Heat Exchanger Service Life Estimation from Temperature Stress Models
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Solution Overview
Problem
Existing methods are inadequate for real-time monitoring and determining the remaining service life of process-engineering apparatuses like heat exchangers and phase separation containers, which experience material fatigue due to stress fluctuations rather than vibrations, making it difficult to estimate service life effectively.
Innovation Solution
The method involves using temperature measurement values from sensors to calculate mechanical stresses and determine the remaining service life through equivalent models or machine learning, with data transmitted to a remote computing unit for processing, enabling real-time estimation and predictive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If finite element method is used to calculate stress levels in material, then calculation accuracy is improved, but real-time monitoring capability deteriorates due to complexity and time required for calculation
Solution Approach 1:
The patent pre-calculates stress influence coefficients using finite element method before actual monitoring begins. These pre-computed coefficients are stored and reused during real-time operation, allowing rapid stress calculation from temperature measurements without repeating complex FEM computations. This preliminary preparation enables both high accuracy and real-time performance.
Solution Approach 2:
The patent creates a simplified computational model that copies the essential stress-temperature relationship from the complex finite element model. By establishing a linear relationship model with pre-computed influence coefficients, the system replicates the accurate stress calculation capability of FEM while using much simpler real-time computations based on measured temperature data.
2Reliability
If sensors are installed to measure temperature for stress calculation, then service life determination capability is improved, but device complexity increases
Solution Approach 1:
The patent makes the temperature sensors serve multiple functions: they monitor process conditions for operational control and simultaneously provide data for stress calculation and service life prediction. This multi-functionality justifies the added sensor infrastructure by extracting additional value from the same measurement data.
Solution Approach 2:
The patent introduces a computational model with pre-calculated influence coefficients as an intermediary between simple temperature measurements and complex stress analysis. This intermediary layer transforms readily available temperature sensor data into accurate stress predictions without requiring direct complex mechanical measurements, thereby simplifying the overall system architecture.
Data Source
AI summary
A remaining service life of a process-engineering apparatus through which fluid flows and which is embodied as a heat exchanger, column, or container for phase separation is acquired. A computing unit is mounted on the apparatus and coupled to a remote computing unit. Temperature measurement values are obtained by a plurality of sensors arranged in or on the apparatus. Mechanical stress is acquired as a characteristic variable not directly measurable from the measurement values of the temperature. The remaining service life is acquired from the mechanical stress. The mechanical stress is acquired by means of the computing unit and the mechanical stress and/or the temperature measurement values are transmitted to the remote computing unit, and the remaining service life is acquired there. Alternatively, the temperature measurement values are transmitted to the remote computing unit, and the mechanical stress and remaining service life are acquired there.