The Heat Exchanger Real Time Health Monitoring
Let us consider an example of a heat exchanger and a feedstock recuperator operation on a reactor unit under the COMPACS system monitoring at one of the process facilities. The Artificial intelligence of the COMPACS system implements the real-time diagnostics of the heat exchanger’s technical state. Using acoustic emission sensors, the system monitors integrity of housings and absence of leaks, and using temperature sensors – heat exchange efficiency. The COMPACS system recorded a progressive decrease in the relative thermal efficiency ratio since the beginning of operation after the unit overhaul.
Equipment Monitoring Log
In 4 years, the system detected the coefficient reduction to “ACTION REQUIRED” state. It issued automatically a prescription to the personnel “HEAT EXCHANGE REDUCTION – PREPARE CLEANING of tube bundle”. And simultaneously warned the process unit and facility responsible engineers on the incident. The unit operator checked the heat exchanger performance parameters according to the ACS (Automated Control System) data. An increase in the hot stream outlet temperature and a decrease in the cold stream outlet temperature were confirmed. Maintenance team entered the prescription into the unit overhaul schedule, and the reliability department engineer – into the unit inspection plan.
Six months later, the system detected the heat exchange coefficient reduction to “UNACCEPTABLE” state. This indicated a change in the unit performance and the products quality. The technical meeting was conducted. The unit specialists discussed the issue. Finally, they proposed to adjust the date of the unit scheduled maintenance according to the prediction.
Six months later, the unit unscheduled repair was performed, and the heat exchanger bundle tubes were disassembled, inspected and cleaned from deposits. The maintenance team didn’t extract the bundle due to the repair urgency. After commissioning, the system confirmed the heat exchange efficiency recovery. However, in six months the system detected the heat exchange efficiency decrease back again. The COMPACS system pointed the need for the heat exchanger repeated cleaning. Following inspection confirmed the system’s prescription.
The Heat Exchanger Maintenance
A repair carried out six months later with the tubes thorough cleaning. It included those on the outer surface, restored the heat exchange efficiency up to an acceptable level. Thus, the COMPACS system made it possible to timely diagnose the heat exchanger operational problems. And also organize their elimination and monitor the repairs quality.
The COMPACS system rightfully occupies a central place in the personnel work, providing diagnostics of the heat exchanger internal and external devices.
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DO YOU USE OTHER INSPECTION METHODS BESIDE VIBRATIONS AND ANALYSIS IN YOUR COMPACS SYSTEM
Dear Rafi,
For real-time diagnostics of heat exchangers, acoustic emission and temperature sensors are sufficient in most cases to provide a comprehensive picture of the equipment’s technical state.