Reliability-Based Maintenance Strategies for Heat Exchangers Subject to Fouling

1996 ◽  
Vol 118 (4) ◽  
pp. 306-312 ◽  
Author(s):  
A. K. Sheikh ◽  
S. M. Zubair ◽  
M. U. Haq ◽  
M. O. Budair
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Unit Cost ◽  
Heat Transfer Process ◽  
Economic Behavior ◽  
Periodic Maintenance ◽  
Cleaning Cycle ◽  
Cost Parameters ◽  
Special Case ◽  
Additional Fuel

Fouling in heat exchangers is an unavoidable by-product of the heat transfer process. The decision regarding periodic maintenance (cleaning) of the exchangers subject to fouling is generally based on thermal and economic behavior of the process. In this paper, a reliability-based maintenance strategy is discussed by incorporating the risk and scatter parameters of the linear random fouling growth model. In addition, the dimensionless cost-objective function is formulated by considering various cost elements for a heat exchanger used in a crude oil preheat train. The variation in the dimensionless cost Γ with reduced time tp/(tp + tdown) is presented for different values of unit cost parameters γ1, γ2, and γ3 representing additional fuel cost, antifoulant cost, and miscellaneous costs, respectively. Furthermore, the optimal cleaning cycle of the heat exchanger recently investigated by Casado (1990) is demonstrated to be a special case of the results presented in the paper.

scholarly journals HAZARDS OF STANDARD HEAT-EXCHANGE EQUIPMENT IMPLEMENTATION IN CHEMICAL TECHNOLOGY WITHOUT CONSIDERING THE PROCESS SPECIFIC CHARACTER

2016 ◽  
Vol 11 (5) ◽  
pp. 57-64
Author(s):  
K. O. Goncharuk ◽  
D. S. Kornilova ◽  
D. S. Yakovlev ◽  
N. N. Prokhorenko
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Heat Transfer Process ◽  
Chemical Plants ◽  
Standard Equipment ◽  
Tube Heat Exchanger ◽  
Standard Heat ◽  
Conditions Of Work ◽  
Made In

Standard equipment is a considerable part of modern equipment of chemical plants. In particular, standard heat exchangers are widespread. Possible deviations in the operation of heat exchangers at plants from the preset parameters of their operation can lead to deterioration of the operation of the whole technological system. For this reason an attempt is made in the article to suggest a hypothesis explaining what can lead to disfunction in the operation of heat exchangers. The authors use a method of calculating technological reliability to study the operability of a vertical shell-and-tube heat exchanger. First, the size of the heat transfer surface of the vertical heat exchanger is calculated for specific conditions of work, and a standard device is chosen. Then a method of calculating the technological reliability of the calculated and standard heat exchangers is applied. An operating problem is solved on the assumption that external impacts on the heat transfer process are not fixed, but varied and are within their acceptable intervals. After comparing the probability of the workability of the calculated heat exchanger and of the chosen standard apparatus, a conclusion is made about the expediency of using the standard heat exchanger.

scholarly journals Graphing Behaviour of Heat Transfer In Terms of Nusselt and Reynolds

2021 ◽  
Vol 6 (2) ◽  
pp. 41-52
Author(s):  
Mohd Rahimie Md Noor ◽  
Nur Syafiqah Hidayah Mohd Fauzi ◽  
Siti Nur Fadhilah Masrom ◽  
Mohd Azry Abdul Malek ◽  
Muhammad Firdaus Mustapha ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Reynolds Number ◽  
Nusselt Number ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Volume Flow Rate ◽  
Convection Heat Transfer ◽  
Heat Transfer Process ◽  
Two Fluids ◽  
The Relationship

Heat exchangers are tools used to transfer thermal energy between two fluids (liquid or gas) by convection and conduction at different level of temperatures. Heat exchangers are the common equipment and employed in many different applications because of ability to withstand high temperatures and compactness. There are no intermixing or leakage occurred between two fluids during the heat transfer process as fluids are separated by walls of heat exchanger. The main objective of this project is to determine the heat exchanger effectiveness in heat transfer performance. This will be done by investigating the performance of five different angles of heat exchanger which are 150,300, 450, 600 and 750. The effectiveness of heat exchanger depends on the convection heat transfer coefficient of the fluid. Besides that, this project also aims to develop some parameters such as Nusselt number, Reynolds number and Prandtl number for evaluating the heat transfer. It is found that the Nusselt Number at angle of 150 is lower compared to angle of 750. Meanwhile, Reynolds number for angle 150 is higher than angle 750 which means that the type of flow produced by angle 150 is turbulent flow while for 750 angle is laminar flow. Hence, the overall result of this project proved that 150 is the best angle for heat exchanger in chimney because of higher velocity, higher volume flow rate, higher density of gas and higher LMTD. The relationship between Nusselt number and Reynolds number between different angles can be observed by plotting the graph using Maple Software.

Second-Law-Based Thermoeconomic Optimization of Two-Phase Heat Exchangers

1987 ◽  
Vol 109 (2) ◽  
pp. 287-294 ◽  
Author(s):  
S. M. Zubair ◽  
P. V. Kadaba ◽  
R. B. Evans
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Transfer Coefficient ◽  
Heat Exchangers ◽  
Unit Cost ◽  
Second Law ◽  
Inlet Temperature ◽  
Two Phase ◽  
Transfer Resistance

This paper presents a closed-form analytical method for the second-law-based thermoeconomic optimization of two-phase heat exchangers used as condensers or evaporators. The concept of “internal economy” as a means of estimating the economic value of entropy generated (due to finite temperature difference heat transfer and pressure drops) has been proposed, thus permitting the engineer to trade the cost of entropy generation in the heat exchanger against its capital expenditure. Results are presented in terms of the optimum heat exchanger area as a function of the exit/inlet temperature ratio of the coolant, unit cost of energy dissipated, and the optimum overall heat transfer coefficient. The total heat transfer resistance represented by (1/U = C1 + C2 Re−n) in the present analysis is patterned after Wilson (1915) which accommodates the complexities associated with the determination of the two-phase heat transfer coefficient and the buildup of surface scaling resistances. The analysis of a water-cooled condenser and an air-cooled evaporator is presented with supporting numerical examples which are based on the thermoeconomic optimization procedure of this paper.

THE ANALYSIS OF EXERGY EFFICIENCY IN THE LOW TEMPERATURE HEAT EXCHANGER

2007 ◽  
Vol 21 (18n19) ◽  
pp. 3497-3499 ◽  
Author(s):  
LAN PENG ◽  
YOU-RONG LI ◽  
SHUANG-YING WU ◽  
BO LAN
Keyword(s):  
Heat Transfer ◽  
Heat Capacity ◽  
Heat Exchanger ◽  
Low Temperature ◽  
Transfer Process ◽  
Heat Exchangers ◽  
Heat Transfer Process ◽  
Exergy Efficiency ◽  
Capacity Ratio ◽  
Temperature Heat

Based on the analyzing of the thermodynamic performance of the heat transfer process in the low temperature heat exchangers, the exergy efficiency of the heat transfer process is defined and a general expression for the exergy efficiency is derived, which can be used to discuss the effect of heat transfer units number and heat capacity ratio of fluids on the exergy efficiency of the low temperature heat exchanger. The variation of the exergy efficiency for several kinds of flow patterns in the low heat exchangers is compared and the calculating method of the optimal values of heat capacity ratio for the maximum exergy efficiency is given.

Thermoeconomic Considerations in the Optimum Allocation of Heat Transfer Inventory for Refrigeration and Heat Pump Systems

2002 ◽  
Vol 124 (1) ◽  
pp. 28-33 ◽  
Author(s):  
Mohamed A. Antar ◽  
Syed M. Zubair
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Heat Pump ◽  
Heat Exchangers ◽  
Strong Dependence ◽  
Unit Cost ◽  
Optimum Allocation ◽  
Closed Form Expression ◽  
Cost Ratio ◽  
Additional Parameter

Thermoeconomics is defined as attaching monetary values to heat exchanger conductances of a given plant. In this study, optimum allocation of heat transfer inventory for heat exchangers in a refrigeration system with specified power input or cooling capacity, and for a heat pump with specified heating capacity is investigated. The ratio of hot- to cold-end conductance unit cost ratio, G, was considered in the analysis as an additional parameter of considerable importance to the designer. A closed-form expression is given in terms of unit cost of conductances of both the heat exchangers. The results show a strong dependence of the total cost on the absolute temperature ratios as well as the hot- to the cold-end conductance cost ratio. It is demonstrated in the illustrative example that for G=0.1, the conductance of the hot-end heat exchanger is about three times the cold-end heat exchanger.

Heat Transfer Through an Extended Surface Containing He II

1999 ◽  
Vol 121 (1) ◽  
pp. 142-147 ◽  
Author(s):  
S. W. Van Sciver
Keyword(s):  
Heat Transfer ◽  
Heat Exchangers ◽  
Analytic Solution ◽  
Heat Transfer Process ◽  
Surface Heat ◽  
Bulk Fluid ◽  
Kapitza Conductance ◽  
Extended Surface ◽  
Tube Type ◽  
Special Case

A semi-analytic solution for the heat transfer process between a He II pressurized bath and a saturated tube-type heat exchanger is presented. The problem is modeled with an extended surface heat transfer formulation analogous to that in conventional conduction. The process is governed by Kapitza conductance and counterflow within the bulk fluid in the tube. The resulting nonlinear differential equation may be integrated for the special case of constant properties, yielding a simple solution applicable to design and analysis of practical heat exchangers.

scholarly journals Heat exchanger operating point determination

2009 ◽  
Vol 13 (4) ◽  
pp. 151-164
Author(s):  
Dusan Gvozdenac
Keyword(s):  
Mathematical Model ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Operating Point ◽  
Operating Parameters ◽  
Heat Flow Rate ◽  
Point Determination ◽  
Operating Points ◽  
Special Case ◽  
Micro Balance

This paper indicates 21 possible tasks for the calculation of heat exchangers and specifies in particular the procedure for determining heat exchanger operating point. Features of heat exchanger energy micro-balance are contained in its mathematical model, and features of its macro-balance hold in relations for heat flow rate. Operating point of heat exchanger is defined by satisfying micro and macro balances. The paper presents basic relations for determining operating points for some types of tasks and algorithms of certain procedures. A special case in which two, one or none non-trivial solutions appear within two of 21 tasks is analyzed and discussed separately. Presented procedures are very suitable for the preparation of own software for the calculation of operating parameters of any heat exchanger and analysis of heat exchangers network.

Analysis of the Thermal Stress at the Tubesheet in Floating-Head or U-Tube Heat Exchangers

2017 ◽  
Vol 139 (2) ◽  
Author(s):  
Jiuyi Liu ◽  
Caifu Qian ◽  
Huifang Li
Keyword(s):  
Thermal Stress ◽  
Heat Exchanger ◽  
Temperature Difference ◽  
Heat Exchangers ◽  
Influence Factors ◽  
Area Ratio ◽  
Shell Side ◽  
Tube Heat Exchanger ◽  
Numerical Tests ◽  
Hole Area

Thermal stress is an important factor influencing the strength of a heat exchanger tubesheet. Some studies have indicated that, even in floating-head or U-tube heat exchangers, the thermal stress at the tubesheet is significant in magnitude. For exploring the value, distribution, and the influence factors of the thermal stress at the tubesheet of these kind heat exchangers, a tubesheet and triangle arranged tubes with the tube diameter of 25 mm were numerically analyzed. Specifically, the thermal stress at the tubesheet center is concentrated and analyzed with changing different parameters of the tubesheet, such as the temperature difference between tube-side and shell-side fluids, tubesheet diameter, thickness, and the tube-hole area ratio. It is found that the thermal stress of the tubesheet of floating-head or U-tube heat exchanger was comparable in magnitude with that produced by pressures, and the distribution of the thermal stress depends on the tube-hole area and the temperature inside the tubes. The thermal stress at the center of the tubesheet surface is high when tube-hole area ratio is very low. And with increasing the tube-hole area ratio, the stress first decreases rapidly and then increases linearly. A formula was numerically fitted for calculating the thermal stress at the tubesheet surface center which may be useful for the strength design of the tubesheet of floating-head or U-tube heat exchangers when considering the thermal stress. Numerical tests show that the fitted formula can meet the accuracy requirements for engineering applications.

Application of Equipartition of Entransy Loss Principle in Heat Exchangers

2012 ◽  
Vol 629 ◽  
pp. 699-703
Author(s):  
Chun Sheng Guo ◽  
Wen Jing Du ◽  
Lin Cheng
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Optimization Design ◽  
Loss Rate ◽  
Plate Heat Exchanger ◽  
Loss Minimization ◽  
Plate Heat ◽  
Entransy Loss ◽  
Heat Exchanges ◽  
Minimization Approach

The entransy loss minimization approach for the heat exchanger optimization design was established by Guo Z Y; the study based Guo Z Y’s works, found relationship between the entransy loss uniformity and the heat exchanger performance and the expression of the local entransy loss rate for heat convection was derived, numerical results of the heat transfer in a chevron plate heat exchanger and helix baffle heat exchanger show that the larger entransy loss uniformity factor appear in about Re=2000 and the entransy loss uniformity factor of chevron plate heat exchanges higher than helix baffle one.

Development of Heat Exchanger Fouling Model and Preventive Maintenance Diagnostic Tool

2007 ◽  
Vol 2 (2) ◽  
Author(s):  
H. Zabiri ◽  
V. R. Radhakrishnan ◽  
M. Ramasamy ◽  
N. M. Ramli ◽  
V. Do Thanh ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Predictive Model ◽  
Diagnostic Tool ◽  
Preventive Maintenance ◽  
Heat Exchangers ◽  
Waste Heat ◽  
A Priori ◽  
Transfer Efficiency ◽  
Heat Transfer Efficiency

The Crude Preheat Train (CPT) is a set of large heat exchangers which recover the waste heat from product streams back to preheat the crude oil. The overall heat transfer coefficient in these heat exchangers may be significantly reduced due to fouling. One of the major impacts of fouling in CPT operation is the reduced heat transfer efficiency. The objective of this paper is to develop a predictive model using statistical methods which can a priori predict the rate of the fouling and the decrease in heat transfer efficiency in a heat exchanger in a crude preheat train. This predictive model will then be integrated into a preventive maintenance diagnostic tool to plan the cleaning of the heat exchanger to remove the fouling and bring back the heat exchanger efficiency to their peak values. The fouling model was developed using historical plant operating data and is based on Neural Network. Results show that the predictive model is able to predict the shell and tube outlet temperatures with excellent accuracy, where the Root Mean Square Error (RMSE) obtained is less than 1%, correlation coefficient R2 of approximately 0.98 and Correct Directional Change (CDC) values of more than 90%. A preliminary case study shows promising indication that the predictive model may be integrated into a preventive maintenance scheduling for the heat exchanger cleaning.

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