US20240027148A1 - Instrumented heat exchanger and method for estimating a lifespan of said heat exchanger - Google Patents
Instrumented heat exchanger and method for estimating a lifespan of said heat exchanger Download PDFInfo
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- US20240027148A1 US20240027148A1 US18/266,230 US202118266230A US2024027148A1 US 20240027148 A1 US20240027148 A1 US 20240027148A1 US 202118266230 A US202118266230 A US 202118266230A US 2024027148 A1 US2024027148 A1 US 2024027148A1
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- heat exchanger
- fluid
- gap distance
- closing wall
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- 238000000034 method Methods 0.000 title claims description 16
- 239000012530 fluid Substances 0.000 claims abstract description 51
- 238000005259 measurement Methods 0.000 claims abstract description 18
- 238000004891 communication Methods 0.000 claims abstract description 12
- 238000012545 processing Methods 0.000 claims abstract description 9
- 238000005192 partition Methods 0.000 claims abstract description 8
- 238000007789 sealing Methods 0.000 claims description 43
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000004215 Carbon black (E152) Substances 0.000 description 5
- 229930195733 hydrocarbon Natural products 0.000 description 5
- 150000002430 hydrocarbons Chemical class 0.000 description 5
- 238000012423 maintenance Methods 0.000 description 5
- 238000004364 calculation method Methods 0.000 description 4
- 230000000930 thermomechanical effect Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 2
- 230000002028 premature Effects 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 1
- 238000009530 blood pressure measurement Methods 0.000 description 1
- 238000009529 body temperature measurement Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F27/00—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/001—Casings in the form of plate-like arrangements; Frames enclosing a heat exchange core
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/0219—Arrangements for sealing end plates into casing or header box; Header box sub-elements
- F28F9/0224—Header boxes formed by sealing end plates into covers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0033—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for cryogenic applications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0059—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for petrochemical plants
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2200/00—Prediction; Simulation; Testing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2230/00—Sealing means
Definitions
- the invention relates to the technical field of heat exchangers equipped with measuring instruments. More particularly, the invention belongs to the field of industrial heat exchangers.
- the invention relates to a heat exchanger equipped with measuring instruments and to a method for estimating the service life of the heat exchanger by means of measurements made by said measuring instruments.
- heat exchangers play a central role in production. In the event of a failure of a heat exchanger, the production is affected or even stopped, generating significant financial losses on a daily basis.
- the initial service life of a heat exchanger is defined by the manufacturer.
- the service life is established for a normal use of the heat exchanger, i.e. at pressures and temperatures within a predefined range.
- the manufacturer also plans a provisional schedule for interrupting, for maintenance, the use of the heat exchanger.
- the schedule like the initial service life, is established for a normal use of the heat exchanger.
- the invention aims to remedy such drawbacks by enabling manufacturers to have, in real-time, a provisional schedule for maintenance and replacement of the heat exchanger, which is recalculated according the actual use of the heat exchanger.
- a provisional schedule for maintenance and replacement of the heat exchanger which is recalculated according the actual use of the heat exchanger.
- a heat exchanger is proposed in the first place, including:
- Such a heat exchanger makes it possible to have, in real-time, a provisional schedule of maintenance and replacement of the heat exchanger which is recalculated according to the actual use of the heat exchanger.
- FIG. 1 is a perspective view of a heat exchanger according to a first embodiment of the invention
- FIG. 2 is another perspective view of the heat exchanger shown in FIG. 1 ,
- FIG. 3 is a top view of the heat exchanger shown in FIG. 1 ,
- FIG. 4 is a perspective view of heat exchanger according to a second embodiment of the invention.
- FIG. 5 is a schematic representation of a method according to the invention.
- FIG. 1 shows a heat exchanger 1 according to the invention.
- a longitudinal axis X extending along a length L of the heat exchanger 1 is defined in the first place, corresponding to the largest dimension thereof.
- a first transverse axis Y substantially perpendicular to the longitudinal axis X and extending along a width I of the heat exchanger 1 , is defined.
- a second transverse axis Z substantially perpendicular to the axes X and Y and extending along a height H of the heat exchanger 1 , is defined.
- the heat exchanger 1 comprises a plurality of frames 2 .
- the frames 2 have a rectangular shape.
- Each frame 2 is made by assembling a plurality of substantially rectilinear bars 3 beveled at each of the ends thereof, so as to form a substantially right angle.
- the frames 2 are adjacent to each other. In other words, the frames 2 are overlaid one on top of the other.
- Each rectangular frame 2 defines an inner volume 4 .
- the heat exchanger 1 includes partition walls 5 .
- a partition wall 5 is arranged between each rectangular frame 2 . Thereby, a given rectangular frame 2 is not in immediate contact with an adjacent rectangular frame 2 .
- a partition wall 5 separates the rectangular frames 2 from each other.
- the partition walls 5 separate the inner volume 4 of the rectangular frames 2 from one another, thereby creating compartments along the axis Z.
- the latter On either side of the heat exchanger 1 , the latter includes an end frame 6 , identical to the other rectangular frames 2 but located at the lower and upper ends 7 , 8 .
- a closing wall 9 is arranged on each end frame 6 , for closing the inner volume 4 thereof.
- each frame 2 includes at least one fluidic inlet 10 .
- Each fluidic inlet 10 of a given frame 2 is in fluidic communication with the inner volume 4 of the given frame 2 .
- each frame 2 except the end frames 6 has at least one fluidic outlet 31 .
- Each fluidic outlet 31 of a given frame 2 is in fluidic communication with the inner volume 4 of the given frame 2 .
- the fluidic inlets 10 are substantially aligned along the axis Z and the fluidic outlets 31 are also substantially aligned along the axis Z.
- the heat exchanger 1 includes at least one distributor 11 of fluids and at least one collector 12 of fluids.
- the distributor 11 and the collector 12 of fluids have a substantially identical shape. Same is a curved sheet metal part defining a closed volume.
- the distributor 11 and the collector 12 are provided with a supply line 13 and with a discharge line 14 , respectively, opening onto the closed volume.
- the supply pipe 13 is used for conveying the fluid into the closed volume of the distributor 11 and the discharge pipe 14 is used for discharging the fluid from the closed volume of the collector 12 .
- distributors and collectors are referred to, indistinctly, by the expression “heads”.
- the rectangular frames 2 define faces 16 , 17 , namely two lateral faces 16 extending along the axis X and two transverse faces 17 extending along the axis Y.
- the heads can be attached to the lateral faces 16 and/or to the transverse faces 17 , defining a junction between said heads 11 , 12 and said faces 16 , 17 .
- the heads 11 , 12 extend over the entire height H, measured along the axis Z, of the heat exchanger 1 .
- the heads 11 , 12 are attached both to the rectangular frames 2 via a first junction 18 which extends substantially along the axis Z and to the closing walls 9 via a second junction 19 which extends substantially along the axis X or Y along the face 16 , 17 on which said heads 11 , 12 are positioned.
- first junctions 18 and the second junctions 19 are called lateral junctions 18 and end junctions 19 , respectively.
- the distributor 11 of fluid thus arranged is used for distributing the fluid towards the fluidic inlets 10 .
- the collector 12 of fluids thus arranged is used for collecting the fluid leaving the fluidic outlets 31 .
- the junction is welded so as to rigidly attach the heads 11 , 12 to the rectangular frames and to the closing walls.
- the heat exchanger 1 comprises at least one temperature gage 20 apt to measure a temperature of the fluid.
- the heat exchanger 1 comprises at least one pressure gage 21 apt to measure a pressure of the fluid.
- the heat exchanger 1 includes a plurality of strain gages 22 apt to measure deformations on the heat exchanger 1 .
- the heat exchanger 1 further includes a communication device 23 apt to receive the measurements from the different gages 20 , 21 , 22 and to send said measurements to a computer processing unit 24 .
- the invention also relates to an assembly 25 comprising a heat exchanger 1 and a computer processing unit 24 .
- the strain gages 22 are advantageously arranged on the closing walls 9 .
- the heat exchanger 1 includes so-called “junction” strain gages 22 , hereinafter called junction gages 26 .
- the junction gages 26 are situated in the vicinity of the end junctions 19 and arranged on the closing walls 9 .
- the junction gages 26 are situated at a first gap distance D1 from the end junctions 19 , comprised between 44 and 150 millimeters.
- the first gap distance D1 is measured along the longitudinal axis X.
- junction gages 26 is advantageously used for obtaining measurements of the deformation stresses in a zone of the heat exchanger 1 prone to mechanical rupture and hence to leak.
- the heat exchanger 1 can comprise a plurality of junction gages 26 arranged on the closing walls 9 .
- the junction gages 26 are spaced apart from each other by a first gap distance D2 comprised between 10 and 500 millimeters.
- the first gap distance D2 is measured along the axis X when the head 11 , 12 is situated on one of the lateral faces 16 and along the axis Y when the head 11 , 12 is situated on one of the transverse faces 17 .
- the first gap distance D2 is substantially equal to 50 millimeters.
- Such a first gap distance D2 makes it possible to obtain a precise distribution of the stress in the vicinity of the end junction 19 .
- the end junctions 19 extend over a length substantially equal to a width of the heads 11 , 12 .
- the junction gages 26 are arranged substantially parallel to the end junctions 19 in a zone corresponding to the length of the end junction 19 .
- junction gages 26 can be arranged beyond the length of the end junctions 19 .
- An additional junction gage 26 can be arranged beyond the length of the end junction 19 .
- FIGS. 1 and 2 illustrating a first embodiment.
- the closing walls define a rectangle.
- a so-called central strain gage is arranged on the closing walls 9 at the intersection of two diagonals d of the rectangle formed by each of said closing walls 9 .
- the central strain gage 27 is used for measuring the stresses in a zone of the closing walls 9 where the deformations are particularly significant.
- a plurality of strain gages 22 are arranged on the closing walls 9 .
- the strain gages 22 are aligned along the axis X.
- the aligned arrangement of a plurality of strain gages 22 including the central strain gage 27 makes it possible to measure the stresses along the heat exchanger 1 along the axis X.
- the strain gages 22 aligned with the closing walls 9 are spaced apart from each other by a second gap distance D3 measured along the axis X.
- the second gap distance D3 is between 0.6 meters and 1.6 meters.
- the second gap distance D3 is substantially equal to 1 meter.
- strain gages 22 thus arranged make it possible to mesh the closing walls 9 in order to obtain reliable measurements.
- FIG. 3 illustrating a variant of embodiment.
- the heat exchanger 1 includes sealing bars 28 .
- the sealing bars 28 separate the inner volume 4 of a frame 2 , into two sub-volumes. In other words, the sub-volumes form sealed compartments.
- the sealing bars 28 thus allow a first fluid to flow through a first compartment 29 and a second fluid to enter a second compartment 30 , without the fluids mixing.
- the sealing bars 28 are arranged along the axis Y. However, same can also be arranged along the axis X. In FIG. 3 , the sealing bar 28 is visible in order to facilitate understanding. From the outside of the heat exchanger, the sealing bars 28 are not visible because same are located in the rectangular frames.
- the heat exchanger 1 comprises sealing bars 28 , as is the case in the second embodiment, a plurality of strain gages 22 are arranged on the closing walls 9 , around the sealing bars 28 .
- the strain gages 22 are situated at a second gap distance D4 from the sealing bar 28 , which is comprised between 10 and 50 millimeters.
- the second gap distance D4 is measured along the axis X.
- the second gap distance D4 is measured along the axis Y.
- the strain gages 22 thus arranged make it possible to measure the stresses around the sealing bar 28 .
- the zone surrounding the sealing bar 28 can be the seat of leaks.
- the strain gages 22 located around the sealing bar 28 are spaced apart from each other by a third gap distance D5 comprised between 10 and 500 millimeters.
- the third gap distance D5 is measured along the axis Y when the sealing bars 28 are arranged along the axis Y as is the case in FIG. 4 .
- the third gap distance D5 is measured along the axis X when the sealing bars 28 are arranged along X (not shown).
- strain gages 22 thus arranged make it possible to mesh the zone around the sealing bars 28 in order to detect as well as possible excesses which are potentially dangerous for the heat exchanger 1 and useful in the calculation of the service life of said heat exchanger 1 . Indeed, analyses carried out by the applicant were used for demonstrating the fact that the zones around the sealing bars 28 cause deformations on the closing wall 9 .
- the sealing bar 28 defines sub-rectangles on the closing wall 9 .
- Each sub-rectangle corresponds to a compartment 29 , 30 projected along the axis Z onto the closing walls 9 .
- Each sub-rectangle includes a central strain gage 27 arranged at an intersection of the diagonals d of said sub-rectangles, on the closing walls 9 .
- Each sub-rectangle corresponds to an inner sub-volume within a frame.
- a plurality of strain gages 22 are arranged on each sub-rectangle of the closing wall 9 .
- the strain gages 22 are aligned along the X axis.
- the aligned arrangement of a plurality of strain gages 22 including the central strain gage 27 makes it possible to measure the stresses along each sub-rectangle on the closing walls 9 .
- the strain gages 22 are spaced apart from each other by a fourth gap distance D6 comprised between 0.6 meters and 1.6 meters.
- the fourth gap distance D6 is substantially equal to 1 meter.
- strain gages 22 thus arranged make it possible to mesh the closing walls 9 in order to obtain reliable measurements.
- the estimation method 35 applies to the heat exchanger 1 described hereinabove whichever embodiment described.
- the heat exchanger 1 has a known initial service life.
- the initial service life is calculated by the manufacturer of the heat exchanger 1 .
- the estimation method comprises a first step E1 of measurement of the temperature of the fluid, by means of the temperature gages 20 .
- thermo-mechanical stress is calculated using the following formula:
- thermo-mechanical stresses are stored in a computer memory.
- the method 35 further comprises a fourth step E4 of continuous measurement of the pressure, by means of the pressure gages 21 .
- the computer processing unit 24 calculates, in real-time, a mechanical pressure stress for each pressure measurement performed.
- the calculated mechanical pressure stresses are stored in a computer memory.
- the method comprises a seventh step E7 of continuous measurement of the mechanical stresses on the closing walls 9 , by means of the strain gages 22 .
- step E8 the measured mechanical stresses are stored.
- the method further comprises a ninth step E9 of determining a series of ranges of mechanical stress values.
- ranges of values are determined by taking the interval between the maximum value and the minimum value of the previously calculated and measured stresses.
- the interval between the minimum and maximum is discretized so as to obtain ranges of values.
- the discretization can be variably coarse depending on the precision sought.
- a discretization can be performed with a step equal to 10. According to such example, but not limited to, the interval between extrema is divided into 10 ranges of values.
- the method includes a tenth step E10 during which the stress calculated and stored in memory are associated with a range of values.
- the stress calculated and stored in memory are associated with a range of values.
- the method 35 comprises an eleventh step E11 during which the number of occurrences for each range of values is determined. In other words, for a given range of values, it is determined how many times the previously calculated and measured stresses fall within the given range of values.
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
Abstract
A heat exchanger including:
-
- a plurality of adjacent rectangular frames, each rectangular frame defining an inner volume wherein a fluid is apt to flow,
- a partition wall arranged between each adjacent frame and separating the inner volumes from each other,
- a closing wall arranged on each rectangular end frame and intended for closing the inner volume of said rectangular end frames,
- a plurality of fluidic inlets, each in fluidic communication with an inner volume and a plurality of fluidic outlets, each in fluidic communication with an inner volume, said fluidic inlets and outlet being situated on the rectangular frames,
- at least one distributor of fluids arranged for distributing a fluid to at least a part of the fluid inlets,
- at least one collector of fluids arranged for collecting a fluid coming out of at least a part of the fluidic outlets,
- at least one temperature gage apt to measure a temperature of the fluid,
- at least one pressure gage apt to measure a pressure of a fluid,
- at least one strain gage apt to measure a deformation on the heat exchanger,
- a communication device apt to receive the measurements from the gages and to send same to a computer processing unit.
Description
- The invention relates to the technical field of heat exchangers equipped with measuring instruments. More particularly, the invention belongs to the field of industrial heat exchangers.
- The invention relates to a heat exchanger equipped with measuring instruments and to a method for estimating the service life of the heat exchanger by means of measurements made by said measuring instruments.
- Industrial heat exchangers are used in various industries.
- As an illustration, in the oil, gas and petrochemical industries, production requires the use of heat exchangers for cooling or heating fluids. E.g., a gas is cooled for being liquefied and stored in a large volume for transporting by ship whereas the oil is heated for facilitating the movement thereof through the supply lines.
- In such plants, heat exchangers play a central role in production. In the event of a failure of a heat exchanger, the production is affected or even stopped, generating significant financial losses on a daily basis.
- In some cases, damage to the heat exchanger cannot be repaired. Replacement of the heat exchanger becomes necessary. Such industrial heat exchangers are specific and custom-made, so as to meet the needs of the plant. Sometimes large (a plurality of meters) and often complex in the inner architecture thereof, the manufacture of these heat exchangers requires a plurality of weeks or months to assemble, bake, cool and finally verify the leak-tightness. The delivery, often by boat, and finally the installation on site, extends the period during which production at the plant is interrupted or disrupted.
- The initial service life of a heat exchanger is defined by the manufacturer. The service life is established for a normal use of the heat exchanger, i.e. at pressures and temperatures within a predefined range. The manufacturer also plans a provisional schedule for interrupting, for maintenance, the use of the heat exchanger. The schedule, like the initial service life, is established for a normal use of the heat exchanger.
- However, it happens that industrial companies use heat exchangers outside of the predefined intervals. Such situations occur frequently in the oil and gas industry. Depending on the prices of each hydrocarbon, it can be interesting to produce a particular hydrocarbon. E.g. the same heat exchanger is used for producing a hydrocarbon in the morning and another hydrocarbon of a different type in the afternoon.
- Such interruptions followed by resumptions of production to which are added different operating temperatures and pressures for each hydrocarbon lead to a premature wear of the heat exchangers. Such premature wear distorts the planned schedule of shutdowns for the maintenance of the heat exchanger and reduces the service life thereof.
- The invention aims to remedy such drawbacks by enabling manufacturers to have, in real-time, a provisional schedule for maintenance and replacement of the heat exchanger, which is recalculated according the actual use of the heat exchanger. By following with the planned maintenance schedule and the replacement of the heat exchanger as determined according to the invention, the untimely shutdown of production due to a failure of the heat exchanger is prevented, and financial losses are controlled.
- To this end, a heat exchanger is proposed in the first place, including:
-
- a plurality of adjacent rectangular frames, each rectangular frame defining an inner volume wherein a fluid is apt to flow,
- a partition wall arranged between each adjacent frame and separating the inner volumes from each other,
- a closing wall arranged on each rectangular end frame and intended for closing the inner volume of said rectangular end frames,
- a plurality of fluidic inlets, each in fluidic communication with an inner volume and a plurality of fluidic outlets, each in fluidic communication with an inner volume, said fluidic inlets and outlet being situated on the rectangular frames,
- at least one distributor of fluids arranged for distributing a fluid to at least a part of the fluidic inlets,
- at least one collector of fluids arranged for collecting a fluid coming out of at least a part of the fluidic outlets,
- at least one temperature gage apt to measure a temperature of the fluid,
- at least one pressure gage apt to measure a pressure of the fluid,
- at least one strain gage apt to measure a deformation on the heat exchanger,
- a communication device apt to receive the measurements from the gages and to send same to a computer processing unit
- Such a heat exchanger makes it possible to have, in real-time, a provisional schedule of maintenance and replacement of the heat exchanger which is recalculated according to the actual use of the heat exchanger.
- Various additional features can be provided alone or in combination:
-
- the rectangular frames define faces, the heat exchanger defining a longitudinal axis and a transverse axis extending along a length and a width, respectively, of said heat exchanger, each collector and each distributor being attached to the faces and defining an end junction between both said collector and/or distributor and the closing walls, at least one junction gage being arranged on the clos wall, at a first gap distance from the end junction, comprised between 44 and 150 millimeters, the first gap distance being measured along the longitudinal axis or the transverse axis;
- a plurality of junction gages are arranged on the closing wall, the junction gages being spaced apart from each other by a first gap distance comprised between 10 and 500 millimeters;
- the first gap distance is substantially equal to 50 millimeters;
- the closing wall defines a rectangle, a central strain gage being arranged on said closing wall at an intersection of the diagonals of said rectangle;
- a plurality of strain gages are arranged on the closing wall, aligned along the longitudinal axis of said heat exchanger;
- the strain gages arranged on the closing wall are spaced apart by a second gap distance measured along the longitudinal axis, the second gap distance being comprised between 0.6 meters and 1.6 meters;
- the second gap distance is substantially equal to 1 meter;
- the heat exchanger includes at least one sealing bar for separating the inner volume of a frame into at least two sub-volumes, each sub-volume being suitable for receiving a different fluid, said sealing bar extending along the transverse axis or the longitudinal axis, and wherein the heat exchanger comprises at least one strain gage arranged on the closing wall, said strain gage being situated at a second gap distance from the sealing bar comprised between 10 and 50 millimeters, the second gap distance being measured along the longitudinal axis when the sealing bar extends along the transverse axis and along the transverse axis when the sealing bar extends along the longitudinal axis;
- a plurality of strain gages are arranged around the sealing bar on the closing wall, the strain gages being spaced apart from each other by a third gap distance measured along the longitudinal axis when the sealing rod extends along the transverse axis, and along the transverse axis when the sealing bar extends along the longitudinal axis, said third gap distance being between 10 and 500 millimeters;
- the at least one sealing bar defines sub-rectangles on the closing wall, each sub-rectangle corresponding, in a projection on the said closing wall, to a sub-volume, and wherein a central strain gage is arranged on said closing wall at an intersection of the diagonals of each sub-rectangle;
- a plurality of strain gages are arranged on each sub-rectangle of the closing wall, aligned along the longitudinal axis of said heat exchanger, and wherein said strain gages are spaced apart from each other by a fourth gap distance measured along the longitudinal axis, the fourth gap distance being comprised between 0.6 meters and 1.6 meters and preferably substantially equal to 1 meter.
- Secondly, an assembly comprising a heat exchanger as described hereinabove and a computer processing unit, is proposed.
- Thirdly, a method is proposed for estimating a service life of a heat exchanger by means of an assembly as described hereinabove, the heat exchanger having a predetermined initial service life wherein the method comprises:
-
- a step of continuous measurement of the temperature of the fluid by means of the temperature gage,
- a step of continuous calculation of a mechanical stress by means of measurement of the temperature of the fluid,
- a step of storage of the calculated mechanical stresses in memory,
- a step of continuous measurement of the pressure of the fluid by means of the pressure gage,
- a step of calculation of a mechanical stress by means of the measurement of the pressure of the fluid,
- a step of storing the calculated mechanical stresses in memory,
- a step of continuous measurement of a mechanical stress by means of the strain gage,
- a step of storage of the measured mechanical stresses in memory,
- a step of determination of a series of ranges of mechanical stress values,
- a step consisting in counting occurrences wherein the stored mechanical stress falls within a range of values established during the step of determination of a series of ranges of values,
- a step of calculation of an estimate of a service life by comparing the occurrences of the step with a database.
- Other features and advantages of the invention will appear during reading the following description, the understanding of which will be supported by to the enclosed drawings, wherein:
-
FIG. 1 is a perspective view of a heat exchanger according to a first embodiment of the invention, -
FIG. 2 is another perspective view of the heat exchanger shown inFIG. 1 , -
FIG. 3 is a top view of the heat exchanger shown inFIG. 1 , -
FIG. 4 is a perspective view of heat exchanger according to a second embodiment of the invention, -
FIG. 5 is a schematic representation of a method according to the invention. -
FIG. 1 shows aheat exchanger 1 according to the invention. A longitudinal axis X extending along a length L of theheat exchanger 1 is defined in the first place, corresponding to the largest dimension thereof. Secondly, a first transverse axis Y substantially perpendicular to the longitudinal axis X and extending along a width I of theheat exchanger 1, is defined. Finally, a second transverse axis Z substantially perpendicular to the axes X and Y and extending along a height H of theheat exchanger 1, is defined. - The
heat exchanger 1 comprises a plurality offrames 2. As can be seen, theframes 2 have a rectangular shape. Eachframe 2 is made by assembling a plurality of substantially rectilinear bars 3 beveled at each of the ends thereof, so as to form a substantially right angle. Theframes 2 are adjacent to each other. In other words, theframes 2 are overlaid one on top of the other. Eachrectangular frame 2 defines an inner volume 4. - The
heat exchanger 1 includespartition walls 5. Apartition wall 5 is arranged between eachrectangular frame 2. Thereby, a givenrectangular frame 2 is not in immediate contact with an adjacentrectangular frame 2. Apartition wall 5 separates therectangular frames 2 from each other. Thepartition walls 5 separate the inner volume 4 of therectangular frames 2 from one another, thereby creating compartments along the axis Z. - On either side of the
heat exchanger 1, the latter includes an end frame 6, identical to the otherrectangular frames 2 but located at the lower andupper ends 7, 8. Aclosing wall 9 is arranged on each end frame 6, for closing the inner volume 4 thereof. - As can be seen in
FIG. 2 , eachframe 2, with the exception of the end frames 6, includes at least onefluidic inlet 10. Eachfluidic inlet 10 of a givenframe 2 is in fluidic communication with the inner volume 4 of the givenframe 2. - In the same way, each
frame 2 except the end frames 6 has at least onefluidic outlet 31. Eachfluidic outlet 31 of a givenframe 2 is in fluidic communication with the inner volume 4 of the givenframe 2. - As can be seen in the drawings, the
fluidic inlets 10 are substantially aligned along the axis Z and thefluidic outlets 31 are also substantially aligned along the axis Z. - The
heat exchanger 1 includes at least onedistributor 11 of fluids and at least onecollector 12 of fluids. Thedistributor 11 and thecollector 12 of fluids have a substantially identical shape. Same is a curved sheet metal part defining a closed volume. Thedistributor 11 and thecollector 12 are provided with asupply line 13 and with adischarge line 14, respectively, opening onto the closed volume. Thesupply pipe 13 is used for conveying the fluid into the closed volume of thedistributor 11 and thedischarge pipe 14 is used for discharging the fluid from the closed volume of thecollector 12. - Hereinafter, distributors and collectors are referred to, indistinctly, by the expression “heads”.
- The
rectangular frames 2 define faces 16, 17, namely two lateral faces 16 extending along the axis X and twotransverse faces 17 extending along the axis Y. The heads can be attached to the lateral faces 16 and/or to the transverse faces 17, defining a junction between saidheads heads heat exchanger 1. Thus, theheads rectangular frames 2 via afirst junction 18 which extends substantially along the axis Z and to theclosing walls 9 via asecond junction 19 which extends substantially along the axis X or Y along theface first junctions 18 and thesecond junctions 19 are calledlateral junctions 18 andend junctions 19, respectively. - The
distributor 11 of fluid thus arranged is used for distributing the fluid towards thefluidic inlets 10. Thecollector 12 of fluids thus arranged is used for collecting the fluid leaving thefluidic outlets 31. - According to a preferred embodiment, the junction is welded so as to rigidly attach the
heads - Advantageously, the
heat exchanger 1 comprises at least one temperature gage 20 apt to measure a temperature of the fluid. - Advantageously, the
heat exchanger 1 comprises at least one pressure gage 21 apt to measure a pressure of the fluid. - Advantageously, the
heat exchanger 1 includes a plurality ofstrain gages 22 apt to measure deformations on theheat exchanger 1. - The
heat exchanger 1 further includes acommunication device 23 apt to receive the measurements from thedifferent gages 20, 21, 22 and to send said measurements to acomputer processing unit 24. - Advantageously, the invention also relates to an
assembly 25 comprising aheat exchanger 1 and acomputer processing unit 24. - As can be seen in the drawings, the
strain gages 22 are advantageously arranged on theclosing walls 9. Theheat exchanger 1 includes so-called “junction” strain gages 22, hereinafter called junction gages 26. The junction gages 26 are situated in the vicinity of theend junctions 19 and arranged on theclosing walls 9. The junction gages 26 are situated at a first gap distance D1 from theend junctions 19, comprised between 44 and 150 millimeters. The first gap distance D1 is measured along the longitudinal axis X. - Such arrangement of the junction gages 26 is advantageously used for obtaining measurements of the deformation stresses in a zone of the
heat exchanger 1 prone to mechanical rupture and hence to leak. - Advantageously, the
heat exchanger 1 can comprise a plurality of junction gages 26 arranged on theclosing walls 9. The junction gages 26 are spaced apart from each other by a first gap distance D2 comprised between 10 and 500 millimeters. The first gap distance D2 is measured along the axis X when thehead head - In a preferred embodiment, the first gap distance D2 is substantially equal to 50 millimeters.
- Such a first gap distance D2 makes it possible to obtain a precise distribution of the stress in the vicinity of the
end junction 19. - The
end junctions 19 extend over a length substantially equal to a width of theheads end junctions 19 in a zone corresponding to the length of theend junction 19. - Advantageously, junction gages 26 can be arranged beyond the length of the
end junctions 19. An additional junction gage 26 can be arranged beyond the length of theend junction 19. - Hereinafter, reference is made to
FIGS. 1 and 2 illustrating a first embodiment. - As can be seen in particular in
FIG. 2 , the closing walls define a rectangle. - Advantageously, a so-called central strain gage is arranged on the
closing walls 9 at the intersection of two diagonals d of the rectangle formed by each of saidclosing walls 9. - The central strain gage 27 is used for measuring the stresses in a zone of the
closing walls 9 where the deformations are particularly significant. - Advantageously, a plurality of
strain gages 22 are arranged on theclosing walls 9. The strain gages 22 are aligned along the axis X. - The aligned arrangement of a plurality of
strain gages 22 including the central strain gage 27 makes it possible to measure the stresses along theheat exchanger 1 along the axis X. The applicant determined that the deformations along theexchanger 1 along the longitudinal direction thereof and passing through the center of theclosing walls 9 are particularly likely to reduce the service life thereof. - Advantageously, the
strain gages 22 aligned with theclosing walls 9 are spaced apart from each other by a second gap distance D3 measured along the axis X. The second gap distance D3 is between 0.6 meters and 1.6 meters. Preferentially, the second gap distance D3 is substantially equal to 1 meter. - The strain gages 22 thus arranged make it possible to mesh the
closing walls 9 in order to obtain reliable measurements. - Hereinafter, reference is made to
FIG. 3 illustrating a variant of embodiment. - The
heat exchanger 1 includes sealing bars 28. The sealing bars 28 separate the inner volume 4 of aframe 2, into two sub-volumes. In other words, the sub-volumes form sealed compartments. The sealing bars 28 thus allow a first fluid to flow through a first compartment 29 and a second fluid to enter a second compartment 30, without the fluids mixing. - In the drawing shown in
FIG. 3 , the sealing bars 28 are arranged along the axis Y. However, same can also be arranged along the axis X. InFIG. 3 , the sealingbar 28 is visible in order to facilitate understanding. From the outside of the heat exchanger, the sealing bars 28 are not visible because same are located in the rectangular frames. - When the
heat exchanger 1 comprises sealingbars 28, as is the case in the second embodiment, a plurality ofstrain gages 22 are arranged on theclosing walls 9, around the sealing bars 28. - Advantageously, the
strain gages 22 are situated at a second gap distance D4 from the sealingbar 28, which is comprised between 10 and 50 millimeters. When the sealingbar 28 is arranged along the axis Y, as is the case in the second embodiment, the second gap distance D4 is measured along the axis X. When the sealingbar 28 is arranged along the axis X (not shown), the second gap distance D4 is measured along the axis Y. - The strain gages 22 thus arranged make it possible to measure the stresses around the sealing
bar 28. Indeed, the zone surrounding the sealingbar 28 can be the seat of leaks. - The strain gages 22 located around the sealing
bar 28 are spaced apart from each other by a third gap distance D5 comprised between 10 and 500 millimeters. The third gap distance D5 is measured along the axis Y when the sealing bars 28 are arranged along the axis Y as is the case inFIG. 4 . The third gap distance D5 is measured along the axis X when the sealing bars 28 are arranged along X (not shown). - The strain gages 22 thus arranged make it possible to mesh the zone around the sealing bars 28 in order to detect as well as possible excesses which are potentially dangerous for the
heat exchanger 1 and useful in the calculation of the service life of saidheat exchanger 1. Indeed, analyses carried out by the applicant were used for demonstrating the fact that the zones around the sealing bars 28 cause deformations on theclosing wall 9. - As can be seen in
FIG. 3 , the sealingbar 28 defines sub-rectangles on theclosing wall 9. Each sub-rectangle corresponds to a compartment 29, 30 projected along the axis Z onto theclosing walls 9. Each sub-rectangle includes a central strain gage 27 arranged at an intersection of the diagonals d of said sub-rectangles, on theclosing walls 9. - Each sub-rectangle corresponds to an inner sub-volume within a frame.
- It has been determined by the applicant that deformations in the central zone of each sub-rectangle have an impact on the service life of the
heat exchanger 1. The central strain gage 27 arranged at said place advantageously makes it possible to measure the deformations in said zone. - As can be seen in
FIG. 3 , a plurality ofstrain gages 22 are arranged on each sub-rectangle of theclosing wall 9. The strain gages 22 are aligned along the X axis. - The aligned arrangement of a plurality of
strain gages 22 including the central strain gage 27 makes it possible to measure the stresses along each sub-rectangle on theclosing walls 9. The applicant determined that the deformations of the sub-rectangles on theclosing wall 9 along the longitudinal direction of the latter and passing through the center of the sub-rectangles are particularly likely to reduce the service life thereof. - The strain gages 22 are spaced apart from each other by a fourth gap distance D6 comprised between 0.6 meters and 1.6 meters. The fourth gap distance D6 is substantially equal to 1 meter.
- The strain gages 22 thus arranged make it possible to mesh the
closing walls 9 in order to obtain reliable measurements. - Hereinafter, a method 35 for estimating a service life of the
heat exchanger 1 will be described. The estimation method 35 applies to theheat exchanger 1 described hereinabove whichever embodiment described. Theheat exchanger 1 has a known initial service life. The initial service life is calculated by the manufacturer of theheat exchanger 1. - The estimation method comprises a first step E1 of measurement of the temperature of the fluid, by means of the temperature gages 20.
- During a second step E2, the
computer processing unit 24 calculates, in real-time, a thermo-mechanical stress for each temperature measurement performed. The thermo-mechanical stress is calculated using the following formula: -
σth(T) =E·α·ΔT -
- where
- E is the coefficient of elasticity of the material of the closing walls,
- α is the coefficient of thermal expansion of the material of the closing walls,
- ΔT is the temperature measured between two different fluids separated by a
partition wall 5.
- In a third step E3, the calculated thermo-mechanical stresses are stored in a computer memory.
- The method 35 further comprises a fourth step E4 of continuous measurement of the pressure, by means of the pressure gages 21.
- During a fifth step E5, the
computer processing unit 24 calculates, in real-time, a mechanical pressure stress for each pressure measurement performed. - In a sixth step, the calculated mechanical pressure stresses are stored in a computer memory.
- The method comprises a seventh step E7 of continuous measurement of the mechanical stresses on the
closing walls 9, by means of the strain gages 22. - In an eighth step E8, the measured mechanical stresses are stored.
- The method further comprises a ninth step E9 of determining a series of ranges of mechanical stress values. Such ranges of values are determined by taking the interval between the maximum value and the minimum value of the previously calculated and measured stresses. The interval between the minimum and maximum is discretized so as to obtain ranges of values. The discretization can be variably coarse depending on the precision sought. As an example, a discretization can be performed with a step equal to 10. According to such example, but not limited to, the interval between extrema is divided into 10 ranges of values.
- The method includes a tenth step E10 during which the stress calculated and stored in memory are associated with a range of values. In other words, whenever a stored stress has a value within a range of values, the stored stress being associated with the corresponding range of values.
- The method 35 comprises an eleventh step E11 during which the number of occurrences for each range of values is determined. In other words, for a given range of values, it is determined how many times the previously calculated and measured stresses fall within the given range of values.
- In this way, it is possible, in a twelfth step E12 of the method, to determine an estimation of a service life. The above is done in a comparative way with a database empirically developed by performing many laboratory tests.
Claims (17)
1-14. (canceled)
15. A heat exchanger including:
a plurality of adjacent rectangular frames, each rectangular frame defining an inner volume wherein a fluid is apt to flow,
a partition wall arranged between each adjacent frame and separating the inner volumes from each other,
a closing wall arranged on each rectangular end frame and intended for closing the inner volume of said rectangular end frames,
a plurality of fluidic inlets, each in fluidic communication with an inner volume and a plurality of fluidic outlets, each in fluidic communication with an inner volume, said fluidic inlets and outlet being situated on the rectangular frames,
at least one distributor of fluid arranged for distributing a fluid to at least a part of the fluid inlets,
at least one collector of fluid arranged for collecting a fluid coming out of at least a part of the fluidic outlets,
at least one temperature gage apt to measure a temperature of the fluid,
at least one pressure gage apt to measure a pressure of the fluid,
at least one strain gage apt to measure a deformation on the heat exchanger,
a communication device apt to receive the measurements from the gages and to send same to a computer processing unit.
16. The heat exchanger according to claim 15 , wherein the rectangular frames define faces, the heat exchanger defining a longitudinal axis (X) and a transverse axis (Y) extending along a length (L) and a width (I), respectively, of said heat exchanger, each collector and each distributor being attached to the faces and defining an end junction between both said collector and/or distributor and the closing walls, at least one junction gage being arranged on the closing wall at a first gap distance (D1) from the end junction, comprised between 44 and 150 millimeters, the first gap distance (D1) being measured along the longitudinal axis (X) or the transverse axis (Y).
17. The heat exchanger according to claim 16 , wherein a plurality of junction gages are arranged on the closing wall, the junction gages being spaced apart from each other by a first gap distance (D2) comprised between 10 and 500 millimeters.
18. The heat exchanger according to claim 17 , wherein the first gap distance (D2) is substantially equal to 50 millimeters.
19. The heat exchanger according to claim 15 , wherein the closing wall defines a rectangle, a central strain gage being arranged on said closing wall at an intersection of the diagonals (d) of said rectangle.
20. The heat exchanger according to claim 19 , wherein a plurality of strain gages are arranged on the closing wall, aligned along the longitudinal axis (X) of said heat exchanger.
21. The heat exchanger according to claim 20 , wherein the strain gages arranged on the closing wall are spaced apart by a second gap distance (D3) measured along the longitudinal axis (X), the second gap distance (D3) being comprised between meter and 1.6 meter.
22. The heat exchanger according to claim 21 , wherein the second gap distance (D3) is substantially equal to 1 meter.
23. The heat exchanger according to claim 16 , further including at least one sealing bar intended for separating the inner volume of the frame into at least two sub-volumes, each sub-volume being apt to accommodate a different fluid, said sealing bar extending along the transverse axis (Y) or the longitudinal axis (X), and wherein at least one of the at least one strain gage is arranged on the closing wall, being situated at a second gap distance (D4) from the sealing bar, comprised between 10 and 50 millimeters, the second gap distance (D4) being measured along the longitudinal axis (X) when the sealing bar extends along the transverse axis (Y) and along the transverse axis (Y) when the sealing bar extends along the longitudinal axis (X).
24. The heat exchanger according to claim 23 , wherein a plurality of the at least one strain gage are arranged around the sealing bar on the closing wall, the plurality of strain gages being spaced apart by a third gap distance (D5) measured along the longitudinal axis (X) when the sealing bar extends along the transverse axis (Y) and along the transverse axis (Y) when the sealing bar extends along the longitudinal axis (X), said third gap distance (D5) being comprised between 10 and 500 millimeters.
25. The heat exchanger according to claim 23 , wherein the at least one sealing bar defines sub-rectangles on the closing wall, each sub-rectangle corresponding, in a projection on said closing wall, to a sub-volume, and wherein a central strain gage is arranged on said closing wall at an intersection of the diagonals (d) of each sub-rectangle.
26. The heat exchanger according to claim 25 , wherein a plurality of the at least one strain gage are arranged on each sub-rectangle of the closing wall, aligned along the longitudinal axis (X) of said heat exchanger, and wherein said plurality of strain gages are spaced apart from each other by a fourth gap distance (D6) measured along the longitudinal axis, said fourth gap distance (D6) being comprised between 0.6 meter and 1.6 meter, and preferentially substantially equal to 1 meter.
27. An assembly comprising the heat exchanger according to claim 15 and a computer processing unit.
28. A method for estimating a service life of a heat exchanger by means of the assembly according to claim 27 , the heat exchanger having a predetermined initial service life, wherein the method comprises:
continuously measuring the temperature of the fluid by means of the temperature gage,
continuously calculating a mechanical stress by means of measurement of the temperature of the fluid,
storing the calculated mechanical stresses in memory,
continuously measuring a fluid pressure by means of the pressure gage,
calculating a mechanical stress by means of measuring the fluid pressure,
storing the calculated mechanical stresses in memory,
continuous measuring a mechanical stress by means of the strain gage,
storing in memory the measured mechanical stresses,
determining a series of ranges of mechanical stress values,
counting the occurrences wherein the stored mechanical stresses fall within a range of values established in the determining of the series of ranges of values, and
calculating an estimate of a service life by comparing the occurrences with a database.
29. The heat exchanger according to claim 18 , further including at least one sealing bar intended for separating the inner volume of the frame into at least two sub-volumes, each sub-volume being apt to accommodate a different fluid, said sealing bar extending along the transverse axis (Y) or the longitudinal axis (X), and wherein at least one of the at least one strain gage is arranged on the closing wall, being situated at a second gap distance (D4) from the sealing bar, comprised between 10 and 50 millimeters, the second gap distance (D4) being measured along the longitudinal axis (X) when the sealing bar extends along the transverse axis (Y) and along the transverse axis (Y) when the sealing bar extends along the longitudinal axis (X).
30. The heat exchanger according to claim 24 , wherein the at least one sealing bar defines sub-rectangles on the closing wall, each sub-rectangle corresponding, in a projection on said closing wall, to a sub-volume, and wherein a central strain gage is arranged on said closing wall at an intersection of the diagonals (d) of each sub-rectangle.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR2012926A FR3117202B1 (en) | 2020-12-09 | 2020-12-09 | Instrumented heat exchanger and method for estimating a lifetime of this heat exchanger |
FR2012926 | 2020-12-09 | ||
PCT/EP2021/085007 WO2022122926A1 (en) | 2020-12-09 | 2021-12-09 | Instrumented heat exchanger and method for estimating a lifespan of said heat exchanger |
Publications (1)
Publication Number | Publication Date |
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US20240027148A1 true US20240027148A1 (en) | 2024-01-25 |
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ID=74206093
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US18/266,230 Pending US20240027148A1 (en) | 2020-12-09 | 2021-12-09 | Instrumented heat exchanger and method for estimating a lifespan of said heat exchanger |
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US (1) | US20240027148A1 (en) |
EP (1) | EP4259996A1 (en) |
FR (1) | FR3117202B1 (en) |
WO (1) | WO2022122926A1 (en) |
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US10794644B2 (en) * | 2017-03-28 | 2020-10-06 | Uop Llc | Detecting and correcting thermal stresses in heat exchangers in a petrochemical plant or refinery |
HUE059391T2 (en) * | 2017-05-23 | 2022-11-28 | Linde Gmbh | Method and system for determining at least one non-directly measurable quantity of a fluid thrust-conducting apparatus |
DE102017128122A1 (en) * | 2017-11-28 | 2019-05-29 | Akg Thermotechnik International Gmbh & Co. Kg | Method for condition monitoring of a heat exchanger and heat exchanger |
-
2020
- 2020-12-09 FR FR2012926A patent/FR3117202B1/en active Active
-
2021
- 2021-12-09 EP EP21839053.2A patent/EP4259996A1/en active Pending
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EP4259996A1 (en) | 2023-10-18 |
FR3117202A1 (en) | 2022-06-10 |
FR3117202B1 (en) | 2023-03-31 |
WO2022122926A1 (en) | 2022-06-16 |
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