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Detection of Fouling in Heat Exchangers - Final Version
Detection of Fouling in Heat Exchangers - Final Version
Detection of Fouling in Heat Exchangers - Final Version
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dTh,ij (t)
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dt
= ṁh (t)ch [Th,ij−1 (t) − Th,ij (t)] − Ah Uij (t)F ΔTij (t) #FL$
dTc,ij (t)
M c cc
dt
= ṁc (t)cc [Tc,i−1j (t) − Tc,ij (t)] + Ac Uij (t)F ΔTij (t) #FK$
ΔTij (t)
ij
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F = 1
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ΔTij (t)
#2 .
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ΔTij (t) = Th,ij (t) − Tc,ij (t) #FG$
A
ΔTij (t) = [Th,ij−1 (t) + Th,ij (t)]/2 − [Tc,i−1j (t) + Tc,ij (t)]/2 #FH$
F
[Th,ij−1 (t) − Tc,ij (t)] − [Th,ij (t) − Tc,i−1j (t)]
ΔTij (t) =
ln([[Th,ij−1 (t) − Tc,ij (t)]/[Th,ij (t) − Tc,i−1j (t)]
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βij (t) =
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τh (t) =
ṁh (t)
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τc (t) =
ṁc (t)
#FEA$
#FJ$ #FEB$ #FEE$ #FEA$ #FH$ #FL$ #FK$
%
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dTh,ij (t) αij −1 αij −1 αij αij
= (1− )τh Th,ij−1 (t)−(1+ )τh Th,ij (t)+( )Tc,i−1j (t)+( )Tc,ij (t)
dt 2 2 2τh 2τh
#FEF$
d
dt
T = (ṁ, θ)T + +(ṁ, θ)Tin #FEK$
6 #2 $
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−(1+ 11 ) α11
2 0 0 0 0 0 0
⎢ 2τh ⎥
⎢ τh ⎥
⎡ ⎤ ⎢ α α ⎥ ⎡ ⎤
⎢ (1− 12 ) −(1+ 12 ) α12 ⎥
Th,11 ⎢ 2 2 0 0 0 0 0 ⎥ T
⎢ ⎥ ⎢ τh τh 2τh ⎥ ⎢ h,11 ⎥
⎢ ⎥ ⎢ α21 ⎥ ⎢ ⎥
⎢T ⎥ ⎢ −(1+ ) ⎥ ⎢ ⎥
⎢ h,12 ⎥ ⎢ 2 α 21 α 21 ⎥ ⎢ Th,12 ⎥
⎢ ⎥ ⎢ 0 0 0 0 0 ⎥ ⎢ ⎥
⎢ ⎥ ⎢ τh 2τh 2τh ⎥ ⎢ ⎥
⎢ Th,21 ⎥ ⎢ α22 α22 ⎥ ⎢T ⎥
⎢ ⎥ ⎢ (1− ) −(1+ ) ⎥ ⎢ h,21 ⎥
⎢ ⎥ ⎢ 0 0 2 2 0
α22
0
α22 ⎥ ⎢ ⎥
d ⎢ T
⎢ h,22 ⎥
⎥ ⎢
⎢ τh τh 2τh 2τh ⎥
⎥
⎢T
⎢ h,22
⎥
⎥
⎢ ⎥ =⎢ β ⎥ ⎢ ⎥
⎢ ⎥
dt ⎢ Tc,11 ⎥ ⎢
⎢ β11 −(1+ 11 ) ⎥
⎥
⎢
⎢ Tc,11
⎥
⎥
⎢ ⎥ ⎢ 0 0 0 2 0 0 0 ⎥ ⎢ ⎥
⎢ ⎥ ⎢ 2τc τc ⎥ ⎢ ⎥
⎢T ⎥ ⎢ β12 ⎥ ⎢T ⎥
⎢ c,12 ⎥ ⎢ β12 β12 −(1+ ) ⎥ ⎢ c,12 ⎥
⎢ ⎥ ⎢ 0 0 0 2 0 0 ⎥ ⎢ ⎥
⎢ ⎥ ⎢ 2τc 2τc τc ⎥ ⎢ ⎥
⎢ Tc,21 ⎥ ⎢ ⎥ ⎢ Tc,21 ⎥
⎣ ⎦ ⎢ β21 β31 ⎥ ⎣ ⎦
⎢ β21 (1− ) −(1+ ) ⎥
Tc,22 ⎢ 0 0 0 2 0 2 0 ⎥ Tc,22
⎢ 2τc τc τc ⎥
⎢ β22 ⎥
⎣ (1−
β22
) −(1+ ) ⎦
β22 β22 2 2
0 0 0 0
2τc 2τc τc τc
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8
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∞
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+
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8
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%
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d
dt
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d
dt
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(t) = (x̂(t)) (t) +
(t)*T (x̂(t), t) + 7(t) #FFL$
0
∂
f (ṁ, T , θ, Tin )
F (x̂(t)) =
∂x
|(x(t) = x̂(t)) #FFK$
F
%
%
#FFG$
⎡ ⎤
⎢ 0 ⎥
⎢ ⎥
⎢ 0 ⎥
⎢ ⎥
⎡ ⎤ ⎢ ⎥
α∗ (t) ⎢ (1+ 2
α11
) (1− 2
α11
) ⎥
⎢ − T + α11
T + Th,10 + α 11
T ⎥
⎢ β ∗ (t) ⎥ ⎢ τ h,11 2τ c,11 τ 2τh c,01 ⎥
⎢ ⎥
h h h
⎢ ⎥ ⎢ (1− 2 )
α12 α12
(1+ 2 ) ⎥
⎢ Th,11 ⎥ ⎢ Th,11 − Th,12 + 2τh Tc,12 + 2τh Tc,02
α12 α12
⎥
⎢ ⎥ ⎢ τh τh
⎥ ⎡ ⎤
⎢ Th,12 ⎥ ⎢ ⎥
⎢ ⎥ α21
⎢ − (1+ 2 ) Th,21 + α21 Tc,11 + α21 Tc,21 + (1− 2 ) Th,20
α21
⎥
d ⎢⎢ Th,21 ⎥
⎥ ⎢ τh 2τh 2τh τh
w
⎥ ⎢ θ ⎥
=⎢ ⎥+⎣ ⎦
dt ⎢
⎢ Th,22 ⎥
⎥ ⎢ (1− α222 ) (1+ 2
α22
) ⎥
⎢ ⎥ ⎢ Th,21 − Th,22 + α 22
T
2τh c,12
+α 22
T
2τh c,22
⎥ wf
⎢ Tc,11 ⎥ ⎢ τh τh ⎥
⎢ ⎥ ⎢ β β11 β11 ⎥
⎢ Tc,12 ⎥ ⎢ (1+ ) (1− ) ⎥
⎢ 2τc Th,11 − Tc,11 + β2τ11c Th,10 +
11 2 2
Tc,01 ⎥
⎣ Tc,21 ⎦ ⎢
τc τc
⎥
⎢ β12 (1+
β12
) (1−
β12
) ⎥
Tc,22 ⎢ 2τ Th,11 + β2τ12 Th,12 − 2
Tc,12 + 2
Tc,02 ⎥
⎢ c c τc τc ⎥
⎢ β21 β21 ⎥
⎢ (1− ) (1+ ) ⎥
⎢ 2τ21c Th,21 + Tc,11 − Tc,21 + 2τ21c Th,20
β 2 2 β
⎥
⎣ τc
β22
τc
β22
⎦
(1− 2 ) (1+ 2 )
β22
T
2τc h,21
+ β2τ22c Th,22 + τc
Tc,12 − τc
Tc,22
( #2 $
⎡ ⎤
0
⎢ 0 ⎥
⎢ ⎥
⎢ f1 ⎥
⎢ ⎥
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⎢ ⎥
=⎢
⎢
f3
f4
⎥ + wθ
⎥ wf
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⎢ f5 ⎥
⎢ ⎥
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x̂k = x̂− −
k + Kk (zk − H x̂k ) #FLA$
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Kk = Pk− HkT (Hk Pk− HkT + Vk Rk VkT )−1 #FLG$
K :
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SH (0) = 0 SL (0) = 0 SH (i) SL(i)
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#% %2 &
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dh dc
%
Tc Th
%
∂Tc ṁc ∂ U
∂t
+
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(cTc ) =
ρcdc
(Th − Tc ) #LE$
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∂t
+
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x y N
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f ouled
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& LE
8 LA
clean
U
#LL$
0.9
0.8
0.8
0.6
0.4
0 0.2 0.4 0.6 0.8 1
Dimensionless time
$'
'
( )
arccos(cf 1 )
a=
m − floor(mcf2 ) + 1
b = −a(floor(mcf2 ) + 1)
#LK$
cf 1
Ufouling
Uclean
cf 2
cf 1 cf 2 [0, 1]
%2 * #)
Rf=0.0001
1
0.644
0
0 0.2 0.4 0.6 0.8 1
Dimensionless time
Evolution of the resistance
−3 to heat transfer because of fouling
x 10
1.5
Fouling factor, Rf [m2K/(W)]
0.5
0.395
0.876
Rf=0.0001
0
0 0.2 0.4 0.6 0.8 1
Dimensionless time
$'
Rf
BBE
Q
E
BK
BBBA
I F
34 4
'
!
AKU
!
34 4
ABU
U U
& LE
"
!
& LF
!
ch = cc =
4200 [J/Kg◦ C]
ρ = 998 [kg/m3 ] & 34
4
E R
"
E R
U = 3.780 [W/m2 K] #FAG$ SGT
%2# 9 #.
50
tcout
0
0 2000 4000 6000 8000 10000
Sample no.
2
mh
mc
l/s
0
0 2000 4000 6000 8000 10000
Sample no.
Closer look on the data set above
100
thin
tcin
thout
°C
50
tcout
0
1000 1100 1200 1300 1400 1500
Sample no.
1.5
mh
mc
l/s
0.5
1000 1100 1200 1300 1400 1500
Sample no.
%6 %2 &
8
"
& FE
%
?
Ah,ij U (W H/4)U
α= =
ṁh ch (ṁh /2)ch
Ac,ij U (W H/4)U
β= =
ṁc cc (ṁc /2)cc
Mh,ij W Hdρ/4
τh = =
ṁh (ṁh /2)
Mc,ij W Hdρ/4
τc = =
ṁc (ṁc /2)
LE
'
I
θ E[θ]
α BEEAK
β BEEAK
τh BALJK
τc BALJK
y BC
34 4
U KBU U
& LE
& LL
%2# 9 %
thout
50 tcout
0
0 2 4 6 8 10
Sample no. 4
x 10
6
mh
4 mc
l/s
0
0 2 4 6 8 10
Sample no. 4
x 10
Closer look on the data set above
150
thin
100 tcin
°C
thout
50 tcout
0
1000 1100 1200 1300 1400 1500
Sample no.
6
mh
4 mc
l/s
0
1000 1100 1200 1300 1400 1500
Sample no.
"
" #
!
34
!
8
9
Thin Tcin ṁh
ṁc
Thout Tcout
N
?
• N
α
• N
β
•
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LF
%% 2 '
$ ()
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M
!
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!
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M
%
!
6
&
X
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6
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JKU
2:((θ))
ˆ
[(θ)]
ˆ =
N − (t1 + p)
H (−1) #KE$
KE
&
!
KE
KA JKU τ
M
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&
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1
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α BBJLL BBBBL BBJFH BBJKE
β BEBFH BBBBL BEBAJ BEBLK
τh BBBG BAJ BKG BKH
τc BBE EBC AE AE
y BCE BBEL BHC BCL
$
*+, ' -
1
θ σ(θ) 2; .)2;
α BEEB BBBBF BEBJL BEEBG
β BEEL BBBBF BEEAJ BEELA
τh BBA BEK BF BF
τc BBL BCK EG EH
y BCE BBE BHJ BCF
& KE
!
!
M
&
KA KF
100
th,out tc,out th,out,pred tc,out,pred
80
Temperature [°C]
60
40
20
0 50 100 150 200 250
Observation no.
!
SB AT
%
!
KL
α β y
1
Error
−1
50 100 150 200 250 300 350
No.
Residuals of the predicted cold output
0.5
Error
−0.5
50 100 150 200 250 300 350
No.
.
'
−1
0 5 10 15 20
Correlation
Autocorrelation of the residuals for the cold output
1
No.
−1
0 5 10 15 20
Correlation
%, 2 '
'
/00 - '
8
EBB
"
τh τc
$
-
ij
! 8 KE
"
τ
LF
y
BC
SGT
2 34 %.
!
α1 = α11 = α21 α2 = α12 = α22 β1 = β11 = β12 β2 = β21 = β22
Q ij
& FE
α β
N
α β
"
α β
M
200
=
%
!
20
0
!
0
N
%
0
N
8 FA
α
β
Q
I8
8
FK
K
FKB FLJ
I8
FB
N
&
& KL
!
6 2 '
AKU
!
& KK α
0.77 β 0.40
& 5
! &
KG KH &
KL KK
8
34
20
34 ; 20
I8
1
I8
N
JKU
0.35 0.84
0.09
Value
0.08
0.07
0 200 400 600 800
Estimation no.
Off−line estimation of the β values
0.11
0.1
Value
0.09
0.08
0.07
0 200 400 600 800
Estimation no.
$'
CuSum chart for the off−line method
2.5
Fouled heat exchanger
Shift detected in α: 0.77
Sampling time dt = 1
CuSum values
1.5
0.5
0
β α
−0.5
0 0.2 0.4 0.6 0.8 1
Dimensionless time
"
-
2 '
0.11
Value
0.1
0.09
0.08
0 200 400 600 800
Estimation no.
Off−line estimation of the β values
0.12
Value
0.1
0.08
0 200 400 600 800
Estimation no.
$'
CuSum chart for the off−line method
3
Fouled heat exchanger
2.5 936 CuSum values
Shift detected in α: 0.71
Shift detected in β:0.4
2 Sampling time dt = 1
CuSum values
1.5
0.5
0
β α
−0.5
0 0.2 0.4 0.6 0.8 1
Dimensionless time
"
-
2 4 #
M
!
0
$ ()
!
α β
1
#1&$
α β
N
8 FA
α β
I8
# .
Q
1&
M
Q '
!
α β ! c
c = 10−9
AFU
!
c = 10−9
% 2 '
Estimated parameters
Estimated parameters
0.2
α c = 10−5 β
0.14 c = 10−5
0.18
0.12
0.1 0.16
0.08
0 500 1000 1500 0 500 1000 1500
sample number sample number
Estimated parameters
Estimated parameters
0.13 α c = 10−7 0.17 β c = 10−7
0.12
0.16
0.11
0.1 0.15
0 500 1000 1500 0 500 1000 1500
sample number sample number
Estimated parameters
Estimated parameters
0.164
α c = 10−9 β c = 10−9
0.118
0.163
0.117
0.162
0.116
0.115 0.161
0 500 1000 1500 0 500 1000 1500
sample number sample number
Estimated parameters
Estimated parameters
0.118 0.164
β c = 10−10
α c = 10−10
0.163
0.117
0.162
0.116 0.161
0 500 1000 1500 0 500 1000 1500
sample number sample number
-
-
' 1
2 4
Standard deviation
β
0.4
0.2 β
0.2
0.1 α
α
0
0 100 200 0 10 20 30
sample number sample number
Sampling time of 10 s Sampling time of 10 s
Estimated parameters
Standard deviation
0.4 β
0.2 β
0.2
α α
0.1
0
0 100 200 0 10 20 30
sample number sample number
2
α β
/ /0 '
'
N
34
EBB
B A
α β
! & KJ
%
EBB
! & KEB
!
1
EU
100
& 10
−1 −1
10 10
−2 −2
10 10
Standard deviation
Standard deviation
β α
−3 −3
10 10
−4 α −4
10 10
β
−5 −5
10 10
−6 −6
10 10
0 100 200 300 0 100 200 300
sample number sample number
'
'
α β
/
/0
N
ABB
%
!
100
N
!
4
30
α β
I8
8 FK
2 4 )
0.3
0.2
0.1
0
α β
−0.1
0 0.2 0.4 0.6 0.8 1
Dimensionless time
"
&
KEF KEL
4 !
!
Sampling time dt = 1
0.4
0.2
0
α β
"
!
!
10
FHK I8
FHKB I8
1
I8
O
N
4
KB
JKU
0.65 0.91
0.1
0
α β
−0.1
0 0.2 0.4 0.6 0.8 1
Dimensionless time
0
α β
0 0.2 0.4 0.6 0.8 1
Dimensionless time
" dt = 2 dt = 4
N
34 4
α
34
β
α1 = α11 = α21 α2 = α12 = α22 β1 = β11 = β12 β2 = β21 = β22
ij
& FE
"
α β
9
"
α β
(6 2 '
0.05
0
β α
0 0.2 0.4 0.6 0.8 1
Dimensionless time
Sampling time dt = 10
0.15
0.1
0.05
0
α
0 0.2 0.4 0.6 0.8 1
Dimensionless time
" dt = 6 dt = 10
SBBBBE
2# (
BBBBAET I
SBBBBE BBBBHT
• !
N N
M
&
0
•
"
α β
$
8 FF
!
9
34 4
N
8 LF
AKU
&
" U
KBU U
& LE ! &
KEK
! & KEG
AU F
AU F
!
!
8 LA
( 2 '
5 The slope, UAF, calculated with window size=400
x 10
4
Equation of the line:
Reference slope
y = 1.96e+004*x − 1.4e+006
3.5 UAF = 1.96e+4
h
mc ΔT
3
p
2.5
2
82 83 84 85 86 87 88
ΔTLMTD
$
Rf = 0.00016
SBBBBE BBBBHT
50
; 50
4
JKU
0.33 0.92
1
82 84 86 88 90 92 94
ΔT
LMTD
5 The slope, UAF, calculated with window size=400
x 10
4
Reference slope
3.5 Clean Gradually fouling
mcpΔTh
2
0.2 0.4 0.6 0.8 1
ΔTLMTD
3 4
AU F
3 4
'
'
'
0
Fouled heat exchanger
Shift detected in ΔUA: 0.42
−1000
−2000
−3000
−4000
0 0.2 0.4 0.6 0.8 1
Dimensionless time
"
$ !
34 4
" 8
Q
?
• 34
< JKU
SBFK BCLT
!
34
4
34
4
!
! SEGT
Rf ≈ 0.00008 !
&
?
• :
• !
• 1
α β
!
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
RR ABBKR
SJT N D @ ' I 6 8 8 9 ' >
I 6RI>I A ABBF
GJ
)6 ++-0'
=
SEET < @
;' 8 I
AG @
EJJB
;< <
SEKT D @
:
% % $%
EJJE
SEGT D > @
' 9
:
" ! ABBG
' 9
I
" 5!! ABBH
EJJJ
SAKT < O N 9 N
ABBK
++-0'
= )
SAGT ABBC O!8 R81N 1I6 6 8
?RR
RCJCRR
SAHT 1 < ?RRRR
SACT 88 > 8 Q 6
Y9 I
' '
N
@ ABBK
?RR
RR ABBKR
SAJT D >MM 6 `8 1 > !
? !
@
ABBK ?RR
RR ABBKR
SFBT 8 8
'M O 8
#$
$(
! &
ABBH
M
"
EL @
EJJF
! I K
!
*
I K
8
LA ! I K
& NE
* ()
!
I K
50 thout
tcout
0
0 0.5 1 1.5 2
Sample no. 4
x 10
2
mh
mc
l/s
0
0 0.5 1 1.5 2
Sample no. 4
x 10
Closer look on the data set above
100
thin
tcin
°C
50 thout
tcout
0
1000 1100 1200 1300 1400 1500
Sample no.
2
mh
mc
l/s
0
1000 1100 1200 1300 1400 1500
Sample no.
2# 4 )
$
*+, ' -
1
θ V ar(θ) 2; .)2;
α BEBJK BBBBF BBHFF BELKC 8
β BEEGH BBBBL BBHGJ BEKGK 8
τh BBAJF BHHJL EHFGL EHJKB O
τc BBAAH EAKFB AAEGE AAGEK O
$ BCBCL BBEFA BKHCC EBFCB 8
/
NE
Q
KA
!
τ
& NA
!
* ()
!
I K
)( 2 -
0.1
0.08
0 200 400 600 800 1000
Estimation no.
Off line estimation of the β values
0.12
0.1
Value
0.08
0.06
0 200 400 600 800 1000
Estimation no.
$'
2 Sampling time dt = 1
1.5
1
0.5
0
α β
−0.5
0 0.2 0.4 0.6 0.8 1
Dimensionless time
"
-
2 Sampling time dt = 1
CuSum values
1.5
0.5
0
β α
−0.5
0 0.2 0.4 0.6 0.8 1
Dimensionless time
"
'
&
F
HJ
,6 +2 *
&
f3 ?
∂f3 1
= (−Th,20 − Th,21 + Tc,11 + Tc,21 )
∂α 2τh
∂f3 1 + α/2
=−
∂Th,21 τh
∂f3 α
=
∂Tc,11 2τh
∂f3 α
=
∂Tc,21 2τh
∂f3 ∂f3 ∂f3 ∂f3 ∂f3 ∂f3
= = = = = =0
∂β ∂Th,11 ∂Th,12 ∂Th,22 ∂Tc,12 ∂Tc,22
FE I
FB
FL 1
FE
CF
,% -" * *09'!"
LE 1
" :
FG
LA 1 Rf
FH
LF 8 FJ
LL 9
LE
LG
KA >
LH
KF N
LH
KL 1
KE
KK 9
KE
KG 1
KA
KH 9
KA
KC
P KL
KJ 5
α β
E
EB
KK
KEB
α β
E
EB
KG
KEE 9
4
KH
KEA 9
4
KC
KEF 9
dt = 2 dt = 4 KJ
KEL 9
dt = 6 dt = 10 GB
KEK 1
GA
-" * *09'!" ,
KEG & $
AU F
& $
GF
KEH 9
GL
NE 8 HL
NA 1
HG
NF 9
HH
NL 9
HH
(
LE I
LB
KE 1
JKU
LK
KA 1
JKU
LK
KF 8
EBB
LC
KL 1
LC
NE 1
JKU
HK
CH