A method for detecting a leak in a heat exchanger plate includes positioning the heat exchanger plate between a first fixture and a second fixture to create both a first sealed space between the heat exchanger plate and the first fixture and a second sealed space between the heat exchanger plate and the second fixture. The first sealed space is on one side of the heat exchanger plate and the second sealed space is on the other side of the heat exchanger plate. The method includes supplying an inert gas to the second sealed space, drawing a vacuum in the first sealed space, and detecting whether the first sealed space includes the inert gas. The presence of inert gas indicates the plate is not leak-tight.

A computer-implemented method for designing a built-in test is described. The method includes receiving, via a processor, a subsystem model including system parameters for a heat exchanger, wherein each of the system parameters includes a sensor variance; determining, via the processor, a test design vector based on one or more of the system parameters; and designing, via the processor, the built-in test based on the test design vector.

A heat exchange system having desired anti-scaling performance and an anti-scaling method thereof are disclosed. The heat exchange system at least comprises a load control unit, a temperature and pressure detection unit and an anti-scaling treatment unit. The heat exchange system conditions bonding ways of water quality in a HVAC chiller unit, an air compressor, a heat exchanger, a cooling unit, or a boiler under a variety of scaling conditions in both field operation and water quality, by integrating the interaction of those units together with the anti-scaling method for simulating water quality that has a water quality limit same as that in field operation. The heat exchange system further integrates with a testing of anti-scaling performance to make water quality no longer charged and lose the reaction power so as to prevent scaling formation, enhance the anti-scaling performance, and ensure operating efficiency and performance.

A method of predicting temperature of at least one location in a fluid flow system that has a heating system for heating fluid. The method includes obtaining a mass flow rate of fluid flow of the fluid flow system, obtaining at least one of a fluid outlet temperature and a fluid inlet temperature of a heater of the heating system, obtaining power provided to the heater, and calculating temperature at the at least one location based on a model of the fluid flow system and the obtained mass flow rate, fluid outlet temperature, and fluid inlet temperature.

A method can comprise dividing a heat exchanger design into a plurality of modules, the plurality of modules arranged in a grid, each module in the plurality of modules including: a first fluid conduit defining an inlet, an outlet, and a heat-transfer surface, and a first flow direction, and a second fluid conduit defining a second inlet, a second outlet, a second heat-transfer surface, and a second flow direction, the second flow direction different from the first flow direction; and determining a heat-transfer augmenter arrangement for the first fluid conduit and the second fluid conduit of each module in the plurality of modules based on a stress threshold of the module in the plurality of modules.

A susceptor for use in a heated fluid flow system is provided. In one form, a susceptor is arranged within a conduit and adapted to absorb radiant energy from at least one heating element and inhibit the radiant energy from being absorbed by the at least one wall of the conduit and/or other components. In another form, the susceptor absorbs and inhibits the radiant energy from being absorbed by the outer wall of the conduit.

The following provides a system and method to predict an indicator of tube fouling in a fired apparatus such as a boiler. Historical data can be collected when the tubing is still considered to be clean, and used to build a first model between an indicator of fouling, such as tube skin temperature, and boiler load. The actual measurement of that indicator of fouling can then be compared against the model output, such that the error between the model and measurement is considered an indication of the tube fouling. Moreover, the rate of change of the model error can be used to measure the fouling rate. Next, historical data on the fluid feed quality can be collected and together with the historical error rate change data can be combined to develop a second model. This second model reflects how fluid feed quality variables may affect the fouling rate over time.

The apparatus is used for testing heat exchangers having mutually separate first and second flow paths. The apparatus provides a high pressure fluid source (10) to connect with a first pressure-sealed flow path of the heat exchanger under test. A volumetric sensor (VS) is connected to a selected pressure-sealed flow path, having a sensing chamber arranged to receive fluid from the selected flow path. The sensing chamber is connected to a further fluid source such as a compressed air reservoir (16) which provides a high pressure gas supply. Movement of a magnetic float within the sensing chamber is detected by an array of Hall effect sensors, enabling a CPU to calculate the rate of leakage between the two flow paths which may be signaled to a local display and/or alarm or remotely via an internet connection.

A heat exchanger control and diagnostic apparatus includes a heat exchanger having a primary inlet of a primary heat-transport liquid mounted with a first temperature sensor and a primary outlet of the primary heat-transport liquid mounted with a second temperature sensor, wherein the primary outlet is piped to a pump, the pump comprising a pump impeller connected to a motor, the primary heat-transport liquid being piped by plumbing from the pump impeller to a heat source and from the heat source back to the primary inlet, and a control unit connected to the heat exchanger and the pump and comprising a motor control unit bi-directionally connected to the motor. The heat exchanger has a secondary inlet for a secondary heat-transport liquid and a secondary outlet ducted to a temperature zone and back to the secondary inlet, the control unit being augmented by a temperature module, the temperature module having a first input connected by a communication channel to an output of the temperature sensor, and a second input connected by a communication channel to an output of the second temperature sensor, the temperature module having an output for outputting a primary inlet temperature connected to one input of a power calculation module, and an output for outputting a primary outlet temperature connected to another input of the power calculation module, the power calculation module having a third input connected to a flow estimation module, one input of the flow estimation module being connected to an output of a memory unit, and another input being connected by a bus to an output of the motor control unit, an output of the power calculation module for outputting a heat flow estimate being connected to one input of a heat flow controller, and another input of the heat flow controller for inputting a heat flow demand being connected to an output of an operator unit, and an output of the operator unit being connected to an input of the motor control unit.

A heat exchanger monitoring system includes a heat exchanger 11 capable of receiving a flow F of a working fluid therethrough. A first sensor 12 is disposed upstream of the heat exchanger 11 for measuring at least one property of fluid relating to an amount of contaminant material carried by a first flow entering the heat exchanger 11 and configured to output a first sensor signal indicative of the measured property of the fluid. A second sensor 14 is disposed downstream of the heat exchanger 11 for measuring the same property of the fluid relating to an amount of contaminant material carried by a second flow exiting the heat exchanger 11 and configured to output a second sensor signal indicative of the measured property of the fluid.