Detection of Fouling in Heat Exchangers

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11
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11

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90
80
Equation of the line:

y = 5.08*x 366
mcpTh
UAF = 5.08
70
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f ouled
clean
U

#LL$
Ufouling = Uclean cos(at + b)
#LL$
#(
%2 &

Changes in the overall heat transfer
coefficient, U, because of fouling
Continuously fouling heat exchanger
20% decrease in U
Ufouled/Uclean
0.9
0.8
0
0.2
0.4
0.6
0.8
Dimensionless time
Changes in the overall heat transfer
coefficient, U, because of fouling
Ufouled/Uclean

50% decrease in U
0.8
0.6
0.4
0.2
0.4
0.6
0.8
Dimensionless time

$'

'
( )

arccos(cf 1 )
m oor(mcf2 ) + 1
b = a(oor(mcf2 ) + 1)
a=
#LK$

cf 1
Ufouling
Uclean

cf 2

cf 1 cf 2 [0, 1]
%2 *
#)
Evolution of the resistance
to heat transfer because of fouling

20% decrease in U
3
2
Rf=0.0001
1
0
0.644
Fouling factor, Rf [m2K/(W)]
x 10
0.2
0.4
0.6
0.8
Dimensionless time
Evolution of the resistance
to heat transfer because of fouling
1.5
x 10

50% decrease in U
0.5
Rf=0.0001
0.2
0.4
0.876
Rf=0.0007
0.395
Fouling factor, Rf [m2K/(W)]
0.6
0.8
Dimensionless time

$'

Rf

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ch = cc =
4200 [J/Kg C]

= 998 [kg/m3 ] & 34
4

E R

"
E R
U = 3.780 [W/m2 K] #FAG$ SGT
%2# 9
#.
Example of a typical data set
100
thin
tcin
thout
tcout
50
2000
4000
6000
8000
10000
Sample no.
l/s
mh
mc
2000
4000
6000
8000
10000
Sample no.
Closer look on the data set above
100
thin
tcin
thout
tcout
50
0
1000
1100
1200
1300
1400
1500
Sample no.
1.5
l/s
mh
mc
0.5
1000
1100
1200
1300
Sample no.

1400
1500
%6
%2 &
8

"

N

8 FA
L

L

& FE

%
?
=
Ah,ij U
(W H/4)U
=
m
h ch
(m
h /2)ch
Ac,ij U
(W H/4)U
=
m
c cc
(m
c /2)cc
h =
Mh,ij
W Hd/4
=
m
h
(m
h /2)
c =
Mc,ij
W Hd/4
=
m
c
(m
c /2)
LE

'

I

h
c
y
!
E[]
BEEAK
BEEAK
BALJK
BALJK
BC
(
8

34 4

U KBU U

& LE

& LL

%2# 9
%
150
thin
tcin
thout
tcout
100
50
0
Sample no.
10
4
x 10
6
mh
mc
l/s
4
2
0
Sample no.
10
4
x 10
150
thin
tcin
thout
tcout
100
50
0
1000
1100
1200
1300
1400
1500
Sample no.
6
mh
mc
l/s
4
2
0
1000
1100
1200
1300
1400
Sample no.

"

1500
" #
!

34

!

8

9

Thin Tcin m h
m
c
Thout Tcout

N

?
N

N

%
LF
%%
2 '
$
()
M
M

!

?
<

8

8

!

!

#

8
FL

M
%

!

6

&
X
SJT '

6

#KE$ '

JKU

2:(())
=
H (1)
[()]
N (t1 + p)
#KE$

KE

2 34
%

KA

&

!

KE
KA JKU
M

"
&

$

*+, ' -

1

h
c
y
()
2; .)2;
BBJLL BBBBL BBJFH BBJKE

BEBFH BBBBL BEBAJ BEBLK
BBBG BAJ BKG BKH
BBE
EBC
AE
AE
BCE BBEL BHC
BCL

$

*+, ' -

1

h
c
y
()
2;
BEEB BBBBF BEBJL

BEEL BBBBF BEEAJ
BBA BEK
BF
BBL BCK
EG
BCE BBE
BHJ
.)2;
BEEBG
BEELA
BF
EH
BCF
& KE

!

! M

&
KA KF

& KF

& LF
M

x(t + )

x(t)
%(
2 '

100
Temperature [C]
th,out
tc,out
th,out,pred
tc,out,pred
80
60
40
20
0
50
100
150
200
250
Observation no.

#
" )
!

SB AT

M

y

LE "

h
c

h c BBBE BBK
8

KF
!
KF

%

!

#
("
! M

KL

y

2 34
%)
Residuals of the predicted hot output
Error
1
0
1
50
100
150
200
250
300
350
300
350
No.
Residuals of the predicted cold output
Error
0.5
0
0.5
50
100
150
200
250
No.

.
'
Autocorrelation of the residuals for the hot output
No.
1
0
1
10
15
20
Correlation
Autocorrelation of the residuals for the cold output
No.
1
0
1
10
15
Correlation

20
%,
2 '

'
/00 - '
8

EBB
E[]
[]
[2.5%, 97.5%]
BBCCJGAH 0.0005 SBBCCJGAA BBCCJGFJT
BBJKCHLF 0.0005 SBBJKCHFC BBJKCHKFT

h BBELB
0.008
SBBBE B BAAJT
c BBEHK
0.01
SBBBE BBACLT
y
BCAAC
0.01
SBCAAC BCAACT
"

h c

$

-
"

E
A
F
L
K
G
H
C
J
EB
#!
BBJKB
BBJLJ
BBJKE
BBJLC
BBJLH
BBJLG
BBJKE
BBJKB
BBJKG
BBJKH
BEBLE
BEBLE
BEBLE
BEBLE
BEBLA
BEBLL
BEBLB
BEBLA
BEBLA
BEBLB
BBBEB
BBLJL
BBFGF
BBKHA
BBAGC
BBAKE
BBALC
BBAFL
BBJJC
BFFGE
BBFAK
BBGAH
BBALL
BBEJF
BBAHH
BBAJL
BBAEK
BBFFG
BAFEH
BLFFG
BCBHE
BCBLE
BCBGJ
BHJGA
BHJJK
BCBLF
BHJJH
BCBAJ
BCAAE
BCABG
*
8

! #FEG$

ij

! 8 KE

"

LF

y

BC

SGT
2 34
%.
!

1 = 11 = 21 2 = 12 = 22 1 = 11 = 12 2 = 21 = 22
Q ij

& FE

N

"

##
( "
Q 34

M !

M

200

=

%

!

20

0

!

0

N

%

0

N

8 FA

Q

I8

8
FK

K
FKB FLJ

I8

FB

N

&

& KL

!

6
2 '
AKU
!
& KK

0.77 0.40

& 5

! &
KG KH &
KL KK

8

34

#+
), ,
! 8 FA

20

34 ; 20

I8
1

I8

N

JKU
0.35 0.84

SBBBBBF BBBBECT
& LA
#
"
! 34

&
34

SBFK BCLT

SBBBBBF BBBBECT !

8 LA

N

SBBBBE BBBBHT
34 "

!

N N

2 34

Offline estimation of the values
Value
0.1
0.09
0.08
0.07
0
200
400
600
800
Estimation no.
0.11
Value
0.1
0.09
0.08
0.07
0
200
400
600
800
Estimation no.

$'

CuSum chart for the offline method
2.5
936 CuSum values
Sampling time dt = 1
1.5
1
0.5
Shift detected in :0.4
CuSum values
0
0.5
Shift detected in : 0.77
Fouled heat exchanger
0.2
0.4
0.6
0.8
Dimensionless time

"
-

2 '

Value
0.11
0.1
0.09
0.08
0
200
400
600
800
Estimation no.
Value
0.12
0.1
0.08
0
200
400
600
800
Estimation no.

$'

1.5
1
0.5
0
0.5
936 CuSum values

CuSum values
2.5
0.2
0.4
0.6
0.8
Dimensionless time

"
-
2 4
#
M

!

0
$ ()
!

1
#1&$

N
8 FA

I8

8 FK

!

?
8
M

8

8

8

!

!

#
.
Q
1&

M

Q '

!

;

! & KC

c Q

!
Q
EBEB Q(1, 1) = Q(2, 2) = cq

! c

c = 109

AFU

!
c = 109

0.14
c = 105
0.12
0.1
0.08
0
500
1000
1500
Estimated parameters
2 '
%
0.2
0.18
0.16
0
c = 107
0.12
0.11
0.1
500
1000
1500
0.17
c = 109
0.117
0.116
0.115
500
1000
0.15
1500
500
1000
sample number
1500
c = 1010
0.117
500
1000
1500
c = 109
0.163
0.162
0.161
500
1000
1500
sample number
0.118
0.116
c = 107
0.164
sample number
1500
sample number
0.118
1000
0.16
sample number
500
sample number
sample number
0.13
c = 105
0.164
c = 1010
0.163
0.162
0.161
500
1000
sample number

-
-

' 1
1500
2 4

Sampling time of 1 s
Standard deviation
0.2
0.1
100
0.6
0.2
0
200
0.4
10
0.1
100
sample number
Standard deviation
0.2
20
30
sample number
sample number
200
0.4
0.2
0
10
20
30
sample number

2

/ /0 '

'
#
" )
N
34

EBB
B A

! & KJ

%

EBB

! & KEB

!

1

EU
100

& 10

EU 70

& &
KJ KEB

%
(
2 '

10
10
10
10
Standard deviation
Standard deviation
10
10
10
10
10
10
10
10
10
100
200
sample number
300
10
100
200
300
sample number

'

'

/
/0

N

ABB

%

!

100

#
(
N

!
4

30

I8

8 FK
2 4
)
0.5
3750 CuSum values
0.4
0.3
0.2
0.1
0.6
CuSum values
CuSum chart for the on line method
0.1
0
0.2
0.4
0.6
0.8
Dimensionless time

"

&

! & KEE

0.81

0.83 !

1s
& 5

! &
KEA KEE

!

4
# !
"

&
KEF KEL

4 !

!

,
2 '

3750 CuSum values
0.6
CuSum values
0.4
0.2
0.8
0.2
0.4
0.6
0.8
Dimensionless time

"

!

!

10
FHK I8

FHKB I8

1

I8

O

# #
), ,
N

4
KB

JKU
0.65 0.91

SBBBBE BBBBAAT
& LA
2 4
.
CuSum values
0.3

1875 CuSum values
0.2
0.1
0.4
0
0.1
0.2
0.4
0.6
0.8
Dimensionless time
CuSum values
0.1

938 CuSum values
0.05
0.15
0.2
0.4
0.6
0.8
Dimensionless time

" dt = 2 dt = 4
# +
*
N
34 4

34

1 = 11 = 21 2 = 12 = 22 1 = 11 = 12 2 = 21 = 22
ij

& FE
"

9

"

(6
2 '

CuSum values

626 CuSum values
0.15
0.1
0.2
0.05
0
0.2
0.4
0.6
0.8
0.8
Dimensionless time
CuSum values
0.25
375 CuSum values
0.2
0.15
0.1
0.05
0.3
0.2
0.4
0.6
Dimensionless time

" dt = 6 dt = 10

#

&

4

&
4
SBGK BJET

SBBBBE
2#
(
BBBBAET I

SBBBBE BBBBHT

!

N N

M

&

0

"

$

8 FF

!

9

34 4

N
8 LF
AKU

&

" U

KBU U
& LE ! &
KEK

! & KEG

AU F

AU F

!

I8

8 FK

U AF = U AF U AF

& KEH

I8

I8

0.42

!

8 LA

(
2 '

5
x 10
Equation of the line:

y = 1.96e+004*x 1.4e+006
UAF = 1.96e+4
Reference slope
mc T
3.5
The slope, UAF, calculated with window size=400
2.5
2
82
83
84
85
TLMTD
86
87
88

$

Rf = 0.00016

SBBBBE BBBBHT
#
), ,
! 8 FA

50

; 50

4

JKU
0.33 0.92

SBBBBBH BBBBCT
& LA
!

!

!

8

2#

5
x 10
(#

Reference slope
mcpTh
Fouled slope
3
2
1
82
84
86
88
T
90
92
94
LMTD
x 10

Reference slope
mcpTh
3.5
Clean
Gradually fouling
3
2.5
2
Fouled slope
0.2
0.4
0.6
0.8
TLMTD

3 4

AU F

3 4

'
'
'

!

%

#

SBBBBBH BBBBCT

"

SBBBBE BBBBHT
(%
2 '
CuSum chart for the slope method

1471 CuSum values
1000
2000
3000
4000
0.2
Shift detected in UA: 0.42
CuSum values
0.4
0.6
Dimensionless time

"

0.8
$ !

N
8 AF

%

SBBBBE BBBBHT
!

34 4

" 8

"

!

Q

!

!

!

B

?
34
< JKU
SBFK BCLT

SBBBBBF
BBBBECT
GK
((
(2 &

<

y
%
<
<
<

h c

4
< JKU
SBGK BJET
<
<

SBBBBE
BBBBAET

8"
EKB

<
<
"
<

<

JKU

SBFF BJAT

SBBBBBH
BBBBCT
!

34

4

34

4
!

!

34 4
!

8

! SEGT

Rf 0.00008 !

%
% &

&

?
:

!

1

!

GH
'

SET N = N' ?RR ? 6

SAT ' '
Y9 I &

@ ABBK ?RR

RR ABBKR
SFT Q '
I
M

AK

@ ABBK
?RR

RR ABBKR
SLT > D ' < ZI 6

@ Q

F EJJH
SKT I
>
> '

?

@ ABBK
?RR

RR ABBKR
SGT Z
N I > 6
D 6 A ABBK
SHT Y 9 I 9 Y Z = 8 Y P = O [M ;
R

\%

GE ABBL
SCT & & N< Q
O 1

I

@ ABBK
?RR

RR ABBKR
SJT N D @ ' I 6 8 8 9 ' >
I 6RI>I A ABBF
SEBT N8 62 =& N 8
' <@'& & I

"
?

EJJH
GJ
)6
++-0' =
SEET < @

;' 8 I

AG @ EJJB
SEAT 6 @
! " <9

9 !
ABBG
SEFT D @
;< <
N

# ! $ EEG
@ EJJL
SELT D @
;< <
80

# !
$ EEL 9 EJJA
SEKT D @
; < <
:

% % $%
EJJE
SEGT D > @
8 = ; < <
' 9

:

" ! ABBG
SEHT 8 = ;< <
D> @
' 9
I

" 5!! ABBH
SECT 8 = 8 = ' 9

$
" ! FA ABBK
SEJT = @ =
?
O ]

?RR
R RR= EJJHR= EJJH&^Q

SABT ' !
!

= &
%

?RR
R&!6 1

SAET 6
! 9 : A ABBG
SAAT 9
I D I > &'
' @ Q 8
! F ABBA
SAFT N D; 8Z N6 1

EJJJ
SALT N O0 I @
P _ 6 `8 !

EJJJ
SAKT < O N 9 N

ABBK
++-0' =
)
SAGT ABBC O!8 R81N 1I6 6 8

?RR
RCJCRR
SAHT 1 < ?RRRR
SACT 88 > 8 Q 6 Y9 I
' '

N

@ ABBK
?RR

RR ABBKR
SAJT D >MM 6 `8 1 > !

? !
@
ABBK ?RR

RR ABBKR
SFBT 8 8 'M O 8
#$
$(
! & ABBH
SFET > 8 6
`8 M <

M

"
EL @ EJJF
SFAT D Q D '
N
@ AL ABBG
SFFT Q ?RRR
SFLT < Q
:

%

% (

)% EJJG
(

! I K

!

*

I K
8
LA ! I K

& NE

* ()
!

I K

8 KE

LB

0
AB

HF
)%
2 -

100
thin
tcin
thout
tcout
50
0.5
1.5
Sample no.
2
4
x 10
2
l/s
mh
mc
0.5
1.5
Sample no.
2
4
x 10
thin
tcin
thout
tcout
50
0
1000
1100
1200
1300
1400
1500
Sample no.
2
mh
mc
l/s
100
0
1000
1100
1200
1300
Sample no.

1400
1500
2# 4
)

$

*+, ' -

1

h
c
$
/
BEBJK
BEEGH
BBAJF
BBAAH
BCBCL
V ar()
2; .)2;
BBBBF BBHFF BELKC

8
BBBBL BBHGJ BEKGK
8
BHHJL EHFGL EHJKB O

EAKFB AAEGE AAGEK O

BBEFA BKHCC EBFCB
8

NE

Q
KA

!

/
( "
& NA

!

AKU

N
8 FA

! & NF

BLL BFL

* ()
!

I K

)(
2 -

Off line estimation of the values
Value
0.12
0.1
0.08
200
400
600
800
1000
800
1000
Estimation no.
Off line estimation of the values
Value
0.12
0.1
0.08
0.06
200
400
600
Estimation no.

$'

/
(
! & NL

BGG

BHG
2# 4
))
3.5
3
2
1.5
1
0.5
0
0.5
934 CuSum values
2.5
CuSum values
0.2
0.4
0.6
0.8
Dimensionless time

"
-
1.5
1
0.5
CuSum values
17500 CuSum values
2.5
0
0.5
0.2
0.4
0.6
0.8
Dimensionless time

"

'
&
F

CB

#FFH$ ' %

#FFG$

M
&
f1 ?
1
f1
=
(Th,10 Th,11 + Tc,01 + Tc,11 )
2h
f1
1 + /2
=
Th,11
h
f1
=
Tc,11
2h
f1
f1
f1
f1
f1
f1
f1
=
=
=
=
=
=
=0
Th,12
Th,21
Th,22
Tc,12
Tc,21
Tc,22
&

f2 ?
1
f2
=
(Th,11 Th,12 + Tc,02 + Tc,12 )
2h
f2
1 /2
=
Th,11
h
f2
1 + /2
=
Th,12
h
f2
=
Tc,12
2h
f2
f2
f2
f2
f2
f2
=
=
=
=
=
=0
Th,21
Th,22
Tc,11
Tc,21
Tc,22
HJ
,6
+2 *
&

f3 ?
1
f3
(Th,20 Th,21 + Tc,11 + Tc,21 )
=
2h
1 + /2
f3
=
Th,21
h
f3
=
Tc,11
2h
f3
=
Tc,21
2h
f3
f3
f3
f3
f3
f3
=
=
=
=
=
=0
Th,11
Th,12
Th,22
Tc,12
Tc,22
&

f4 ?
1
f4
=
(Th,21 Th,22 + Tc,12 + Tc,22 )
2h
1 /2
f4
=
Th,21
h
f4
1 + /2
=
Th,22
h
f4
=
Tc,12
2h
f4
=
Tc,22
2h
f4
f4
f4
f4
f4
=
=
=
=
=0
Th,11
Th,12
Tc,11
Tc,21
&

f5 ?
1
f5
=
(Th,10 + Th,11 Tc,01 Tc,11 )
2c
f5
=
Th,11
2c
f5
1 + /2
=
Tc,11
c
f5
f5
f5
f5
f5
f5
f5
=
=
=
=
=
=
=0
Th,12
Th,21
Th,22
Tc,12
Tc,21
Tc,22
,
&
f6 ?
f6
1
=
(Th,11 + Th,12 Tc,02 Tc,12 )
2c
f6
=
Th,11
2c
f6
=
Th,12
2c
f6
1 + /2
=
Tc,12
c
f6
f6
f6
f6
f6
f6
=
=
=
=
=
=0
Th,21
Th,22
Tc,11
Tc,21
Tc,22
&

f7 ?
1
f7
=
(Th,20 + Th,21 Tc,11 Tc,21 )
2c
f7
=
Th,21
2c
f7
1 /2
=
Tc,11
c
f7
1 + /2
=
Tc,21
c
f7
f7
f7
f7
f7
f7
=
=
=
=
=0
=
Th,11
Th,12
Th,22
Tc,12
Tc,22
&

f8 ?
1
f8
=
(Th,21 + Th,22 Tc,12 Tc,22 )
2c
f8
=
Th,21
2c
f8
=
Th,22
2c
f8
1 /2
=
Tc,12
c
f8
1 + /2
=
Tc,22
c
f2
f2
f2
f2
f2
=
=
=
=
=0
Th,11
Th,12
Tc,11
Tc,21
(
&

AE <
AA
<
AF I
AL
I
AK I

AG I

AH 8

Q EE
AC <
9 6 1

EA
FE I
L

EH
FA

mc
p T
TLMT D
AC
FF 1

FB
FL 1

FE
CF
,%
-" * *09'!"
LE 1
" :
FG
LA 1 Rf

FH
LF 8 FJ
LL 9

LE
KE <
LG
KA >

LH
KF N

LH
KL 1

KE
KK 9

KE
KG 1

KA
KH 9

KA
KC

P KL
KJ 5

E
EB

KK
KEB

E
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Detection of Fouling in Heat Exchangers

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Copyright:

Verfügbare Formate

Detection of Fouling in Heat Exchangers

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Copyright:

Verfügbare Formate

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