Tube Sheet Imaging for Accurate Heat Exchanger Maintenance Tracking
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Solution Overview
Problem
Shell-and-tube heat exchangers require extensive and costly maintenance due to the large number of tubes, leading to significant manpower expenses and process downtime, with challenges in tracking maintenance status and identifying omission and performance errors.
Innovation Solution
An automated method using imaging devices to monitor and track the status of individual tubes during maintenance, employing two-view imaging and array mathematics to determine which tube a projecting object is associated with, thereby minimizing errors and reducing maintenance time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tracking of tube maintenance status is used, then implementation complexity is low, but measurement precision and reliability of maintenance status tracking deteriorate
Solution Approach 1:
The patent uses imaging devices to create visual copies (images) of the tube sheet and projecting objects. These image copies are then processed through array mathematics to determine tube status, replacing complex manual tracking while maintaining simplicity in the physical domain.
Solution Approach 2:
The patent replaces manual mechanical tracking methods with an automated optical system using imaging devices and computational image processing. The mechanical/manual inspection process is substituted by capturing images and using array mathematics to automatically determine which tube each projecting object belongs to.
2Reliability
If comprehensive monitoring of all tubes is implemented, then reliability of maintenance completion is improved, but loss of time for maintenance activities increases
Solution Approach 1:
The imaging devices continuously or periodically capture images of the tube sheet during maintenance activities. This continuous monitoring ensures that all tubes are tracked without interrupting the maintenance workflow, providing real-time assurance of completion without adding significant time overhead.
Solution Approach 2:
The system allows the maintenance process to self-document through automatic image capture and processing. The imaging system and array mathematics automatically track which tubes have been serviced, eliminating the need for separate manual tracking activities and ensuring comprehensive monitoring without proportionally increasing maintenance time.
3Measurement precision
If multiple imaging devices are used to track projecting objects, then measurement precision of tube identification is improved, but device complexity increases
Solution Approach 1:
The patent uses array mathematics to map two-dimensional image coordinates to one-dimensional tube identifiers. By transforming the spatial coordinates from multiple imaging devices into a structured array format, the system accurately identifies which tube each projecting object belongs to, resolving the complexity of multi-device coordination through mathematical transformation.
4Productivity
If real-time monitoring and analysis of maintenance status is implemented, then productivity through error reduction is improved, but use of energy for computing and processing increases
Solution Approach 1:
The system processes images and determines tube status only when necessary - specifically when projecting objects are detected or when maintenance status needs verification. Rather than continuously analyzing all tubes, the array mathematics focuses computational resources on identifying changes in tube status, reducing overall energy consumption while maintaining productivity through targeted real-time monitoring.
Data Source
AI summary
Shell-and-tube devices typically require regular maintenance. Described herein is an automated method for tracking the status of individual tubes during maintenance activities and recording status data for review and analysis. Status data may optionally be reported in real-time summary format and/or used to predict time-to-completion. The method helps to reduce the expense of performing maintenance activities in shell-and-tube devices, including shell-and-tube reactors and heat exchangers.