Modern Day Automation for Heat Exchanger Monitoring

Sanjay Dehran

doi:doi:10.11648/j.ijmea.20170501.12

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Modern Day Automation for Heat Exchanger Monitoring

Sanjay Dehran

Published in International Journal of Mechanical Engineering and Applications (Volume 5, Issue 1)

Received: 21 September 2016 Accepted: 16 December 2016 Published: 21 January 2017

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Abstract

Heat exchanger monitoring for efficiency & fouling is a considerable economic & technical concern for any process plant/industry, be it chemical, oil & gas or power. Heat Exchangers cleaning/repair forms the major part of the maintenance budget & its availability continues to be a major concern for operations. Non-availability of a Critical exchanger directly affects the production of the refinery unit. BUT traditionally it’s still ignored during engineering & draws little attention from process engineers. The purpose of this paper is to highlight heat exchanger performance related issues in brief & will detail the instrumentation / automation options to address these issues. The article will also include the various options available for each method of monitoring depending upon the site conditions, criticality & will also include the cost element. The paper will be focused on the different types of instrumentation schemes for effective monitoring including achieving these solutions through HART, FF, Modbus or Wireless sensors & multiplexers. Technological developments in this field will also be discussed in brief. Typical case implementation will also be discussed from the various solutions implemented during the vast experience gained working on various solutions provided in Fluor for different brown field & green field Refineries / Petrochemical units. Fluor’s Subject Matter Experts can develop algorithm for effective monitoring of various types of exchangers using the existing PCS or new PCS systems by utilizing their experience & customize it for specific units based on the discussions with the end user’s process/maintenance engineers & offline data available from past records. Economic model & its necessity for the ultimate result of reaping benefits by implementing effective maintenance schedule with correct timing & cleaning methodology.

Published in	International Journal of Mechanical Engineering and Applications (Volume 5, Issue 1)
DOI	10.11648/j.ijmea.20170501.12
Page(s)	15-19
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Industrial Automation, Engineering, Maintenance, Heat Exchanger

References

[1]	Fluor Practices & Procedures.
[2]	Smart Wireless Applications, By Emerson, www.EmersonProcess.com/SmartWireless
[3]	Scimod “Scientific Modeling Software”, techno software International, India.
[4]	Ganapathy. V, “Fouling factor estimated quickly”, O&G Journal, Aug 1992.
[5]	Elizabeth Garcia, Susan H. Leach, W. L. VanNostrand, “Heat Exchanger Monitoring & its application to Cleaning, Exxon Chemical Company, ESL-IE-83-04-94.
[6]	Shady Yehia, “Applying heat exchanger control strategies”, Control Engineering.
[7]	Energy Performance Assessment of Heat Exchangers, Bureau of Energy Efficiency.
[8]	Petro-SIMTM HX Monitor www.kbcat.com
[9]	AMS Suite: Equipment Performance Monitor. Emerson Process Management, www.assetweb.com
[10]	Andrea Heins, Ramón Veiga, Carlos Ruiz, Andrés Riera, Heat Exchanger Fouling and Cleaning – VII, July 1 - 6, 2007, Tomar, Portugal, Fouling Monitoring and Cleaning Optimization in a Heat Exchanger Network of a Crude Distillation Unit.
[11]	F. dos Santos Liporace and S. Gregório de Oliveira, 2005, June 5 – 10, Real time fouling diagnosis and heat exchanger performance, ECI Symposium Series, Volume RP2: Proceedings of 6th International Conference on Heat Exchanger Fouling and Cleaning, Kloster Irsee, Germany.
[12]	A white paper issued by: Siemens, Sector Industry, IA AS S SM. © Siemens AG 2013, Asset Management of mechanical plant components in SIMATIC PCS 7.
[13]	Engineer Insight Report, 00870-0200-3001, Rev AA, October 2014, Top 5 Measurements in Energy Management.

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APA Style

Sanjay Dehran. (2017). Modern Day Automation for Heat Exchanger Monitoring. International Journal of Mechanical Engineering and Applications, 5(1), 15-19. https://doi.org/10.11648/j.ijmea.20170501.12

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ACS Style

Sanjay Dehran. Modern Day Automation for Heat Exchanger Monitoring. Int. J. Mech. Eng. Appl. 2017, 5(1), 15-19. doi: 10.11648/j.ijmea.20170501.12

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AMA Style

Sanjay Dehran. Modern Day Automation for Heat Exchanger Monitoring. Int J Mech Eng Appl. 2017;5(1):15-19. doi: 10.11648/j.ijmea.20170501.12

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@article{10.11648/j.ijmea.20170501.12,
  author = {Sanjay Dehran},
  title = {Modern Day Automation for Heat Exchanger Monitoring},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {5},
  number = {1},
  pages = {15-19},
  doi = {10.11648/j.ijmea.20170501.12},
  url = {https://doi.org/10.11648/j.ijmea.20170501.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20170501.12},
  abstract = {Heat exchanger monitoring for efficiency & fouling is a considerable economic & technical concern for any process plant/industry, be it chemical, oil & gas or power. Heat Exchangers cleaning/repair forms the major part of the maintenance budget & its availability continues to be a major concern for operations. Non-availability of a Critical exchanger directly affects the production of the refinery unit. BUT traditionally it’s still ignored during engineering & draws little attention from process engineers. The purpose of this paper is to highlight heat exchanger performance related issues in brief & will detail the instrumentation / automation options to address these issues. The article will also include the various options available for each method of monitoring depending upon the site conditions, criticality & will also include the cost element. The paper will be focused on the different types of instrumentation schemes for effective monitoring including achieving these solutions through HART, FF, Modbus or Wireless sensors & multiplexers. Technological developments in this field will also be discussed in brief. Typical case implementation will also be discussed from the various solutions implemented during the vast experience gained working on various solutions provided in Fluor for different brown field & green field Refineries / Petrochemical units. Fluor’s Subject Matter Experts can develop algorithm for effective monitoring of various types of exchangers using the existing PCS or new PCS systems by utilizing their experience & customize it for specific units based on the discussions with the end user’s process/maintenance engineers & offline data available from past records. Economic model & its necessity for the ultimate result of reaping benefits by implementing effective maintenance schedule with correct timing & cleaning methodology.},
 year = {2017}
}

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TY  - JOUR
T1  - Modern Day Automation for Heat Exchanger Monitoring
AU  - Sanjay Dehran
Y1  - 2017/01/21
PY  - 2017
N1  - https://doi.org/10.11648/j.ijmea.20170501.12
DO  - 10.11648/j.ijmea.20170501.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 15
EP  - 19
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20170501.12
AB  - Heat exchanger monitoring for efficiency & fouling is a considerable economic & technical concern for any process plant/industry, be it chemical, oil & gas or power. Heat Exchangers cleaning/repair forms the major part of the maintenance budget & its availability continues to be a major concern for operations. Non-availability of a Critical exchanger directly affects the production of the refinery unit. BUT traditionally it’s still ignored during engineering & draws little attention from process engineers. The purpose of this paper is to highlight heat exchanger performance related issues in brief & will detail the instrumentation / automation options to address these issues. The article will also include the various options available for each method of monitoring depending upon the site conditions, criticality & will also include the cost element. The paper will be focused on the different types of instrumentation schemes for effective monitoring including achieving these solutions through HART, FF, Modbus or Wireless sensors & multiplexers. Technological developments in this field will also be discussed in brief. Typical case implementation will also be discussed from the various solutions implemented during the vast experience gained working on various solutions provided in Fluor for different brown field & green field Refineries / Petrochemical units. Fluor’s Subject Matter Experts can develop algorithm for effective monitoring of various types of exchangers using the existing PCS or new PCS systems by utilizing their experience & customize it for specific units based on the discussions with the end user’s process/maintenance engineers & offline data available from past records. Economic model & its necessity for the ultimate result of reaping benefits by implementing effective maintenance schedule with correct timing & cleaning methodology.
VL  - 5
IS  - 1
ER  -

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Author Information

Sanjay Dehran

Control Systems Department, Fluor, New Delhi, India

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Plain Text BibTeX RIS

APA Style

Sanjay Dehran. (2017). Modern Day Automation for Heat Exchanger Monitoring. International Journal of Mechanical Engineering and Applications, 5(1), 15-19. https://doi.org/10.11648/j.ijmea.20170501.12

Copy | Download

ACS Style

Sanjay Dehran. Modern Day Automation for Heat Exchanger Monitoring. Int. J. Mech. Eng. Appl. 2017, 5(1), 15-19. doi: 10.11648/j.ijmea.20170501.12

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AMA Style

Sanjay Dehran. Modern Day Automation for Heat Exchanger Monitoring. Int J Mech Eng Appl. 2017;5(1):15-19. doi: 10.11648/j.ijmea.20170501.12

Copy | Download

@article{10.11648/j.ijmea.20170501.12,
  author = {Sanjay Dehran},
  title = {Modern Day Automation for Heat Exchanger Monitoring},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {5},
  number = {1},
  pages = {15-19},
  doi = {10.11648/j.ijmea.20170501.12},
  url = {https://doi.org/10.11648/j.ijmea.20170501.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20170501.12},
  abstract = {Heat exchanger monitoring for efficiency & fouling is a considerable economic & technical concern for any process plant/industry, be it chemical, oil & gas or power. Heat Exchangers cleaning/repair forms the major part of the maintenance budget & its availability continues to be a major concern for operations. Non-availability of a Critical exchanger directly affects the production of the refinery unit. BUT traditionally it’s still ignored during engineering & draws little attention from process engineers. The purpose of this paper is to highlight heat exchanger performance related issues in brief & will detail the instrumentation / automation options to address these issues. The article will also include the various options available for each method of monitoring depending upon the site conditions, criticality & will also include the cost element. The paper will be focused on the different types of instrumentation schemes for effective monitoring including achieving these solutions through HART, FF, Modbus or Wireless sensors & multiplexers. Technological developments in this field will also be discussed in brief. Typical case implementation will also be discussed from the various solutions implemented during the vast experience gained working on various solutions provided in Fluor for different brown field & green field Refineries / Petrochemical units. Fluor’s Subject Matter Experts can develop algorithm for effective monitoring of various types of exchangers using the existing PCS or new PCS systems by utilizing their experience & customize it for specific units based on the discussions with the end user’s process/maintenance engineers & offline data available from past records. Economic model & its necessity for the ultimate result of reaping benefits by implementing effective maintenance schedule with correct timing & cleaning methodology.},
 year = {2017}
}

Copy | Download

TY  - JOUR
T1  - Modern Day Automation for Heat Exchanger Monitoring
AU  - Sanjay Dehran
Y1  - 2017/01/21
PY  - 2017
N1  - https://doi.org/10.11648/j.ijmea.20170501.12
DO  - 10.11648/j.ijmea.20170501.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 15
EP  - 19
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20170501.12
AB  - Heat exchanger monitoring for efficiency & fouling is a considerable economic & technical concern for any process plant/industry, be it chemical, oil & gas or power. Heat Exchangers cleaning/repair forms the major part of the maintenance budget & its availability continues to be a major concern for operations. Non-availability of a Critical exchanger directly affects the production of the refinery unit. BUT traditionally it’s still ignored during engineering & draws little attention from process engineers. The purpose of this paper is to highlight heat exchanger performance related issues in brief & will detail the instrumentation / automation options to address these issues. The article will also include the various options available for each method of monitoring depending upon the site conditions, criticality & will also include the cost element. The paper will be focused on the different types of instrumentation schemes for effective monitoring including achieving these solutions through HART, FF, Modbus or Wireless sensors & multiplexers. Technological developments in this field will also be discussed in brief. Typical case implementation will also be discussed from the various solutions implemented during the vast experience gained working on various solutions provided in Fluor for different brown field & green field Refineries / Petrochemical units. Fluor’s Subject Matter Experts can develop algorithm for effective monitoring of various types of exchangers using the existing PCS or new PCS systems by utilizing their experience & customize it for specific units based on the discussions with the end user’s process/maintenance engineers & offline data available from past records. Economic model & its necessity for the ultimate result of reaping benefits by implementing effective maintenance schedule with correct timing & cleaning methodology.
VL  - 5
IS  - 1
ER  -

Copy | Download