Diagnostics of the technical condition of heat exchange equipment by changes in temperature pressure and hydraulic resistance

RELEVANCE. Industries such as power, oil and gas, chemical, pharmaceutical, and metallurgy use heat exchangers (HE). Their significant role in technological processes necessitates careful monitoring of their technical condition to prevent emergency situations.

THE PURPOSE. To examine the problems that arise during HE operation. To analyze existing diagnostic methods and identify their pros and cons. To propose a comprehensive HE diagnostic method that utilizes a combined analysis of thermal and hydraulic characteristics to detect corrosion deposits, coolant leaks, and transfers to another circuit. To determine the impact of deposits, coolant leaks, and transfers to another circuit on the temperature difference and hydraulic resistance of HE.

METHODS. To solve this problem, the Number of Transfer Units (NTU) method, the Darcy-Weisbach formula, and the Aspen Exchanger Design & Rating V12 software were used.

RESULTS. The developed mathematical model and calculations performed in Aspen Exchanger Design & Rating V12 showed that the presence of deposits increases the temperature difference and hydraulic resistance, while coolant leaks or transfers to another circuit reduce the temperature difference and hydraulic resistance.

CONCLUSION. A comprehensive analysis of the temperature and pressure characteristics during the operation of the thermal hydraulic system will enable diagnostics of its technical condition, and the resulting mathematical models will serve as an algorithmic basis for the creation of a real-time monitoring software and hardware system. Monitoring thermal hydraulic parameters will enable a transition from scheduled preventive maintenance to condition-based repairs, minimizing the risk of unexpected production shutdowns, reducing operating costs, and extending the equipment's service life.

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