thus, if fouling is predicted, corrective measures can be taken to prevent subsequent production losses.

[0012] Referring here to the drawings, Figure 1 schematically shows an exemplary heat exchanger fouling prediction system 100 according to an embodiment disclosed herein. In the example of Figure 1, the heat exchanger fouling prediction system 100 comprises a shell-and-tube heat exchanger 102 and a computing device 200. As used herein, the shell-and-tube heat exchanger 102 may be referred to as a heat exchanger.

[0013] Multiple sensors may be clamped onto the heat exchanger 102 or otherwise attached to the heat exchanger 102, as disclosed herein. The sensors may collect data about the heat exchanger 102 and transmit the data wirelessly to a computing device 200, as disclosed herein. The sensors may be evaluated against hazardous area classifications so that they can operate in the environment of the heat exchanger 102. In embodiments, the sensors may be evaluated against at least Class 1, Division 2, as defined by the National Electric Code. The computing device 200 can receive the data and predict the condition of the heat exchanger 102, such as whether the heat exchanger 102 is experiencing fouling or other conditions.

[0014] The heat exchanger 102 includes a shell and one or more tubes arranged inside the shell. A first fluid may flow through one or more tubes, and a second fluid may flow through the shell and over the tubes. If the first and second fluids have different temperatures, heat can be transferred from one fluid to the other. Therefore, a colder first fluid can be placed inside the shell to cool the second fluid flowing through the tubes.

[0015] In the example shown in Figure 1, the heat exchanger 102 may include a shell inlet port 104, a tube inlet port 106, a shell outlet port 108, and a tube outlet port 110. The shell inlet port 104 may be used to deposit fluid into the shell, and the tube inlet port 106 may be used to deposit fluid into the tube. The shell outlet port 108 may be used to discharge fluid from the shell, and the tube outlet port 110 may be used to discharge fluid from the tube. A first T-fitting 112 may be connected to the shell inlet port 104. A second T-fitting 114 may be connected to the tube inlet port 106. A third T-fitting 116 may be connected to the shell outlet port 108. A fourth T-fitting 118 may be connected to the tube outlet port 110.

[0016] In the example shown in Figure 1, the first temperature sensor 120 and the first flow sensor 122 may be mounted on the outer surface of the shell inlet port 104. The first pressure sensor 124 may be located inside the first T-fitting 112. The second temperature sensor 126 and the second flow sensor 128 may be mounted on the outer surface of the tube inlet port 106. The second pressure sensor 130 may be located inside the second T-fitting 114. The third temperature sensor 132 may be mounted on the outer surface of the shell outlet port 108. The third pressure sensor 134 may be located inside the third T-fitting 116. The fourth temperature sensor 136 may be mounted on the outer surface of the tube outlet port 110. The fourth pressure sensor 138 may be located inside the fourth T-fitting 118.

[0017] In the illustrated example, the first, second, third, and fourth temperature sensors 120, 126, 132, 136, and the first and second flow sensors 122, 128 may be clamped to their respective valves. However, in other examples, the temperature sensors and flow sensors may be mounted to the outside of the valves in any other manner. The first, second, third, and fourth pressure sensors 124, 130, 134, 138 may be positioned inside their respective T-fittings but not inserted into the flow of fluid through the T-fittings.

[0018] The first, second, third, and fourth temperature sensors 120, 126, 132, 136 can each directly measure the surface temperature of the shell inlet port 104, the tube inlet port 106, the shell outlet port 108, and the tube outlet port 110. Each temperature sensor can then determine the internal temperature of the fluid flowing through each valve based on the measured surface temperature and the parameters of the valve including the thickness, diameter, and material of the pipe. Thus, the temperature sensors 120, 126, 132, 136 can each measure the temperature of the fluid inside the shell inlet port 104, the tube inlet port 106, the shell outlet port 108, and the tube outlet port 110.

[0019] The first and second flow rate sensors 122, 128 can measure the flow rate of the fluid flowing through the shell inlet port 104 and the tube inlet port 106, respectively. In the illustrated example, the first and second flow rate sensors 122, 128 include ultrasonic sensors. However, in other examples, the first and second flow rate sensors 122, 128 may be constructed in other ways.

[0020] FIG. 2 shows an exemplary first flow sensor 122. The second flow sensor 128 may be similarly configured. In the example of FIG. 2, the first flow sensor 122 includes an upstream transducer 122A and a downstream transducer 122B. The fluid may flow through the shell inlet port 104 in a direction from the upstream transducer 122A to the downstream transducer 122B. In the example of FIG. 2, the upstream transducer 122A can emit an ultrasonic signal through the fluid in the shell inlet port 104, and the downstream transducer 122B can receive the ultrasonic signal. The time delay between when the ultrasonic signal is emitted by the upstream transducer 122A and when it is received by the downstream transducer 122B can vary based on the velocity at which the fluid flows through the shell inlet port 104. Accordingly, the first flow sensor 122 can measure the time delay between when the ultrasonic signal is emitted by the upstream transducer 122A and when it is received by the downstream transducer 122B, and based on this time delay, determine the flow rate of the fluid passing through the shell inlet port 104.

[0021] Referring back to FIG. 1, the first, second, third, and fourth pressure sensors 124, 130, 134, 138 may each measure the pressure within the first, second, third, and fourth T-joints 112, 114, 116, 118. The measured values of temperature, flow rate, and pressure can be used to determine the operating parameters of the heat exchanger 102, as will be described in more detail below.

[0022] Continuing to refer to Figure 1, System 100 comprises multiple wireless transmitters for transmitting data from various sensors to the computing device 200. In particular, System 100 comprises wireless transmitters 140, 146, 152, and 156 connected to the first, second, third, and fourth temperature sensors 120, 126, 132, and 136, respectively. System 100 comprises wireless transmitters 142 and 148 connected to the first and second flow sensors 122 and 128, respectively. System 100 comprises wireless transmitters 144, 150, 154, and 158 connected to the first, second, third, and fourth pressure sensors 124, 130, 134, and 138, respectively.

[0023] In the embodiments, each of the wireless transmitters 140, 142, 144, 146, 148, 150, 152, 154, 156, and 158 may receive data from the corresponding sensors to which they are connected, and may transmit the sensor data to the computing device 200. In some examples, the wireless transmitters may supply power to the sensors to which they are connected.

[0024] By mounting sensors on the exterior surface of the heat exchanger 102 and wirelessly transmitting the sensor data to the computing device 200, the system 100 can determine the operating state of the heat exchanger 102 without requiring internal sensors. Therefore, the sensors and wireless transmitters can be placed on an existing shell-and-tube heat exchanger. Furthermore, by wirelessly transmitting the sensor data to the computing device 200, the operating state of the heat exchanger 102 can be determined from a remote location where the computing device 200 is located while the situation is online.

[0025] Figure 4 schematically shows an exemplary configuration of the computing device 200 of Figure 1. In some embodiments, the computing device 200 may be a remote computing device (e.g., a cloud computing device). However, in other embodiments, the computing device 200 may be located in the same position as the heat exchanger 102. In the illustrated embodiment, the computing device 200 includes one or more processors 202, a communication path 204, one or more memory modules 206, a data storage component 208, and network interface hardware 210, the details of which are described in the following paragraphs.

[0026] Each of the one or more processors 202 may be any device capable of executing machine-readable and executable instructions. Thus, each of the one or more processors 202 may be a controller, integrated circuit, microchip, computer, or any other physical or cloud-based computing device. Algorithms, including trained models, signal preprocessing, and denoising methods, discussed below, may be executed by one or more processors 202. The one or more processors 202 are coupled to a communication path 204 that provides signal interconnection between various modules of the computing device 200. Thus, the communication path 204 can connect any number of processors 202 to each other in a communicative manner, enabling modules coupled to the communication path 204 to operate in a distributed computing environment. Specifically, each module can operate as a node capable of transmitting and / or receiving data. As used herein, the term “communicatively coupled” means that coupled components can exchange data signals with each other, such as electrical signals over a conductive medium, electromagnetic signals over air, or optical signals over an optical waveguide.

[0027] Therefore, the communication path 204 can be formed from any medium capable of transmitting signals, such as conductive wires, conductive traces, and optical waveguides. In some embodiments, the communication path 204 can facilitate the transmission of wireless signals such as WiFi, Bluetooth®, and Near Field Communication (NFC). Furthermore, the communication path 204 may be formed from a combination of media capable of transmitting signals. In one embodiment, the communication path 204 includes a combination of conductive traces, conductive wires, connectors, and buses that cooperate to enable the transmission of electrical data signals to components such as processors, memory, sensors, input devices, output devices, and communication devices. Additionally, it should be noted that the term “signal” means a waveform (e.g., electrical, optical, magnetic, mechanical, or electromagnetic) such as DC, AC, sine wave, triangular wave, square wave, or vibration that can be propagated through a medium.

[0028] The computing device 200 includes one or more memory modules 206 coupled to a communication path 204. One or more memory modules 206 may comprise RAM, ROM, flash memory, a hard drive, or any device capable of storing machine-readable and executable instructions so that the machine-readable and executable instructions can be accessed by one or more processors 202. Machine-readable and executable instructions may include, for example, machine language that can be executed directly by the processor, or logic or algorithms written in any programming language of any generation (e.g., 1GL, 2GL, 3GL, 4GL, or 5GL) that can be compiled or assembled into machine-readable and executable instructions and stored in one or more memory modules 206, such as assembly language, object-oriented programming (OOP), scripting language, or microcode. Alternatively, machine-readable and executable instructions may be written in a hardware description language (HDL), such as logic implemented via a field-programmable gate array (FPGA) configuration, an application-specific integrated circuit (ASIC), or an equivalent thereof. Therefore, the methods described herein can be implemented in any conventional computer programming language, either as pre-programmed hardware elements or as a combination of hardware and software components. The memory module 206 is described in more detail below in relation to Figure 4.

[0029] Referring further to Figure 3, the exemplary computing device 200 includes a data storage component 208. The data storage component 208 may store data received from wireless transmitters connected to the various sensors in Figure 1. The data storage component 208 may also store other data used by the various components of the computing device 200.

[0030] Continuing to refer to Figure 3, the computing device 200 includes network interface hardware 210 for communicatively coupling the computing device 200 to the wireless transmitter in Figure 1. Thus, the network interface hardware 210 can receive sensor data from the wireless transmitter connected to the various sensors in Figure 1. The network interface hardware 210 may be any device that can communicatively connect to the communication path 204 and can transmit and / or receive data over the network. Thus, the network interface hardware 210 may include a wireless transmitter for communications to transmit and / or receive communications from the wireless transmitter in Figure 1. For example, the network interface hardware 210 may include an antenna, a modem, a LAN port, a Wi-Fi card, a WiMax card, mobile communication hardware, near-field communication hardware, satellite communication hardware, and / or any wired or wireless hardware for communicating with the wireless transmitter in Figure 1. In some examples, the network interface hardware 210 may also transmit signals to the wireless transmitter in Figure 1.

[0031] Referring here to Figure 4, one or more memory modules 206 include a sensor data receiving module 300 and an operating state determination module 302. Each of the sensor data receiving module 300 and the operating state determination module 302 may be a program module in the form of an operating system, application program module, and other program modules stored in one or more memory modules 206. Such program modules may include, but are not limited to, routines, subroutines, programs, objects, components, data structures, etc., for performing a specific task or for executing a specific data type, as described below.

[0032] The sensor data receiving module 300 can receive sensor data from the wireless transmitters 140, 142, 144, 146, 148, 150, 152, 154, 156, and 158 shown in Figure 1. In particular, as described above, the sensor data receiving module 300 can receive temperature, flow rate, and / or pressure data from the respective temperature sensors, flow rate sensors, and pressure sensors connected to the wireless transmitters. The sensor data received by the sensor data receiving module 300 may be stored in the data storage component 208 and may be used by the operating state determination module 302 to determine the operating state of the heat exchanger 102, as will be described in more detail below.

[0033] Referring back to Figure 4, the operating state determination module 302 can determine the state of the heat exchanger 102 based on sensor data received by the sensor data receiving module 300, as disclosed herein. In the illustrated example, the operating state determination module 302 can determine fouling indicators, including the heat transfer coefficient, heat exchange rate, C coefficient related to the shell, and C coefficient related to the tubes, as disclosed herein. However, in other embodiments, the operating state determination module 302 may determine other indicators of the operating state of the heat exchanger 102.

[0034] The heat transfer coefficient can indicate the rate at which heat is transferred between the first fluid in the tubes of the heat exchanger 102 and the second fluid in the shell of the heat exchanger 102. The heat transfer coefficient can be an indicator of the operating state of the heat exchanger 102. In an embodiment, the operating state determination module 302 can determine the heat transfer coefficient Q using the following equation (1).

[0035]

number

[0036] In equation (1), U is the heat transfer coefficient related to the material of the heat exchanger 102. This may be a constant value related to the manufacture of the heat exchanger 102.

[0037] In equation (1), A is the area over which heat is transferred between the first fluid in the tubes of the heat exchanger 102 and the second fluid in the shell. In the illustrated example, A is the surface area of ​​the shell of the heat exchanger 102.

[0038] In equation (1), LMTD is the logarithmic mean temperature difference between the first fluid in the tubes of the heat exchanger 102 and the second fluid in the shell, and can be calculated using the following equation (2).

[0039]

number

[0040]

number

[0041] In equation (1), the correction factor F may be calculated differently depending on whether the system 100 uses a single shell with two tube paths or two shells with four tube paths. In one example, the system 100 can use a single shell with two tube paths. That is, the system 100 may have a single shell, as shown in the heat exchanger 102 in Figure 1, and the tubes within the shell may pass through the shell twice. That is, when the fluid enters the tube through the tube inlet port 106, the fluid may flow from the first end of the shell to the second end of the shell, and then return from the second end of the shell to the first end of the shell before exiting through the tube outlet port 110. In this example of a single shell with two tube paths, the correction factor F 1-2 This can be calculated using the following formula (3).

[0042]

number

[0043]

number

[0044]

number

[0045] In another example, system 100 can use two shells having four tube paths. That is, system 100 may have a first shell above a second shell that can be configured in the same way as heat exchanger 102 in Figure 1. Within each shell, the fluid may pass through the tubes twice, and when the fluid leaves the first shell, it may enter the second shell and pass through the tubes two more times. In this example of two shells with four paths, the correction factor F 2-4 This can be calculated using the following formula (4).

[0046]

number

[0047] In this embodiment, the operating state determination module 302 uses the above formula F depending on the type of system 100 being used. 1-2 or F 2-4 It is possible to determine one of the following. Next, the operating state determination module 302 determines F 1-2 or F 2-4 The correction factor F in equation (1) can be determined by multiplying one of the following by a manufacturer's correction factor related to the shape of the heat exchanger 102. The manufacturer's correction factor may be provided by the manufacturer of the heat exchanger 102.

[0048] Accordingly, in the embodiment, temperature sensors 120, 126, 132, and 136 may continuously measure the temperature in the shell inlet and outlet ports and the tube inlet and outlet ports of the heat exchanger 102, and wireless transmitters 140, 146, 152, and 156 may transmit the measured temperatures to a computing device 200. A sensor data receiving module 300 can receive the measured temperature values, and an operating state determination module 302 can use the received temperature values ​​to determine the heat transfer coefficient using the above formula. In particular, the operating state determination module 302 may monitor the heat transfer coefficient over time to determine the operating state of the heat exchanger 102. In particular, if fouling or other conditions occur in the heat exchanger 102, the heat transfer coefficient may decrease. Therefore, the calculated heat transfer coefficient may indicate fouling or other conditions, as will be described in more detail below.

[0049] In addition to determining the heat transfer coefficient, the operating state determination module 302 can also determine a heat exchange rate that can represent the ratio of actual heat transfer to the maximum possible heat transfer. In an embodiment, the operating state determination module 302 can determine the heat exchange rate S using the following equation (5).

[0050]

number

[0051] In this embodiment, the operating state determination module 302 can determine the heat exchange efficiency value based on the temperature measurement value received by the sensor data receiving module 300. If fouling or other conditions occur in the heat exchanger 102, the heat exchange efficiency may decrease. Therefore, the calculated heat exchange efficiency may indicate fouling or other conditions in the heat exchanger 102.

[0052] The operating state determination module 302 can also determine a first C coefficient related to the shell of the heat exchanger 102 and a second C coefficient related to the tubes of the heat exchanger 102. The C coefficient can be calculated by correlating the flow rate with the pressure drop due to fouling and using the following equation (6).

[0053]

number

[0054] The operating state determination module 302 can calculate a first C coefficient associated with the shell of the heat exchanger 102 by determining the difference between the pressure in the first T-joint 112 measured by the first pressure sensor 124 and the pressure in the third T-joint 116 measured by the third pressure sensor 134, and by determining the flow rate in the shell inlet port 104 measured by the first flow rate sensor 122. The operating state determination module 302 can calculate a second C coefficient associated with the tubes of the heat exchanger 102 by determining the difference between the pressure in the second T-joint 114 measured by the second pressure sensor 130 and the pressure in the fourth T-joint 118 measured by the fourth pressure sensor 138, and by determining the flow rate in the tube inlet port 106 measured by the second flow rate sensor 128.

[0055] Therefore, in this embodiment, pressure sensors 124, 130, 134, 138 and flow sensors 122, 128 can continuously measure pressure and flow values, and wireless transmitters 144, 150, 154, 158, 142, 148 can transmit the measured pressure and flow values ​​to a computing device 200. The operating state determination module 302 can receive the measured pressure and flow values, and the operating state determination module 302 can use the received values ​​and the above formula to determine the first and second C coefficients of the shell and tubes of the heat exchanger 102, respectively. The C coefficients can provide an indicator of whether fouling is occurring in the heat exchanger 102.

[0056] Continuing to refer to Figure 4, the notification module 304 can monitor indicators (e.g., heat transfer coefficient, heat exchange rate, and C coefficient) determined by the operating state determination module 302, as disclosed herein, and can output notifications based on the values ​​of those indicators. In some embodiments, the user can specify one or more thresholds associated with different indicators determined by the operating state determination module 302. For example, the user can specify minimum values ​​for the heat transfer coefficient, heat exchange rate, and / or C coefficient determined by the operating state determination module 302. The notification module 304 can then monitor the values ​​of these indicators and determine whether any of those values ​​fall below the corresponding threshold. In other examples, the user can specify a maximum allowable change for one or more of the heat transfer coefficient, heat exchange rate, and / or C coefficient. In these examples, the notification module 304 can monitor the values ​​of the indicators and determine whether any of those values ​​have fallen below the maximum allowable amount. In some examples, one or more of these thresholds may be predetermined rather than specified by the user.

[0057] If the notification module 304 determines that one or more indicators determined by the operating state determination module 302 have fallen below a threshold, the notification module 304 may send and / or output a notification indicating this. The notification module 304 may send and / or output such a notification in various ways. For example, the notification module 304 may cause the computing device 200 to output a warning, or the notification module 304 may send a notification to the user's smartphone or other device. In some examples, the notification may indicate a specific indicator or multiple indicators that have fallen below a threshold, and / or a specific value of the indicators.

[0058] Notifications sent and / or output by the notification module 304 can indicate to the user that a fouling may have occurred or is expected to occur in the heat exchanger 102. Therefore, upon receiving a notification, the user can have maintenance performed on the heat exchanger 102 to correct any problems that may be causing the fouling, thereby enabling the heat exchanger 102 to continue operating efficiently.

[0059] Referring now to Figure 5, a portion of an exemplary heat exchanger fouling prediction system 400 is shown. In the example in Figure 5, the system 400 may include a heat exchanger 102 and a computing device 200. Furthermore, the system 400 may include a radio signal repeater 402, a radio signal antenna receiver 404, and a demodulator 406. In the example in Figure 5, the computing device 200 is a local computer that may be located in the same facility as the heat exchanger 102.

[0060] In the example in Figure 5, the wireless transmitter 140 transmits sensor data at a frequency of 900 MHz via a 40 mW wireless signal. However, it should be understood that in other examples, the wireless transmitter 140 may transmit sensor data at different frequencies and / or protocols. In some examples, the wireless transmitter 140 may transmit sensor data at multiple frequencies (e.g., 900 MHz and 2.6 GHz) to increase transmission redundancy. In the example in Figure 5, only the wireless transmitter 140 is shown. However, wireless transmitters 142, 144, 146, 148, 150, 152, 154, 156, and 158 can transmit data in a similar manner.

[0061] In the example shown in Figure 5, the radio signal repeater 402 can receive sensor data transmitted by the radio transmitter 140. The radio signal repeater 402 can then retransmit the received sensor data, thereby increasing the range over which the sensor data can be transmitted. In the example shown in Figure 5, the radio signal repeater 402 transmits the sensor data at a frequency of 900 MHz via a 500 mW radio signal. However, in other examples, the radio signal repeater 402 may transmit the received sensor data at a different frequency and / or protocol.

[0062] The wireless signal antenna receiver 404 can receive sensor data transmitted by the wireless signal repeater 402. Since the wireless signal repeater 402 retransmits the sensor data transmitted by the wireless transmitter 140, the wireless signal antenna receiver 404 may be positioned at a greater distance from the wireless transmitter 140 than would be possible if the wireless signal antenna receiver 404 were receiving signals directly from the wireless transmitter 140. In some examples, the wireless signal antenna receiver 404 can send a signal to the wireless signal repeater 402 if the sensor data is not received properly. This causes the wireless signal repeater 402 to retransmit the data, thereby improving the resilience of the data flow pipeline. The sensor data received by the wireless signal antenna receiver 404 may be input to the demodulator 406.

[0063] Demodulator 406 can demodulate the signal received by the radio signal antenna receiver 404. Demodulator 406 can then output the demodulated signal to the computing device 200. In the illustrated example, demodulator 406 operates with a current of 4–20mA and a DC voltage of 1–5V. However, in other examples, demodulator 406 may operate with any other voltage and current. The computing device 200 can receive the demodulated sensor data via the distributed control system analog input.

[0064] Figure 6 shows a portion of an exemplary heat exchanger fouling prediction system 500. The exemplary system 500 in Figure 6 is similar to the exemplary system 400 in Figure 4 and includes a heat exchanger 102, a radio signal repeater 502, a radio signal antenna receiver 504, and a cellular transmitter 506. In the example in Figure 6, the computing device 200 is a cloud computing device.

[0065] In the example in Figure 6, the radio signal repeater 502 can be constructed in the same manner as the radio signal repeater 402 in Figure 5. The radio signal antenna receiver 504 can be constructed in the same manner as the radio signal antenna receiver 404 in Figure 5.

[0066] In the example shown in Figure 6, the cellular transmitter 506 can convert sensor data received by the radio signal antenna receiver 504 into a cellular signal, which can then be transmitted to a cloud computing device 200. In the example shown in Figure 6, the cellular transmitter converts a 900MHz signal to a 2.4GHz signal and transmits the data using the ModBus protocol. However, in other examples, the cellular transmitter may utilize other frequencies and / or transmission protocols.

[0067] Figure 7 shows a flowchart illustrating an exemplary method for operating a computing device 200 to predict fouling in the heat exchanger 102. In step 600, the sensor data receiving module 300 receives sensor data from wireless transmitters 140, 142, 144, 146, 148, 150, 152, 154, 156, 158, showing temperature, pressure, and flow rate values ​​measured by sensors 120, 122, 124, 126, 128, 130, 132, 134, 136, and 138.

[0068] In step 602, the operating state determination module 302 calculates one or more fouling indicators. In particular, the operating state determination module 302 can determine the heat transfer coefficient of the heat exchanger 102, the heat exchange rate of the heat exchanger 102, the C coefficient of the shell of the heat exchanger 102, and the C coefficient of the tubes of the heat exchanger 102. The operating state determination module 302 can determine the fouling indicators using the formulas described above.

[0069] In step 604, the notification module 304 determines whether one or more of the fouling indicator values ​​calculated by the operating state determination module 302 fall below the relevant threshold. If the notification module 304 determines that none of the fouling indicator values ​​fall below the relevant threshold ("No" in step 604), control returns to step 600, and the sensor data receiving module 300 receives additional sensor data. If the notification module 304 determines that one or more of the fouling indicator values ​​fall below the relevant threshold ("Yes" in step 604), in step 606, the notification module 304 outputs a warning or notification to the user.

[0070] It should be understood here that the embodiments described herein relate to a wireless shell-and-tube heat exchanger fouling prediction system. In particular, temperature sensors, flow sensors, and pressure sensors may be clamped onto the shell-and-tube heat exchanger as described herein. A wireless transmitter may be connected to various sensors and wirelessly transmit sensor data recorded by the various sensors to a computing device. The computing device can determine a fouling indicator based on the received sensor data. Fouling can be predicted based on the fouling indicator determined by the computing device, thereby enabling preventive maintenance. This makes it possible to correct problems with the heat exchanger before they become detrimental to its operation, thereby maintaining the efficient operation of the heat exchanger. Furthermore, by utilizing clamp-on sensors and a wireless transmitter, the fouling prediction system can be retrofitted to existing shell-and-tube heat exchangers and fouling can be monitored remotely.

[0071] It should be noted that in this specification, the terms “substantially” and “about” may be used to describe the degree of inherent uncertainty that may arise from any quantitative comparison, value, measurement, or other expression. These terms are also used in this specification to describe the extent to which a quantitative expression may deviate from the stated standard without altering the fundamental function of the subject matter in question.

[0072] While specific embodiments are illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Furthermore, while various aspects of the claimed subject matter are described herein, such aspects do not need to be used in combination. Accordingly, the attached claims are intended to encompass all such changes and modifications that fall within the scope of the claimed subject matter.

Claims

1. It is a system, A shell-and-tube heat exchanger comprising a shell inlet port, a shell outlet port, a tube inlet port, a tube outlet port, a first T-fitting connected to the shell inlet port, a second T-fitting connected to the shell outlet port, a third T-fitting connected to the tube inlet port, and a fourth T-fitting connected to the tube outlet port, Computing devices and A first temperature sensor is attached to the outer surface of the shell inlet port and configured to measure the first temperature of the fluid inside the shell inlet port, A second temperature sensor is attached to the outer surface of the shell outlet port and configured to measure the second temperature of the fluid inside the shell outlet port, A third temperature sensor is attached to the outer surface of the tube inlet port and configured to measure the third temperature of the fluid inside the tube inlet port, A fourth temperature sensor is attached to the outer surface of the tube outlet port and configured to measure the fourth temperature of the fluid inside the tube outlet port, A first flow sensor is attached to the outer surface of the shell inlet port and configured to measure the flow rate of the fluid inside the shell inlet port, A second flow sensor is attached to the outer surface of the shell outlet port and configured to measure a second flow rate of the fluid inside the shell outlet port, A first pressure sensor is positioned inside the first T-joint and configured to measure the first pressure of the fluid inside the shell inlet port, A second pressure sensor is positioned inside the second T-joint and configured to measure the second pressure of the fluid inside the shell outlet port, A third pressure sensor is positioned inside the third T-fitting and configured to measure the third pressure of the fluid inside the tube inlet port, A fourth pressure sensor is positioned inside the fourth T-fitting and configured to measure the fourth pressure of the fluid inside the tube outlet port, A plurality of wireless transmitters, each of which is connected to one of the first temperature sensor, the second temperature sensor, the third temperature sensor, the fourth temperature sensor, the first flow sensor, the second flow sensor, the first pressure sensor, the second pressure sensor, the third pressure sensor, and the fourth pressure sensor, and each of which is configured to transmit data captured by the connected sensor to the computing device, The computing device is configured to determine one or more fouling indicators based on the data received from the plurality of wireless transmitters, the one or more fouling indicators indicating the possibility of fouling occurring in the shell-and-tube heat exchanger, the system.

2. The system according to claim 1, wherein the first temperature sensor is configured to measure the surface temperature of the outer surface of the shell inlet port and to determine the first temperature of the fluid inside the shell inlet port based at least in part on the surface temperature.

3. The system according to claim 1, wherein the first flow sensor includes an ultrasonic sensor.

4. The system according to claim 1, wherein the first temperature sensor is clamped onto the outer surface of the shell inlet port.

5. The system according to claim 1, wherein the computing device includes a cloud computing device.

6. The system according to claim 1, wherein the first temperature sensor, the first flow sensor, and the first pressure sensor are evaluated against a hazardous area classification.

7. The computing device is It is determined whether one or more of the fouling indicators fall below one or more predetermined thresholds, and The system according to claim 1, wherein it is configured to output a notification to the user when it is determined that one or more of the fouling indicators fall below one or more predetermined thresholds.

8. The system according to claim 1, further comprising a signal repeater configured to receive the data transmitted by the plurality of wireless transmitters and to retransmit the received data to the computing device.

9. The system according to claim 8, further comprising an antenna configured to receive the data retransmitted by the signal repeater, convert the data into cellular data, and transmit the cellular data to the computing device.

10. It is a method, Receiving first temperature data indicating the first temperature of the fluid inside the shell inlet port from a first wireless transmitter coupled to a first temperature sensor mounted on the outer surface of the shell inlet port of a shell-and-tube heat exchanger, The system receives second temperature data indicating the second temperature of the fluid inside the shell outlet port from a second wireless transmitter coupled to a second temperature sensor attached to the outer surface of the shell outlet port of the shell-and-tube heat exchanger, The third temperature data, indicating the third temperature of the fluid inside the tube inlet port, is received from a third wireless transmitter coupled to a third temperature sensor attached to the outer surface of the tube inlet port of the shell-and-tube heat exchanger. The system receives fourth temperature data indicating the fourth temperature of the fluid inside the tube outlet port from a fourth wireless transmitter coupled to a fourth temperature sensor attached to the outer surface of the tube outlet port of the shell-and-tube heat exchanger, The system receives first flow data indicating the first flow rate of the fluid inside the shell inlet port from a fifth wireless transmitter coupled to a first flow sensor attached to the outer surface of the shell inlet port of the shell-and-tube heat exchanger, Receiving second flow data indicating the second flow rate of the fluid inside the shell outlet port from a sixth wireless transmitter coupled to a second flow sensor mounted on the outer surface of the shell outlet port of the shell-and-tube heat exchanger, Receiving first pressure data indicating the first pressure of the fluid inside the shell inlet port from a ninth wireless transmitter coupled to a first pressure sensor located inside a first T-fitting connected to the shell inlet port of the shell-and-tube heat exchanger, Receiving second pressure data indicating the second pressure of the fluid inside the shell outlet port from a tenth wireless transmitter coupled to a second pressure sensor located inside a second T-fitting connected to the shell outlet port of the shell-and-tube heat exchanger, Receiving third pressure data indicating the third pressure of the fluid inside the tube inlet port from an eleventh wireless transmitter coupled to a third pressure sensor located inside a third T-fitting connected to the tube inlet port of the shell-and-tube heat exchanger, Receiving fourth pressure data indicating the fourth pressure of the fluid inside the tube outlet port from a 12th wireless transmitter coupled to a fourth pressure sensor located inside a fourth T-fitting connected to the tube outlet port of the shell-and-tube heat exchanger, A method comprising determining one or more fouling indicators that indicate the likelihood of fouling occurring in the shell-and-tube heat exchanger, based on the first temperature data, the second temperature data, the third temperature data, the fourth temperature data, the first flow rate data, the second flow rate data, the first pressure data, the second pressure data, the third pressure data, and the fourth pressure data.

11. Receiving the first temperature data, which includes the surface temperature of the outer surface of the shell inlet port, The method according to claim 10, further comprising determining the first temperature of the fluid inside the shell inlet port based at least partially on the surface temperature.

12. The method according to claim 10, further comprising receiving the first temperature data from a signal repeater that retransmits the first temperature data transmitted by the first wireless transmitter.

13. The method according to claim 12, further comprising receiving the first temperature data from the signal repeater via a cellular connection.

14. It is a method, A first temperature sensor is attached to the outer surface of the shell inlet port of a shell-and-tube heat exchanger, configured to measure the first temperature of the fluid inside the shell inlet port. A second temperature sensor is attached to the outer surface of the shell outlet port of the shell-and-tube heat exchanger, configured to measure the second temperature of the fluid inside the shell outlet port. A third temperature sensor is attached to the outer surface of the shell inlet port of the shell-and-tube heat exchanger, configured to measure the third temperature of the fluid inside the tube inlet port. A fourth temperature sensor is attached to the outer surface of the tube outlet port of the shell-and-tube heat exchanger, configured to measure the fourth temperature of the fluid inside the tube outlet port. A first flow sensor configured to measure the flow rate of the fluid inside the shell inlet port is attached to the outer surface of the shell inlet port. A second flow sensor configured to measure the second flow rate of the fluid inside the shell outlet port is attached to the outer surface of the shell outlet port. A first pressure sensor is placed inside a first T-joint connected to the shell inlet port, configured to measure the first pressure of the fluid inside the shell inlet port. A second pressure sensor is placed inside a second T-joint connected to the shell outlet port, configured to measure the second pressure of the fluid inside the shell outlet port. A third pressure sensor is placed inside a third T-joint connected to the tube inlet port, configured to measure the third pressure of the fluid inside the tube inlet port. A fourth pressure sensor is placed inside a fourth T-fitting connected to the tube outlet port, configured to measure the fourth pressure of the fluid inside the tube outlet port. A method comprising connecting a wireless transmitter to each of the first temperature sensor, the second temperature sensor, the third temperature sensor, the fourth temperature sensor, the first flow sensor, the second flow sensor, the first pressure sensor, the second pressure sensor, the third pressure sensor, and the fourth pressure sensor, each wireless transmitter being configured to transmit data captured by the connected sensor to a computing device.

15. Receiving first temperature data, second temperature data, third temperature data, fourth temperature data, first flow rate data, second flow rate data, first pressure data, second pressure data, third pressure data, and fourth pressure data, The method according to claim 14, further comprising determining, based on the received data, one or more fouling indicators that indicate the possibility of fouling occurring in the shell-and-tube heat exchanger.

16. Receiving the first temperature data, which includes the surface temperature of the outer surface of the shell inlet port, The method according to claim 14, further comprising determining the first temperature of the fluid inside the shell inlet port based at least partially on the surface temperature.

17. The method according to claim 14, further comprising clamping the first temperature sensor onto the outer surface of the shell inlet port.

18. The method according to claim 14, further comprising receiving the first temperature data from a signal repeater that retransmits the first temperature data transmitted by the first wireless transmitter.

19. The method according to claim 18, further comprising receiving the first temperature data from the signal repeater via a cellular connection.

20. The method according to claim 14, wherein the first flow sensor includes an ultrasonic sensor.

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