Detect Heat Exchanger Fouling Before It Impacts Production
Problem
Undetected fouling reduces heat transfer efficiency and increases energy costs
Solution
Real-time fouling monitoring using thermal performance tracking
The Problem
Heat exchanger fouling is inevitable in oil and gas processing, but detecting it early is challenging. By the time operators notice temperature or pressure issues, heat transfer efficiency has already dropped 20-30%, increasing fuel gas consumption and potentially limiting production rates.
Scheduled cleaning based on fixed intervals often means cleaning too early (wasting downtime) or too late (losing efficiency).
The Approach
Continuous Thermal Performance Monitoring:
- Calculate Real-Time U-value: Track overall heat transfer coefficient using inlet/outlet temperatures and flow rates
- Trend Analysis: Compare current performance against clean-exchanger baseline
- Automated Alerts: Trigger maintenance notifications when U-value drops below threshold
- Predictive Scheduling: Optimize cleaning timing based on actual fouling rates
This can be implemented using existing DCS/SCADA data with simple calculations—no additional sensors required.
Results
Facilities implementing fouling monitoring see:
- 10-15% energy savings through optimized operation
- Reduced downtime from predictive vs. reactive maintenance
- Extended run length between cleanings by 20-30%
- Better planning for turnaround activities
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