Heat Exchanger Tube Plug Matching and Installation Verification
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Solution Overview
Problem
Current methods for installing heat exchanger tube plugs lack assurance of correct product selection and installation verification, leading to potential safety risks and inefficiencies in critical infrastructure, such as refineries and nuclear generating stations, due to the variety of heat exchanger sizes, materials, and operating parameters.
Innovation Solution
A method and device using a software or app to verify the suitability of tube plugs with specific heat exchangers by comparing operating parameters and retaining installation data, ensuring correct plug selection and confirming successful installation through real-time measurements and analysis, with the ability to document and report installation metrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tube plug installation methods are used, then installation speed is maintained, but installation accuracy and verification capability deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where installation parameters (force, displacement, temperature, pressure) are measured in real-time during tube plug installation and compared against pre-stored reference data. The system provides immediate feedback on installation quality through pass/fail indicators, allowing operators to verify correct installation without increasing physical device complexity.
Solution Approach 2:
The patent replaces manual visual inspection and mechanical measurement methods with automated sensor-based detection and software analysis. Electronic sensors substitute for mechanical gauges, and computer-based analysis replaces human judgment, improving measurement precision while keeping the physical installation equipment relatively simple.
2Adaptability or versatility
If diverse heat exchanger specifications are accommodated, then adaptability is improved, but product selection accuracy deteriorates
Solution Approach 1:
The patent stores pre-configured installation parameters, force curves, and reference data for multiple heat exchanger types and tube plug specifications before installation begins. This preliminary preparation allows the system to quickly match the specific application requirements with the correct product and installation parameters, ensuring both adaptability and reliability.
Solution Approach 2:
The patent creates a universal installation and verification system that can handle multiple heat exchanger types, tube sizes, and plug specifications through a single integrated platform. The system uses configurable parameters and databases to adapt to different applications without requiring separate specialized equipment for each case.
3Manufacturing precision
If real-time installation monitoring is implemented, then installation quality is improved, but measurement and detection difficulty increases
Solution Approach 1:
The patent combines multiple measurement functions (force, displacement, temperature, pressure) into a single integrated monitoring system. By merging these detection capabilities into one unified platform with centralized data processing, the system reduces the overall complexity of measurement and detection while maintaining high installation quality through comprehensive monitoring.
Data Source
AI summary
A method of tube plug installation in a heat exchanger or pressure vessel is provided. The method includes verifying the suitability of a selected tube plug with a specifically identified type of heat exchanger or pressure vessel before installation of the selected tube plug. The step of verifying being performed with a device having an app, software, or user interface and after having entered or accessed data concerning the selected tube plug and entering or accessing data concerning the specifically identified type of heat exchanger or pressure vessel and operating parameters of the specifically identified type of heat exchanger or pressure vessel.