METHOD FOR MANAGING A PROCESS ENGINEERING FACILITY

Abstract

The present invention relates to a method and to a graphical user interface for managing a process engineering facility comprising at least one heat exchanger, wherein each of these heat exchangers is designed as a plate heat exchanger and each comprises a plurality of heat exchanger blocks, the method comprising: receiving sensor values from sensors which are arranged on or in the at least one heat exchanger; determining parameters which characterize an operation of the at least one heat exchanger on the basis of the received sensor values, wherein a temperature difference between heat exchanger blocks of the at least one heat exchanger is determined as a parameter; processing the sensor values and/or the parameters for a graphical display of a state of the at least one heat exchanger.

Claims

1. A method for managing a process engineering facility having at least one heat exchanger, wherein each of these heat exchangers is designed as a plate heat exchanger and each comprises a plurality of heat exchanger blocks, comprising: receiving sensor values from sensors which are arranged on or in the at least one heat exchanger; determining parameters wherein an operation of the at least one heat exchanger, on the basis of the received sensor values, wherein a temperature difference between heat exchanger blocks of the at least one heat exchanger is determined as a parameter; processing the sensor values and/or the parameters for a graphical display of a state of the at least one heat exchanger, wherein a service life of the at least one heat exchanger is determined as the state on the basis of the determined temperature difference between the heat exchanger blocks of the at least one heat exchanger, and a graphical display of the service life of the at least one heat exchanger is determined; outputting the processed sensor values and/or parameters in a graphical user interface, wherein the graphical display of the service life of the at least one heat exchanger is output in the graphical user interface; managing the operation of the at least one heat exchanger on the basis of the output, processed sensor values and/or parameters in the graphical user interface, wherein the service life of the at least one heat exchanger is monitored.

2. The method according to claim 1, wherein further a change in the service life of the at least one heat exchanger is determined as the state of the at least one heat exchanger on the basis of the determined temperature difference between the heat exchanger blocks of the at least one heat exchanger, wherein a graphical display of the change in the service life of the at least one heat exchanger is determined, and wherein the graphical display of the change in the service life of the at least one heat exchanger is output in the graphical user interface.

3. The method according to either claim 1, or wherein managing the operation of the at least one heat exchanger further comprises one or more of the following steps: determining a maintenance interval of the at least one heat exchanger on the basis of the graphical display of the service life of the at least one heat exchanger output in the graphical user interface; determining a maintenance work task to be performed on the at least one heat exchanger on the basis of the graphical display of the service life of the at least one heat exchanger output in the graphical user interface; determining hazards for an operation of the at least one heat exchanger on the basis of the graphical display of the service life of the at least one heat exchanger output in the graphical user interface; determining control values of the at least one heat exchanger on the basis of the graphical display of the service life of the at least one heat exchanger output in the graphical user interface, in order to avoid critical states which lead to a shortening of service life.

4. The method according to claim 1, wherein further the performance of the at least one heat exchanger and/or a history of the at least one heat exchanger is determined as the state of the at least one heat exchanger.

5. The method according to claim 1, wherein the sensors arranged on or in the at least one heat exchanger are each designed as a temperature sensor and/or pressure sensor and/or flow sensor and/or sound sensor and/or vibration sensor.

6. The method according to claim 1, wherein, furthermore, one or more of the following variables is determined as parameters: a temperature difference within the at least one heat exchanger; a temperature difference between fluid flows of the at least one heat exchanger; a temperature difference between fluid flows and heat exchanger blocks of the at least one heat exchanger; a rate of cooling processes and/or warming processes of the at least one heat exchanger; a local temperature profile within the at least one heat exchanger; a temporal temperature profile within the at least one heat exchanger; a mechanical stress level of the at least one heat exchanger; a thermal stress level of the at least one heat exchanger; a deviation from a guideline for the operation of the at least one heat exchanger; a deviation from a specification for the at least one heat exchanger.

7. The method according to claim 1, wherein the processing of the sensor values and/or the parameters further comprises one or more of the following steps: determining a graphical display of a temporal profile of individual sensor values and/or individual parameters on the basis of the points in time at which the particular sensor values were determined; determining a graphical display of a local profile of individual sensor values and/or individual parameters within the at least one heat exchanger on the basis of positions within the at least one heat exchanger, at which the particular sensor values were determined; determining a graphical display of a multi-dimensional profile of individual sensor values and/or individual parameters on the basis of points in time at which the particular sensor values were determined and on the basis of positions within the at least one heat exchanger at which the particular sensor values were determined; determining a graphical display of the performance of the at least one heat exchanger; determining a graphical display of a hazard analysis of the at least one heat exchanger; determining a graphical display of cooling processes and/or warming processes of the at least one heat exchanger; determining a graphical display of a thermal expansion of heat exchanger blocks of the at least one heat exchanger.

8. The method according to claim 1, wherein managing the operation of the at least one heat exchanger further comprises one or more of the following steps: monitoring a current state of the at least one heat exchanger; monitoring a future state of the at least one heat exchanger; monitoring a past state of the at least one heat exchanger; determining control values of the at least one heat exchanger in order to increase the performance of the at least one heat exchanger.

9. The method according to claim 1, furthermore comprising: receiving input in the user interface; controlling the at least one heat exchanger on the basis of the inputs received.

10. The method according to claim 1, wherein each heat exchanger block comprises structural sheets and/or sidebars and/or separating sheets and/or cover sheets interconnected.

11. A graphical user interface for managing a process engineering facility having at least one heat exchanger, wherein each of these heat exchangers is designed as a plate heat exchanger and each comprises a plurality of heat exchanger blocks, wherein the graphical user interface comprises at least one display surface which is configured to output sensor values received and processed, and/or parameters determined and processed according to claim 1, wherein the display surface is configured to output the graphical display of the service life of the at least one heat exchanger.

12. The graphical user interface according to claim 11, further comprising at least one control surface which is configured to receive inputs, wherein the graphical user interface is configured to control the at least one heat exchanger on the basis of these received inputs.

13. A computing system that is configured to perform all method steps of a method according to claim 1.

14. The computing system according to claim 13, comprising a graphical user interface.

15. A computer program that causes a computing system, in particular the computing system according to claim 13 to perform all the steps of the method for managing the process engineering facility having at least one heat exchanger, wherein each of these heat exchangers is designed as the plate heat exchanger and each comprises the plurality of heat exchanger blocks, comprising: receiving sensor values from sensors which are arranged on or in the at least one heat exchanger; determining parameters wherein the operation of the at least one heat exchanger, on the basis of the received sensor values, wherein the temperature difference between heat exchanger blocks of the at least one heat exchanger is determined as the parameter; processing the sensor values and/or the parameters for the graphical display of the state of the at least one heat exchanger, wherein the service life of the at least one heat exchanger is determined as the state on the basis of the determined temperature difference between the heat exchanger blocks of the at least one heat exchanger, and the graphical display of the service life of the at least one heat exchanger is determined; outputting the processed sensor values and/or parameters in the graphical user interface, wherein the graphical display of the service life of the at least one heat exchanger is output in the graphical user interface; managing the operation of the at least one heat exchanger on the basis of the output, processed sensor values and/or parameters in the graphical user interface, wherein the service life of the at least one heat exchanger is monitored.

16. A machine-readable storage medium having a computer program according to claim 15 stored thereon.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] FIG. 1 schematically and perspectively shows a heat exchanger for a process engineering facility that can be managed in accordance with one embodiment of the present invention.

[0052] FIG. 2 schematically shows a process engineering facility that can be managed in accordance with one embodiment of the present invention.

[0053] FIG. 3 schematically shows a graphical user interface in accordance with one embodiment of the invention.

EMBODIMENT(S) OF THE INVENTION

[0054] In FIG. 1, a heat exchanger is displayed schematically and labeled 100, which can be used in a process engineering facility that can be managed in accordance with one embodiment of the present invention.

[0055] The heat exchanger 100 shown in FIG. 1 is a brazed plate-fin heat exchanger made of aluminum (PFHE) (designations in accordance with the German and English edition of ISO 15547-2:3005), as can be used in a large number of facilities at very different pressures and temperatures. For example, they are used in cryogenic air separation, in the liquefaction of natural gas and in ethylene production plants. It is understood that aluminumcan also denote an aluminum alloy.

[0056] Brazed plate-fin heat exchangers made of aluminum are shown and described in FIG. 2 of the above-mentioned ISO 15547-2:3005, as well as on page 5 of the ALPEMA publication The Standards of the Brazed Aluminum Plate-Fine Heat Exchanger Manufacturers'Association, 3rd edition, 2010. The present FIG. 1 substantially corresponds to the illustrations of the aforementioned ISO standard and will be explained below.

[0057] The plate heat exchanger 100, displayed partially opened in FIG. 1, is used for the heat exchange of five different process media A to E in the example shown. For heat exchange between the process media A to E, the plate heat exchanger 100 comprises a plurality of separating sheets 4 arranged in parallel with one another (in the previously mentioned publications, to which the subsequent references in brackets also refer, these are called parting sheets), between which heat exchange passages 1 defined by structural sheets with lamellae 3 (fins) are formedin each case for one of the process media A to Eand which can thereby come into heat exchange with one another.

[0058] The structural sheets with the lamellae 3 are typically folded or corrugated, wherein flow channels are formed by each of the folds or corrugations, as also shown in FIG. 1 of the ISO 15547-2: 3005. The provision of the structural sheets with lamellae 3 offers the advantage of improved heat transfer, more targeted fluid guidance and an increase in the mechanical (tensile) strength in comparison with plate heat exchangers without lamellae. In the heat exchange passages 1, the process media A to E flow, in particular separated by the separating sheets 4, but can optionally pass through the latter with lamellae 3 in the case of perforated structural sheets.

[0059] The individual passages 1 or the structural sheets with the lamellae 3 are surrounded on each side by what are known as side bars 8, which leave space free for feed and removal openings 9, however. The side bars 8 hold the separating sheets 4 at a distance and ensure mechanical reinforcement of the pressure chamber. Cover sheets 5 (cap sheets), which are in particular reinforced, are arranged in parallel with the separating sheets 4 and are used in particular to close off at least two sides.

[0060] By means of what are known as headers 7 which are provided with nozzles 6, the process media A to E are supplied and discharged via feed and removal openings 9. In the inlet region of the passages 1, there are further structural sheets with what are known as distributor lamellae 2 (distributor fins), which ensure uniform distribution over the entire width of the passages 1. As seen in the direction of flow, further structural sheets with distributor lamellae 2 can be located at the end of the passage 1 and lead the process media A to E from the passages 1 into the header 7, where they are collected and withdrawn via the corresponding nozzles 6.

[0061] A heat exchanger block 20, which is cuboid in this case, is formed overall by the structural sheets with the lamellae 3, the further structural sheets with the distributor lamellae 2, the side bars 8, the separating sheets 4 and the cover sheets 5, wherein a heat exchanger block is to be understood here as the stated elements without the headers 7 and nozzles 6 in an interconnected state. As not illustrated in FIG. 1, the plate heat exchanger 100 can, in particular for manufacturing reasons, be formed from a plurality of corresponding cuboidal and interconnected heat exchanger blocks 20.

[0062] Corresponding plate heat exchangers 100 are brazed from aluminum. The individual passages 1, comprising the structural sheets with the lamellae 3, the further structural sheets with the distributor lamellae 2, the cover sheets 5 and the side bars 8, are in this case each provided with solder, stacked one on top of the other or arranged accordingly, and heated in an oven. The header 7 and the nozzles 6 are welded onto the heat exchanger block 20 produced in this way. The headers 7 are produced using half-cylindrical extruded profiles, which are brought to the required length and are then welded onto the heat exchanger block 20.

[0063] FIG. 2 schematically shows a process engineering facility 200 that can be managed in accordance with one embodiment of the present invention.

[0064] The process engineering facility 200 can, for example, be designed as an air separation facility or a facility for separating mixtures of substances based on physical properties. The process engineering facility 200 comprises a plurality of heat exchangers 210, each of which is designed, for example, as an aluminum plate heat exchanger PFHE 100 shown in FIG. 1 and each of which comprises a plurality of heat exchanger blocks 20. Furthermore, the facility 200 can also comprise other heat exchangers, for example, each of which can also be designed as a coil-wound heat exchanger. The process engineering facility 200 also comprises further components, e.g., a column 230. For reasons of clarity, only one such further component 230 is displayed in FIG. 2, but it is understood that the facility 200 can comprise a plurality of other different components. It is further understood that the facility 200 can also comprise a larger or smaller number of heat exchangers 210.

[0065] A plurality of sensors 220 are arranged in and on each of the individual plate heat exchangers 210, for example temperature sensors, pressure sensors and flow sensors, in order to detect corresponding physical properties of the particular heat exchanger material and the particular process media. For reasons of clarity, FIG. 2 shows three sensors 220 for each heat exchanger 210. However, it will be understood that each heat exchanger 210 can also comprise a greater or lesser number of sensors 220 in each case, and furthermore can also comprise other types of sensors in each case, for example sound sensors, vibration sensors, etc.

[0066] The sensors 220 arranged in and on the heat exchangers 210 are connected to a local network 201 of the facility 200, which is indicated by dashed lines in FIG. 2. A central controller 240 for controlling and regulating the facility 200 is connected to the individual facility components via the local network 201. The measured values detected by the sensors 220 are transmitted to the controller 240 via the network 201 and stored there. Furthermore, a computer 250 is connected to the network 201, by means of which an operator or user, who may be located in the facility 200 or in the immediate vicinity thereof, can manage the facility 200.

[0067] The controller 240 and the computer 250 are connected via the Internet 205 to a remote computing system 260 in the course of so-called cloud computing. Furthermore, a computer 270 is connected to this cloud 260 via the Internet 205, via which, for example, a manufacturer or owner of the facility 200, who may be located at a great distance from the facility 200, can also manage the facility 200. In each case, such Internet connections are indicated as dotted lines in FIG. 2.

[0068] In order to be able to manage the facility with the aid of the computers 250, 270, a graphical user interface is provided in accordance with one embodiment of the present invention. For this purpose, the computing system 260 is configured, in particular in terms of program technology, to perform an embodiment of a method according to the invention.

[0069] In the course of this, the sensor values detected by the sensors 220 and stored in the controller 240 are transferred from the controller 240 to the computing system 260 via the Internet 205. These sensor values comprise, for example, temperature values of fluid flows within the heat exchanger blocks of the individual heat exchangers 210 and temperature values of the walls of the heat exchanger blocks of the individual heat exchangers 210.

[0070] On the basis of these received sensor values, the computing system 260 determines parameters that identify or characterize the operation of the heat exchangers 210. At least one temperature difference between the heat exchanger blocks of the individual heat exchangers 210 is determined as such parameters. Furthermore, as such parameters, for example, a temperature difference within the individual heat exchangers 210, a temperature difference between fluid flows within the individual heat exchangers 210, a temperature difference between the fluid flows and heat exchanger blocks of the individual heat exchangers 210, a rate of cooling processes and warming processes of the individual heat exchangers 210, a local temperature profile and a temporal temperature profile within the individual heat exchangers 210 and a mechanical stress level and a thermal stress level of the individual heat exchangers 210 can be determined. Furthermore, as parameters, it can be determined, for example, whether the operation of the individual heat exchangers 210 deviates from predefined guidelines.

[0071] The sensor values and parameters are graphically processed by the computing system 260 for a display of a state of the heat exchangers 210. As such a state, a service life of the individual heat exchangers 210 is determined on the basis of the determined temperature difference between the particular heat exchanger blocks of the individual heat exchangers 210. The computing system 260 further determines a graphical display of this service life of the individual heat exchangers 210.

[0072] Furthermore, the computing system 260 can determine as the state a change or a consumption of the service life of the individual heat exchangers 210 on the basis of the particular temperature differences. For example, in the course of processing, a graphical display of this change in the remaining service life of the individual heat exchangers 210 can be determined on the basis of the temperature differences of the particular heat exchanger blocks, furthermore in particular on the basis of operating conditions of the particular heat exchanger 210. Thus, a service life monitor can be configured, for example.

[0073] Furthermore, the computing system 260 can determine as such a state, for example, the current performance of the individual heat exchangers 210 along with a history or a temporal profile of the performance and service life of the individual heat exchangers 210.

[0074] For example, in the course of this processing, a graphical display of a temporal profile of individual sensor values and parameters can also be determined, on the basis of the points in time at which the particular sensor values were determined. For example, two-dimensional diagrams can be generated for this purpose, in which the particular sensor value or the particular parameter is plotted against time. For example, diagrams of the temperature values detected as sensor values and the temperature differences determined as parameters can be determined, each plotted against time.

[0075] Furthermore, a graphical display of a local profile of individual sensor values and individual parameters can be determined in the course of processing, on the basis of positions within the particular heat exchanger 210 at which the particular sensor values were determined. For example, two-dimensional diagrams can be generated for this purpose, in which the particular sensor value or the particular parameter is plotted against the length of the particular heat exchanger. For example, such two-dimensional graphs of the detected temperature values and the determined temperature differences can each be plotted against the length of the particular heat exchanger.

[0076] Furthermore, a multi-dimensional profile of individual sensor values and parameters can be determined in the course of processing, on the basis of the points in time at which the particular sensor values were determined and on the basis of the position within the particular heat exchanger at which the particular sensor values were determined. For example, three-dimensional diagrams can be generated, in which the detected temperatures or the determined temperature differences are each plotted against time and against the length of the particular heat exchanger.

[0077] Furthermore, a graphical display of the performance of the individual heat exchangers 210 can be determined in the course of processing, for example. For example, current sensor values and parameters that characterize the performance or effectiveness of the individual heat exchangers 210 can be displayed for this purpose.

[0078] Furthermore, a graphical display of a hazard analysis of the individual heat exchangers can be determined in the course of processing. For example, alarm messages that have been output can be displayed, along with the circumstances that led to these alarms being sent.

[0079] Furthermore, a graphical display of cooling processes (cool-down) and warming processes (warm-up, startup) of the individual heat exchangers 210 can be determined in the course of processing. For example, cooling rates of the individual heat exchangers 210 can be displayed in the course of this.

[0080] Furthermore, a graphical display of the thermal expansion of the individual heat exchanger blocks can be determined in the course of processing. For example, each heat exchanger block can be graphically displayed in a regular idle state for this purpose and it can be displayed how the particular heat exchanger block is thermally deformed during its operation compared to this idle state. For example, a local, spatial profile of a temperature gradient of the particular heat exchanger block can be displayed along the three spatial directions.

[0081] The sensor values and parameters processed in this manner are output by the computing system 260 in a graphical user interface. In the course of this, at least the graphical display of the service life of the individual heat exchangers 210 is output in the graphical user interface. For this purpose, a graphical user interface is generated centrally and uniformly by the computing system 260 and corresponding data are transmitted via the Internet 205 to the computers 250, 270, so that this user interface can be displayed uniformly on screens of the computers 250, 270.

[0082] In this graphical user interface or user interface, the operation of the individual heat exchangers 210 is managed, wherein at least the service life of the individual heat exchangers 210 is monitored. For this purpose, the correspondingly processed sensor values and parameters, i.e., the two- and multi-dimensional diagrams etc. described above, are output in the user interface. Based on this processed and displayed information, the facility owner and the facility manufacturer can monitor and analyze the individual heat exchangers 210, e.g., with regard to their state, performance, effectiveness, service life, etc.

[0083] On the basis of these analyses, improved operating states or control values can be determined, for example, according to which the heat exchangers are to be operated in future in order to increase their service life and performance. These new control values, e.g., new target values, can be input by the facility owner and facility manufacturer in the user interface displayed on the particular computer 250, 270. These inputs are transmitted from the user interface or from the computing system 260 executing the user interface to the controller 240, so that this controller 240 controls the individual heat exchangers 210 accordingly.

[0084] FIG. 3 schematically shows a graphical user interface or user interface 300 in accordance with an embodiment of the invention, as it can be centrally executed by the computing system 260 and uniformly displayed on the computers 250, 270.

[0085] For example, the current state of the facility 200 can be displayed on a start or overview page 310 in the user interface 300. This overview page 310 can comprise a plurality of display surfaces or display panels 311, 312, 313, 314, in which the remaining service life of the individual heat exchangers 210 and also, for example, a current overall state of the facility 200, a current operating temperature of the facility 200, a temporal temperature difference and a local temperature difference can be displayed.

[0086] Furthermore, buttons 320 are displayed in the user interface 300. By actuating or clicking individual buttons, for example, further display surfaces are opened, in which individual processed sensor values or parameters are displayed.

[0087] For example, the two-dimensional diagrams of the detected temperature values and the determined temperature differences of the individual heat exchanger blocks can each be displayed plotted against time by actuating the button 321.

[0088] By actuating the button 322, for example, the two-dimensional diagrams of the detected temperature values and the determined temperature differences of the individual heat exchanger blocks can be displayed, each plotted against the length of the particular heat exchanger.

[0089] By actuating the button 323, for example, the three-dimensional diagrams of the detected temperatures and the determined temperature differences of the individual heat exchanger blocks can be displayed, each plotted against time and against the length of the particular heat exchanger.

[0090] Furthermore, by actuating the button 324, for example, an input field or input panel can be opened, in which inputs can be undertaken, which are then passed on to the controller 240 for controlling the facility 200.

[0091] The invention thus provides a central, uniform user interface 300 in order to monitor and manage online the operation of the individual heat exchangers 210 of the process engineering facility 200, to display information with respect to the operation and characteristics of the individual heat exchangers 210, to influence the operation of the facility 200 on the basis of this information, and to increase the effectiveness and service life of the individual heat exchangers 210.