Detection of Fouling in Heat Exchangers - Final Version

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M c cc
dt
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dt 2 2 2τh 2τh
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dt
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2 0 0 0 0 0 0
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⎢ τh ⎥
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⎢ (1− 12 ) −(1+ 12 ) α12 ⎥
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⎢ ⎥ ⎢ 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 ⎥
⎥ ⎢
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⎢ 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

⎡ (1− α11 ) α11



2 0 0
τh 2τh
⎢ 0 0 0
α12 ⎥
⎢ 2τh ⎥⎡
⎢ α
(1− 21 ) ⎥ T ⎤
⎢ 0
τh
2 0 0
⎥ h,10
⎢ ⎥ ⎢ Th,20 ⎥
+⎢

0 0 0
β
(1− 11 )
0
⎥⎣
⎥ Tc,01 ⎦ #FEG$
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0 2 0 ⎥
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β
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⎥ Tc,02
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⎣ β21
τc

0 0 0
2τc
0 0 0 0

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⎡ ⎤
Th,11
⎢ Th,12 ⎥
⎢ ⎥
⎢ Th,21 ⎥
⎢ ⎥
0 0.5 0 0.5 0 0 0 0 ⎢ ⎥
Tout =
0 0 0 0 0 0

0.5 0.5 ⎢
Th,22
Tc,11

⎥ #FEH$
⎢ ⎥
⎢ Tc,12 ⎥
⎢ ⎥
⎣ Tc,21 ⎦
Tc,22

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d
dt
T = (ṁ, T , θ)T + +(ṁ, T , θ)Tin + wf (t) = f (ṁ, T , θ, Tin) + wf (t)
8   
  


  
 
    
  

      
  
  
 
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=
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N       #FEK$   #FFE$  


d 0
dt
θ
T
=
f (ṁ, T , θ, Tin )
+

wf
#FFA$

6 wf = N (0, Qf ) 
    #FEK$  
    
 
    

#2   
8    
  
    

 
   1  
   

  
  
 
          


  M      
  
 
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%  
  

  
         
 
     
         
     
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d
dt
T̂ (t) = f (x̂(t)) #FFF$
d
dt
*
(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 ⎥
⎢ ⎥
⎢ f2 ⎥
⎢ ⎥
=⎢

f3
f4
⎥ + wθ
⎥ wf
#FFG$
⎢ ⎥
⎢ f5 ⎥
⎢ ⎥
⎢ f6 ⎥
⎣ f7 ⎦
f8

&     

 

 

 

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• N  
  
   
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• N  
  
   
 β 

!    F      EB  EB  


⎡ ⎤
0 0 0 0 0 0 0 0 0 0
⎢ ⎥
⎢ ⎥
⎢ 0 0 0 0 0 0 0 0 0 0 ⎥
⎢ ⎥
⎢ ⎥
⎢ ∂f1 ∂f1 ∂f1 ∂f1 ∂f1 ∂f1 ∂f1 ∂f1 ∂f1 ∂f1 ⎥
⎢ dα dβ dTc,22 ⎥
⎢ ⎥
dTh,11 dTh,12 dTh,21 dTh,22 dTc,11 dTc,12 dTc,21
⎢ ∂f2 ∂f2 ∂f2 ⎥
⎢ dα dβ dTc,22 ⎥
∂f2 ∂f2 ∂f2 ∂f2 ∂f2 ∂f2 ∂f2
⎢ dTh,11 dTh,12 dTh,21 dTh,22 dTc,11 dTc,12 dTc,21

⎢ ∂f3 ∂f3 ∂f3 ⎥
⎢ dα dβ ∂f3 ∂f3 ∂f3 ∂f3 ∂f3 ∂f3 ∂f3

F =⎢
⎢ ∂f4 ∂f4
dTh,11 dTh,12 dTh,21 dTh,22 dTc,11 dTc,12 dTc,21 dTc,22 ⎥
⎥ #FFH$
⎢ dα dβ ∂f4 ∂f4 ∂f4 ∂f4 ∂f4 ∂f4 ∂f4 ∂f4 ⎥
⎢ dTh,11 dTh,12 dTh,21 dTh,22 dTc,11 dTc,12 dTc,21 dTc,22 ⎥
⎢ ∂f ∂f ⎥
⎢ 5 5 ∂f5 ∂f5 ∂f5 ∂f5 ∂f5 ∂f5 ∂f5 ∂f5 ⎥
⎢ dα dβ dTh,11 dTh,12 dTh,21 dTh,22 dTc,11 dTc,12 dTc,21 dTc,22 ⎥
⎢ ⎥
⎢ ∂f6 ∂f6 ∂f6 ∂f6 ∂f6 ∂f6 ∂f6 ∂f6 ∂f6 ∂f6 ⎥
⎢ dα dβ dTc,22 ⎥
⎢ dTh,11 dTh,12 dTh,21 dTh,22 dTc,11 dTc,12 dTc,21

⎢ ∂f7 ∂f7 ∂f7 ⎥
⎢ dα dβ ∂f7 ∂f7 ∂f7 ∂f7 ∂f7 ∂f7 ∂f7
dTc,22 ⎥
⎣ dTh,11 dTh,12 dTh,21 dTh,22 dTc,11 dTc,12 dTc,21

∂f8 ∂f8 ∂f8 ∂f8 ∂f8 ∂f8 ∂f8 ∂f8 ∂f8 ∂f8
dα dβ dTh,11 dTh,12 dTh,21 dTh,22 dTc,11 dTc,12 dTc,21 dTc,22

     

!     


   
     
  


    



  
 
  
  
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Q̇ = U AΔTLMT D = ṁk cp ΔTk #FFC$

 

 k   
      
 
&  

    




        F   


     ΔTLMT D      F      
 SGT
'   #FFC$        ṁΔT ∝ U AF ΔTLMT D 

  
       
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M N    ṁΔT 


ΔTLMT D  N    
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FA '        
   
  

  
 
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,   #2 $

The slope of the line is equal to UAF


90
Equation of the line:
80 y = 5.08*x − 366
UAF = 5.08
70
mΔcpTh

60

50

40
83 84 85 86 87 88
ΔTLMTD

 
  
    

 ṁcp ΔT   ΔTLM T D 

 


! " # 

  

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A <0 
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x̂−
k = Ax̂k−1 + Buk−1 #FFJ$
F <0    
Pk− = APk−1 AT + Q #FLB$
L I    
Kk = Pk− H T (HPk− H T + R)−1 #FLE$
K :   
    
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x̂k = x̂− −
k + Kk (zk − H x̂k ) #FLA$
G :     
Pk = (I − Kk H)Pk− #FLF$
H >

A  G    

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!  $ %& $'

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A <0 
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x̂−
k = f (x̂k−1 , uk−1 , 0) #FLL$
F <0    
Pk− = Ak Pk−1 ATk + Wk Qk−1 WkT #FLK$
L I    
Kk = Pk− HkT (Hk Pk− HkT + Vk Rk VkT )−1 #FLG$
K :   
    
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x̂k = x̂− −
k + Kk (zk − h(x̂k , 0)) #FLH$
G :     
Pk = (I − Kk Hk )Pk− #FLC$
H >

A  G    

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$ 
 

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SH (i) = max[0, x̄i − (μ0 + K) + SH (i − 1)] #FLJ$


SL (i) = max[0, (μ0 − K) − x̄i + SL (i − 1)] #FKB$

Q 
   
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Tc  Th     
  
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∂Tc ṁc ∂ U
∂t
+
ρcHdc ∂x
(cTc ) =
ρcdc
(Th − Tc ) #LE$
∂Th ṁh ∂ U
∂t
+
ρcHdh ∂y
(cTh ) =
ρcdh
(Tc − Th ) #LA$

! 
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ṁc     y   

   
 ṁh     x


  


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1 1
Rf (t) = −
U (t)A U (0)A
#LF$

!    

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U             

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&  LE    UU
f ouled


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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


1 20% decrease in U
Ufouled/Uclean

0.9

0.8

0 0.2 0.4 0.6 0.8 1


Dimensionless time
Changes in the overall heat transfer
coefficient, U, because of fouling

1 Continuously fouling heat exchanger


50% decrease in U
Ufouled/Uclean

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 *  #)

Evolution of the resistance


−4 to heat transfer because of fouling
x 10
4
Fouling factor, Rf [m2K/(W)]

Continuously fouling heat exchanger


3 20% decrease in U

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)]

Continuously fouling heat exchanger


50% decrease in U
1
Rf=0.0007

0.5
0.395

0.876

Rf=0.0001
0
0 0.2 0.4 0.6 0.8 1
Dimensionless time

 
$'


  
  
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! &  LA  


      

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SBGLK ET  


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&  LF

  
   


   


! 
      

  
   ch = cc =
4200 [J/Kg◦ C]   
    
 ρ = 998 [kg/m3 ] &  34 
4    


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  E R
  U = 3.780 [W/m2 K]   #FAG$ SGT
%2# 9  #.

Example of a typical data set


100
thin
tcin
thout
°C

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 
   
    
    
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N

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L
 
  
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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)

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I    
   

θ E[θ]
α BEEAK
β BEEAK
τh BALJK
τc BALJK
y BC

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8     



        
 

 
  
 
 

 
 
   

  
34  4     
  
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%2# 9  %

Example of a typical data set


150
thin
100 tcin
°C

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.

 
"       
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! 
    

    
     


   34   
     

  
 

 
         

     
   

  
  
 
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8         
 

      

         
  
     
    

 
  
     
  
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Thin  Tcin  ṁh 
ṁc    
Thout  Tcout             
 
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2:((θ))
ˆ
 [(θ)]
ˆ =
N − (t1 + p)
H (−1) #KE$

  
    
   

              
    
   
   
      


  
 
  
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2 34  %


    
   
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1
   
     
θ σ(θ) 2; .)2;
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

 
$ 

      

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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

      
    
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!     M      

  
 

 
& 
KA  KF
  
 
       
 


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 M        
 
 
  
 
  x(t + Δ)  Δ 
 

 

   
  x(t)
%(   2 '

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   
 
 
   

      
  
 

     M      


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  τh 
τc   
   
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8  
 

 

      
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!  
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β 
      
  
  


%   

 

!         
        
  
 


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!    M    





        




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    α β  y 
    

2 34  %)

Residuals of the predicted hot output

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.

 
.     
'

Autocorrelation of the residuals for the hot output


1
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 '
 
   
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8  
 



  

 EBB    

θ E[θ] σ[θ] [2.5%, 97.5%]  

α BBCCJGAH 0.0005 SBBCCJGAA BBCCJGFJT


β BBJKCHLF 0.0005 SBBJKCHFC BBJKCHKFT
τh BBELB 0.008 SBBBE B BAAJT
τc BBEHK 0.01 SBBBE BBACLT
y BCAAC 0.01 SBCAAC BCAACT

"  
 
  τh  τc 
 
$ 

      -   

"   α β τh τc $


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

#! *  α  β 

8       


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LF  
      
    
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   SGT
2 34  %.
! 

α1 = α11 = α21  α2 = α12 = α22  β1 = β11 = β12  β2 = β21 = β22 
Q     ij 

    
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6   2 '
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KG  KH    & 
KL  KK 
    

   
        
 
     
    
 
     
  
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          SBBBBBF BBBBECT
 &  LA

#-     "   


• !       34   
     
 

  



 

  
 

    &   
  34   

      SBFK BCLT  


      




          SBBBBBF BBBBECT !   
   
      
 8  LA   

    
  N

     
 
        SBBBBE BBBBHT
•  34   "  

   τ  
   
• !  

    

 N  N  
  

2 34  

Off−line estimation of the α values


0.1

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

2 936 CuSum values


Shift detected in β:0.4

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 '

Off−line estimation of the α values

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     
    
 I 8   

 

 8  FK


! 

     
 ?
• 8 
M    

• 8
   
 
• 8
      

• 8
  
 
• !
    α  β  

!    

   

          


  

    

#   .

Q
  1&     
  
   
      
   

M 
     



       Q '    


 
 
 
  
  
     
    
   
   
 ! 
 

      

   


   
 ;      
 
  
             
    
 ! &  KC
    
  
 c     Q 

 ! 
  Q 

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



   

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  

Sampling time of 1 s Sampling time of 1 s


0.6
Estimated parameters

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

  
   



 EU         70




& & 
KJ  KEB   
     
  % 
(   2 '

Sampling time of 1 s Sampling time of 10 s


0 0
10 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     
    I 8   

8  FK
2 4  )

CuSum chart for the on line method

0.6 Fouled heat exchanger

Shift detected in α: 0.83


Shift detected in β:0.81
0.5 3750 CuSum values
CuSum values

0.4 Sampling time dt = 1

0.3
0.2
0.1
0
α β
−0.1
0 0.2 0.4 0.6 0.8 1
Dimensionless time

 
"         

    
 

&       


! &  KEE   
  
   β   
    0.81 



   0.83   α   ! 






 
1s
&       5  
! & 
KEA  KEE      
 
   
 
     
  ! 
 
      
 
    
            
 
4 

# ! "       


        

  

  
& 
KEF  KEL
           
  

 
 
    
   4  ! 

  
  
 
       
!  
 
     
 

         

,   2 '

CuSum chart for the on line method


0.8
Fouled heat exchanger

Shift detected in α: 0.83


Shift detected in β:0.81
0.6 3750 CuSum values
CuSum values

Sampling time dt = 1
0.4

0.2

0
α β

0 0.2 0.4 0.6 0.8 1


Dimensionless time

  
"         

    
 

 
  

  !

        

 

      
  
 
   

 ! 

  
  
10
   FHK I 8   
  
  FHKB I 8   
 
  
1
 
  
   I 8   
 
  
     
O 

 
 
        
  



   



  

     

# # ), ,   

N

  

       
   4  

   KB    

        

  
 
  


     
     JKU  
  0.65  0.91  


      


  
 


          SBBBBE BBBBAAT
 &  LA
2 4  .

CuSum chart for the on line method


0.4

Shift detected in α: 0.84

Shift detected in β:0.91


0.3 Fouled heat exchanger
CuSum values

1875 CuSum values


0.2 Sampling time dt = 2

0.1

0
α β
−0.1
0 0.2 0.4 0.6 0.8 1
Dimensionless time

CuSum chart for the on line method


0.15

Shift detected in α: 0.86

Shift detected in β:0.93


0.1
CuSum values

Fouled heat exchanger


938 CuSum values
Sampling time dt = 4
0.05

0
α β
0 0.2 0.4 0.6 0.8 1
Dimensionless time

 
"           dt = 2  dt = 4

# + *  α  β 

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 '

CuSum chart for the on line method


0.2

Shift detected in α: 0.89


Shift detected in β:0.71
0.15 Fouled heat exchanger
626 CuSum values
CuSum values

0.1 Sampling time dt = 6

0.05

0
β α
0 0.2 0.4 0.6 0.8 1
Dimensionless time

CuSum chart for the on line method


0.3
Shift detected in α: 0.64

0.25 Fouled heat exchanger


375 CuSum values
0.2
CuSum values

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

    

# -        


• &  

  4    
     

       

         



        
   &   
  4
           SBGK BJET  



      

          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 


           
      
  
     


 
  
 

   ! 
 

        

         


  
 
 
  
  
 
 I 8   

 

 8  FK  


  

  ΔU AF = U AF   − U AF 

&  KEH

  I 8   
         
I 8  
 


 
  0.42  



!     
      
 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

# ), ,   

! 8  FA  


    

 

     
 
 
               

 
   50   

      


            ;  50  

   
 
 

 4  

 
  

    


  


 
  



    
     JKU   
 0.33  0.92  


      


  
 


          SBBBBBH BBBBCT
 &  LA
!
      
 

 
 
   
 
    
   
   
    
 
 
 
   !  
  
 
 

        
      !  
  



        
   
 
  


            8   


  
2#     (#

5 The slope, UAF, calculated with window size=400


x 10
4
Reference slope
Fouled slope
3
mcpΔTh

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

2.5 Fouled slope

2
0.2 0.4 0.6 0.8 1
ΔTLMTD

  
3 4 
     
 
   
    
 AU F 
  
 3 4 

  
       
  '  
'
  ' 
     
 

       ! 




    
% 
       

#        

     


        
 

 
  
 

  



      

        
    SBBBBBH BBBBCT    
       
   "  
 
   

      
    SBBBBE BBBBHT
(%   2 '

CuSum chart for the slope method

0
Fouled heat exchanger
Shift detected in ΔUA: 0.42

1471 CuSum values


CuSum values

−1000

−2000

−3000

−4000
0 0.2 0.4 0.6 0.8 1
Dimensionless time

  
"

    

$ !



    


      

  

       



       
    N

   8  AF  


 
       

                 
  
     

 
      % 

     

     SBBBBE BBBBHT
! 

    
  
       


 
  34  4   
 
  

 

    
        

"     8   
       
 


     


   
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!  

    



          

   
 B  


   

  ?
• 34 
<  JKU            
SBFK BCLT  



  



        SBBBBBF
BBBBECT
GK
((   (2 &
<    
 
 α β  y  
    %   
 

   τh  τc  

<     
     α  β 
<     
   
      
 
<            
  



  
• 4 
<  JKU           
SBGK BJET  



  



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BBBBAET
<     
   
      
 
<            
  



  
< 8 "        
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<     
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• "  
< 
              

     

<  JKU       
   
SBFF BJAT  



  



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BBBBCT

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  34      

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4 
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8 
  
 

  



   
   

 
   
  

  


    
  
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Rf ≈ 0.00008 ! 
 

 
  

  

    


     
 
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SET N = N'  ?RR   ? 6 

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SLT > D '  <  ZI 6   
   
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SKT  I
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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 


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SJT N  D @ ' I 6 8 8   9 ' >    
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SEBT N8 62 =&  N 8


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? 
   
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GJ
)6 ++-0' =
SEET < @
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SEAT 6 @


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SECT 8 =  8 =   ' 9


     
 
 
 
          
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SEJT = @ =   ? O ]


   

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SAAT 9 
I    D I >         &' 
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SAFT N   D;     8Z N6 1 


   

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SALT N O0 I @ 
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SAKT < O  N 9  N   

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

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R CJCR R
SAHT 1 <  ?RRRR  
SACT 88 >  8 Q  6   Y9 I 
' '
 N 
    
  
    
  

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

    

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ABBK  ?RR



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SFBT 8 8   'M O  8       
#$       
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!    &  ABBH

SFET >  8  6


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   EL @  EJJF

SFAT D Q  D '


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@  AL ABBG
SFFT Q   ?RR R
SFLT <   Q 
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    % 
  

         

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( 


! I  K  
 

  
   
      

    
   
 

    
!  
 
         
 
   


      


* 


     

 
   


  I  K
 8 
LA ! I  K  
    
         


          

    



&  NE


   



* ()    

! 


   

        I  K 
 
       
        


    8  KE 


     
 LB 
 


  0
AB 
 
  

 
    
 


    
HF
)%   2 - 

Example of a typical data set


100
thin
tcin
°C

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

   
     
  !  

    
 
 
 
   


      AKU    


 
N
   8  FA    
      

 α 
β

! &  NF    α 


    BLL   β  BFL  




* ()    

! 


   

       I  K 
 
       

)(   2 - 

Off line estimation of the α values


0.12
Value

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.

 
$'


     
    

/ (        

! &  NL   


  
   β   
    BGG 



   BHG   α  


2# 4  ))

CuSum chart for the off−line method


3.5
3 Fouled heat exchanger

Shift detected in α: 0.45


934 CuSum values

Shift detected in β:0.52


2.5
CuSum values

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

 
"   
-     

CuSum chart for the on line method


3
Fouled heat exchanger
2.5 17500 CuSum values
Shift detected in α: 0.77
Shift detected in β:0.64

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  


      CB  


 #FFH$ ' %  
 
 #FFG$   
  
   
  M
&    
 f1 ?
∂f1 1
= (−Th,10 − Th,11 + Tc,01 + Tc,11 )
∂α 2τh
∂f1 1 + α/2
=−
∂Th,11 τh
∂f1 α
=
∂Tc,11 2τh
∂f1 ∂f1 ∂f1 ∂f1 ∂f1 ∂f1 ∂f1
= = = = = = =0
∂β ∂Th,12 ∂Th,21 ∂Th,22 ∂Tc,12 ∂Tc,21 ∂Tc,22

&    


 f2 ?
∂f2 1
= (−Th,11 − Th,12 + Tc,02 + Tc,12 )
∂α 2τh
∂f2 1 − α/2
=
∂Th,11 τh
∂f2 1 + α/2
=−
∂Th,12 τh
∂f2 α
=
∂Tc,12 2τh
∂f2 ∂f2 ∂f2 ∂f2 ∂f2 ∂f2
= = = = = =0
∂β ∂Th,21 ∂Th,22 ∂Tc,11 ∂Tc,21 ∂Tc,22

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

&    


 f4 ?
∂f4 1
= (−Th,21 − Th,22 + Tc,12 + Tc,22 )
∂α 2τh
∂f4 1 − α/2
=
∂Th,21 τh
∂f4 1 + α/2
=−
∂Th,22 τh
∂f4 α
=
∂Tc,12 2τh
∂f4 α
=
∂Tc,22 2τh
∂f4 ∂f4 ∂f4 ∂f4 ∂f4
= = = = =0
∂β ∂Th,11 ∂Th,12 ∂Tc,11 ∂Tc,21

&    


 f5 ?
∂f5 1
= (Th,10 + Th,11 − Tc,01 − Tc,11 )
∂β 2τc
∂f5 β
=
∂Th,11 2τc
∂f5 1 + β/2
=−
∂Tc,11 τc
∂f5 ∂f5 ∂f5 ∂f5 ∂f5 ∂f5 ∂f5
= = = = = = =0
∂α ∂Th,12 ∂Th,21 ∂Th,22 ∂Tc,12 ∂Tc,21 ∂Tc,22
,
&    
 f6 ?
∂f6 1
= (Th,11 + Th,12 − Tc,02 − Tc,12 )
∂β 2τc
∂f6 β
=
∂Th,11 2τc
∂f6 β
=
∂Th,12 2τc
∂f6 1 + β/2
=−
∂Tc,12 τc
∂f6 ∂f6 ∂f6 ∂f6 ∂f6 ∂f6
= = = = = =0
∂α ∂Th,21 ∂Th,22 ∂Tc,11 ∂Tc,21 ∂Tc,22

&    


 f7 ?
∂f7 1
= (Th,20 + Th,21 − Tc,11 − Tc,21 )
∂β 2τc
∂f7 β
=
∂Th,21 2τc
∂f7 1 − β/2
=
∂Tc,11 τc
∂f7 1 + β/2
=−
∂Tc,21 τc
∂f7 ∂f7 ∂f7 ∂f7 ∂f7 ∂f7
= = = = = =0
∂α ∂Th,11 ∂Th,12 ∂Th,22 ∂Tc,12 ∂Tc,22

&    


 f8 ?
∂f8 1
= (Th,21 + Th,22 − Tc,12 − Tc,22 )
∂β 2τc
∂f8 β
=
∂Th,21 2τc
∂f8 β
=
∂Th,22 2τc
∂f8 1 − β/2
=
∂Tc,12 τc
∂f8 1 + β/2
=−
∂Tc,22 τc
∂f2 ∂f2 ∂f2 ∂f2 ∂f2
= = = = =0
∂α ∂Th,11 ∂Th,12 ∂Tc,11 ∂Tc,21
(
  &
 
AE <                           H
AA      <           H
AF I                             C
AL      I             C
AK I

                            J


AG I

                 J


AH 8        
 Q       EE
AC <       
 9  6 1

                                 EA

FE I

     L


 
 
           EH
FA   

    ṁcp ΔT 
ΔTLMT 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 
 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

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