Predicting Fouling Factor

In Heat Exchanger


Heat Exchanger:- 

heat exchanger is a device used to transfer heat between a solid object and a fluid, or between two or more fluids. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact.



Typical Operational Issues in Heat Exchangers 

  • Exchanger Fouling: Fouling occurs when any type of particles both organic or inorganic deposits on heat transfer surfaces creating a resistance to energy exchange between hot and cold fluid
  • Corrosion: Corrosion due to the salt and acidic nature affects the tubes & may lead to tube leakage affecting the integrity of the exchanger.
  • Vibration: Vibration of the tubes may get caused because of flow disturbances.



Business Impact

  • In these exchangers, the overall heat transfer coefficient reduces significantly during operation due to fouling.
  • The rate of fouling is highly dependent on the properties of the crude blends being processed as well as the operating temperature and flow conditions.
  • Thus, leading to decreased energy efficiency of the crude train and the need for maintenance intervention by cleaning, affecting the availability of the crude train.


Defour’s Predictive Model

By developing a predictive model using advanced analytics methods which can predict the rate of Fouling and forecast the cleaning cycles required. A solution that can manage & ensure availability of Heat exchanger in case of fouling

  • Predictive modeling of fouling factor by using advance analytics
  • Proactive planning of maintenance to reduce its impact on availability.
  • Maintain a proper heat duty for efficient operations. 


Defour’s Solution

  • The cleaning cases have been pre-programmed in advance supposing the heat exchangers can be one by one individually cleaned
  • Analytics can intelligently tell the maintenance dates which will not only avoid unplanned shut down but will give maximum utilization of parts before maintenance.