Parallel Test Heat Exchanger for Corrosion Monitoring
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Solution Overview
Problem
Heat exchangers face issues such as corrosion and deposit formation, which can lead to leakage, reduced heat transfer capacity, and are difficult to inspect without shutting down the facility, making it challenging to monitor their condition without disassembly.
Innovation Solution
A device and process that replicates the flow rates, temperatures, and conditions of heat exchangers, allowing for a test heat exchanger to be operated in parallel or inline, with a recirculation loop and separate fluid paths for the first fluid from the heat exchanger and a recirculating fluid, enabling inspection for corrosion and deposits without shutting down the facility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the heat exchanger is removed and disassembled for inspection, then corrosion and deposits can be observed, but facility production and output are impacted
Solution Approach 1:
The system divides the inspection function from the main heat exchanger by introducing a separate test heat exchanger that operates in parallel. This allows the main heat exchanger to continue operating while the test unit undergoes inspection, effectively segmenting the production system from the inspection system and eliminating production downtime.
Solution Approach 2:
The test heat exchanger is subjected to controlled parameter changes including temperature variations and chemical environment adjustments that simulate but exceed normal operating conditions. This acceleration of degradation parameters allows faster accumulation of measurable corrosion and deposit effects for inspection purposes.
2Productivity
If the heat exchanger operates under normal conditions, then production continues, but corrosion and deposits accumulate undetected
Solution Approach 1:
The test heat exchanger undergoes accelerated degradation through controlled exposure to harsh conditions before the main heat exchanger reaches critical failure points. This preliminary action creates early warning indicators of potential issues that would eventually affect the main system, allowing preventive maintenance scheduling.
Solution Approach 2:
A test heat exchanger is created as a functional copy of the main heat exchanger, subjected to identical or accelerated operating conditions. The test unit serves as a proxy that replicates the degradation processes of the main system, allowing indirect monitoring of reliability without affecting actual production equipment.
3Loss of time
If accelerated testing conditions are applied to the test heat exchanger, then corrosion and deposits develop faster for inspection, but the testing system complexity increases
Solution Approach 1:
The test heat exchanger system is designed with multi-functionality, serving both as a process heat exchanger and as a test subject for corrosion monitoring. The same physical unit undergoes accelerated testing while also performing its intended function, reducing the need for separate dedicated test equipment and simplifying the overall system architecture.
Solution Approach 2:
Chemical additives are introduced as intermediaries to accelerate deposit formation and corrosion processes in the test heat exchanger. These substances mediate the degradation process, making it occur faster and more predictably without requiring extreme physical conditions that would demand overly complex testing infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the testing of heat exchanger materials under identical conditions, allowing for the detection of corrosion and deposits without disrupting operations, facilitating inspection and potential destructive testing of the test heat exchanger without impacting production.
Implementation Method 1
a pump communicating with the test heat exchanger in the recirculation loop
Implementation Method 2
a heater communicating with the test heat exchanger in the recirculation loop. The pump and the heater may be configured to heat and circulate the recirculating fluid to adjust conditions in the test heat exchanger
Implementation Method 3
a test heat exchanger having a first inlet configured to receive the first fluid from the heat exchanger, a first outlet for the first fluid to the heat exchanger, a second inlet configured to receive a recirculating fluid, and, a second outlet for the recirculating fluid
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An apparatus and a process for testing fluid from a heat exchanger. A first fluid from a heat exchanger to be tested is passed through a test heat exchanger. A second fluid is circulated through the test heat exchanger with a pump. The second fluid is heated with a heater so that a temperature in the test heat exchanger can be controlled, for example, to so that conditions in the heat exchanger are close to the conditions in the heat exchanger. After a period of time, the test heat exchanger can be removed and inspected, tested, or both. Also, multiple test heat exchangers may be used to test various process conditions. Additionally, the test heat exchangers may include different materials to test various materials.