Description:
Title of The Invention
IoT Enabled System of Monitoring & Performance Predictive Maintenance of Heat Exchanger
Field of the Invention
This invention relates to IoT Enabled System of Monitoring & Performance Predictive Maintenance of Heat Exchanger

Background of the Invention
The industrial effluent is a hot fluid which leads to destruction of turbines by which several issues occurs. Heat-exchanger is used which transfer to heat from high temperature fluid to low temperature fluid. In the present work, IoT based system is develop (used) for performance monitoring and to predict maintenance before breakdown. The temperature, pressure, vibration and heat flux sensors are installed in the heat-exchanger which are used to transfer the signal to processor, which displayed the real time condition of heat-exchanger and it monitors the rate of heat transfer and also predict the maintenance of heat-exchanger with the help of algorithm. This technology will help to reduce the breakdown time and help to maintain better heat transfer rate.
US10962302B2 A plant or refinery may include equipment such as reactors, heaters, heat-exchangers, regenerators, separators, or the like. Types of heat-exchangers include shell and tube, plate, plate and shell, plate fin, air cooled, wetted-surface air cooled, or the like. Operating methods may impact deterioration in equipment condition, prolong equipment life, extend production operating time, or provide other benefits. Mechanical or digital sensors may be used for monitoring equipment, and sensor data may be programmatically analyzed to identify developing problems. For example, sensors may be used in conjunction with one or more system components to detect and correct maldistribution, cross-leakage, strain, pre-leakage, thermal stresses, fouling, vibration, problems in liquid lifting, conditions that can affect air-cooled exchangers, conditions that can affect a wetted-surface air-cooled heat-exchanger, or the like. An operating condition or mode may be adjusted to prolong equipment life or avoid equipment failure.
Research Gap: The present disclosure provides the real-time performance of heat exchanger and transferring the real-time data to control room with the help to data can be reduce the breakdown time and detect the fouling, leakage, vibration with the help of sensors. By using data can be predict the maintenance and data can be save in cloud server. This work will help to improve production operating time. Which help in the data analyzing.
KR101810767B1 The high heat efficiency of the heat-exchanger is improved, and the high-temperature hot water flow at the time of resuming operation accompanying the post-boiling phenomenon is suppressed.
A plurality of heat transfer fins made of stainless steel metal and arranged side by side in the vertical direction between the side walls and of the moving body having the openings and at the upper and lower sides, An upper notch portion formed between the upper and lower tube holes and and the upper tube insert hole and a lower end portion formed between the lower tube insert holes, And an upper notch portion is provided at an upper end portion of the upper end portion from the upper end portion to the upper end portion of the lower end side pipe insertion hole. And the lower notch portion is formed to extend from the lower end portion of the pin to the lower end of the heat transfer pipe insertion hole. The lower end of the lower end portion of the heat transfer pipe insertion hole is connected to the lower end of the heat transfer pipe insertion hole, And the lower edges of the two side edges are downwardly directed toward each other, It is formed.
Research Gap: The present disclosure provides IoT performance monitoring and predict maintenance of heat exchanger with the help of machine learning algorithm which reduce the breakdown time and detect the fouling, leakage, vibration. This work will help to improve production operating time. This data can be saved in cloud server.
US10328408B2 A plant or refinery may include equipment such as reactors, heaters, heat-exchangers, regenerators, separators, or the like. Types of heat-exchangers include shell and tube, plate, plate and shell, plate fin, air cooled, wetted-surface air cooled, or the like. Operating methods may impact deterioration in equipment condition, prolong equipment life, extend production operating time, or provide other benefits. Mechanical or digital sensors may be used for monitoring equipment, and sensor data may be programmatically analyzed to identify developing problems. For example, sensors may be used in conjunction with one or more system components to detect and correct maldistribution, cross-leakage, strain, pre-leakage, thermal stresses, fouling, vibration, problems in liquid lifting, conditions that can affect air-cooled exchangers, conditions that can affect a wetted-surface air-cooled heat-exchanger, or the like. An operating condition or mode may be adjusted to prolong equipment life or avoid equipment failure.
Research Gap: The present disclosure provides IoT performance monitoring, heat flux and predict maintenance of heat exchanger, with the help of machine learning algorithm can be reduce breakdown time and detect the fouling, leakage, vibration. This work will help to improve production operating time. The data saved in cloud server.
US11480517B2 Disclosed is a methodology for determination and prediction of heat exchanger fouling, such as polymer fouling in the circulation loop that forms part of the heat exchanger system. The buildup of a polymer or other undesired material deposit in the heat exchanger provides a distinctive temperature signature (thermal gradient) on the surface of the heat exchanger asset, which is visualized using a thermographic camera. Coupling images (thermograms) from the camera with a machine learning algorithm identifies fouling and, with knowledge of the historical data of the asset and operating and ambient conditions, enables prediction of future fouling. The thermal images provide several types, or orders, of temperature information that are indicative of locations vulnerable to fouling. In one case, the method uses machine learning applied to time-based temperature change/gradient information to detect hidden polymer fouling in areas that form part of the heat exchanger asset
Research Gap: The present disclosure provides the real-time performance of heat exchanger and transferring the real-time data to control room which reduce the breakdown time and detect the fouling, leakage, vibration with the help of sensors in heat exchanger. By using data can predict the maintenance and data can be save in cloud server.
US10533814B2 A method for monitoring that includes the steps of: associating a monitoring module with a heat exchanger unit; operating the monitoring module whereby a microcontroller performs various tasks, and ultimately providing an indication; and taking an action based on the indication. The monitoring module includes an at least one sensor proximate to the cooling side. The module also includes a logic circuit having a microcontroller in operable communication with the at least one sensor.
Research Gap : The present disclosure provides the real-time performance of heat exchanger and transferring the real-time data to processor with the help of algorithm can be reduce breakdown time and detect the fouling, leakage, vibration. By using data can predict the maintenance and data can be save in cloud server.
US10295284B2 A computer-implemented method, environmental control system (ECS) for an aircraft, and system are provided. Air temperatures at the inlet and outlet of a ram air duct for an ECS are measured. Also, air temperatures at outlets from one or more heat exchangers arranged in the ram air duct are measured. The temperatures are typically measured when the aircraft is on the ground and when aircraft engines supplying air to the ECS are operating at idle. Shortly thereafter, the heat exchangers are manually inspected to determine a level of actual fouling (e.g., dirt, dust, or other debris accumulated on heat exchanger surfaces). A supervised machine learning or other statistical analysis is performed on the measured temperatures and associated actual fouling levels to develop a model that predicts an amount of heat exchanger fouling, based on the temperature measurements. An alert can be output if the predicted fouling exceeds a fouling threshold.
Research Gap: The present disclosure provides the real-time performance monitoring in heat exchanger and transferring the real-time data to processor which help to reduce the breakdown time and detect the fouling, leakage, vibration with the help of sensors in heat exchanger. By using data can predict the maintenance and data can be save in cloud server.
US10328408B2 In accordance with an embodiment of the invention, there is provided a method of warming a heat-exchanger array of a very low temperature refrigeration system, the method comprising diverting at least a portion of refrigerant flow in the refrigeration system away from a refrigerant flow circuit used during very low temperature cooling operation of the refrigeration system, to effect warming of at least a portion of the heat-exchanger array; and while diverting the at least a portion of refrigerant flow, preventing excessive refrigerant mass flow through a compressor of the refrigeration system.
Research Gap: The present disclosure provides the real-time performance of heat exchanger and transferring the real-time data to processor which help to reduce the breakdown time and detect the fouling, leakage, vibration with the help of IoT system in heat exchanger. By using data can predict the maintenance and data can be save in cloud server.

None of the prior art indicate above either alone or in combination with one another disclose what the present invention has disclosed. Present invention is IoT Enabled System of Monitoring & Performance Predictive Maintenance of Heat Exchanger

SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
The cost and performance of the heat-exchanger are directly impacted by the maintenance not being done at the time, which is a major concern. So, the real-time monitoring system helps in problem detection in that real-time, which encompasses IoT technology with the help of processor and using machine learning algorithm we can predict future maintenance of heat exchanger. Four type sensors are used in this system: a temperature sensor, a heat flux sensor, a vibration sensor, and a pressure sensor. This technology helps improve heat-exchanger condition by sending real-time performance's information to the control room, which then takes the appropriate action for process development.
Detailed Working of the Proposed System:
Following is the detailed working of the proposed system to display real time monitoring system and collect the data for prediction blind bends.
Detailed operation of Proposed System:
To monitor & maintenance in the heat exchanger, a device is proposed which is a real-time monitoring system and provide alert to the concerned authority regarding any fault. The proposed system comprises of:
[101- 105] Heat Exchanger Module: These are the integral part of the machine Monitoring Unit, where more than one sensor based on the variables that needs to be monitored as per the rated values by the equipment manufacturer. For a Rotating Machine element / Component in service the following sensor used are [111] Vibration sensor, [112] Heat Flux Sensor,[113] Flow meters , [114] Pump RPM sensor, [115] Heat Exchanger Conductivity, [116] Machine Run Time, [117] Ambient Temperature Sensor, [118] Hot & Cold Fluid Temperature Sensor,[119] Decibel Sensor.
[120]. Keyboard: It is a user interface used to feed the Rated Device values as per the prescribed values from the manufacturer. These values are the values specific to the Machine / Structure component under test Like the Input / Output requirement for which the system is suppose to work, Types of load for which the system is designed, Materials specific to the test component etc.
[121] Control Unit: All the sensors employed give their respective inputs to this device. Along with the inputs from the sensors it also receives the data from a user entered Rated Values of the Device.
[122] Power Supply 1: This is the power supply unit for the Machine Monitoring Unit which fulfils the power requirements of all the sensors, Keyboard, RF Modem as well as Computing unit.
[123-124] RF Modem-1: This is used to transmit data from the control unit to a Local Controller for further data processing.
[125] Microcontroller: These are the units employed for multiple locations of the same machine / structure for a holistic analysis of the Machine/Structure. Each of these units consists parts from [111-119] which are the sensors or the input feeds
[106] Local Controller: It comprise of [124] RF Modem which receives the signals from the nearby machine monitoring units, [125] Microcontroller collects the data from RF Modem and stores in [126] Data Storage Device, then gives the modified output through a [127] Wi Fi Modem to Cloud Server.
[128] Power Supply -2: It fulfills the power requirement of all the components of Local Controller i.e. [124], [125], [126] and [127].
The data from the local Controller is feed to the [107] Cloud Server which in turn transmit the data to [108] Android based application and [109] Web based application so as to monitor the condition of the machine from a remote location and take the necessary action for the machine maintenance [110].
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
Fig. 1. Iot Enabled Proposed System For Heat Exchanger Maintenance Prediction System
Fig. 2. Components Of A Heat Exchanger Module
Fig. 3. Components Of A Local Controller
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
The cost and performance of the heat-exchanger are directly impacted by the maintenance not being done at the time, which is a major concern. So, the real-time monitoring system helps in problem detection in that real-time, which encompasses IoT technology with the help of processor and using machine learning algorithm we can predict future maintenance of heat exchanger. Four type sensors are used in this system: a temperature sensor, a heat flux sensor, a vibration sensor, and a pressure sensor. This technology helps improve heat-exchanger condition by sending real-time performance's information to the control room, which then takes the appropriate action for process development.
Detailed Working of the Proposed System:
Following is the detailed working of the proposed system to display real time monitoring system and collect the data for prediction blind bends.
Detailed operation of Proposed System:
To monitor & maintenance in the heat exchanger, a device is proposed which is a real-time monitoring system and provide alert to the concerned authority regarding any fault. The proposed system comprises of:
[101- 105] Heat Exchanger Module: These are the integral part of the machine Monitoring Unit, where more than one sensor based on the variables that needs to be monitored as per the rated values by the equipment manufacturer. For a Rotating Machine element / Component in service the following sensor used are [111] Vibration sensor, [112] Heat Flux Sensor,[113] Flow meters , [114] Pump RPM sensor, [115] Heat Exchanger Conductivity, [116] Machine Run Time, [117] Ambient Temperature Sensor, [118] Hot & Cold Fluid Temperature Sensor,[119] Decibel Sensor.
[120]. Keyboard: It is a user interface used to feed the Rated Device values as per the prescribed values from the manufacturer. These values are the values specific to the Machine / Structure component under test Like the Input / Output requirement for which the system is suppose to work, Types of load for which the system is designed, Materials specific to the test component etc.
[121] Control Unit: All the sensors employed give their respective inputs to this device. Along with the inputs from the sensors it also receives the data from a user entered Rated Values of the Device.
[122] Power Supply 1: This is the power supply unit for the Machine Monitoring Unit which fulfils the power requirements of all the sensors, Keyboard, RF Modem as well as Computing unit.
[123-124] RF Modem-1: This is used to transmit data from the control unit to a Local Controller for further data processing.
[125] Microcontroller: These are the units employed for multiple locations of the same machine / structure for a holistic analysis of the Machine/Structure. Each of these units consists parts from [111-119] which are the sensors or the input feeds
[106] Local Controller: It comprise of [124] RF Modem which receives the signals from the nearby machine monitoring units, [125] Microcontroller collects the data from RF Modem and stores in [126] Data Storage Device, then gives the modified output through a [127] Wi Fi Modem to Cloud Server.
[128] Power Supply -2: It fulfills the power requirement of all the components of Local Controller i.e. [124], [125], [126] and [127].
The data from the local Controller is feed to the [107] Cloud Server which in turn transmit the data to [108] Android based application and [109] Web based application so as to monitor the condition of the machine from a remote location and take the necessary action for the machine maintenance [110].
Advantages of the Invention
1. This is a robust system designed for conditioning monitoring of the machines while they are operating.
2. The design facilitates to monitor the equipment from any remote location.
3. The equipment is equipped with alarming system which automatically actuates if there is any differences recorded in the characteristic curves from the previous.
4. The specialty of this equipment is that, it shows the service requirement on the dashboard to avoid any unnecessary shutdown of the equipment.
5. The foremost advantage of the system is it facilitates real time monitoring from any location as the data is accessible from web or android device. , Claims:We Claim:
1. An IoT Enabled System of Monitoring & Performance Predictive Maintenance of Heat Exchanger Heat Exchanger Module-1 (101), Heat Exchanger Module-2 (102), Heat Exchanger Module-3 (103), Heat Exchanger Module-4 (104), Heat Exchanger Module-5 (105), Local Controller (106), Cloud Server (107), Android Application (108), Web Application (109),Data From The Android/ Web Application Is Analyzed To Determine The Performance And Need For Maintenance Based And Recommendations Are Updated On The Android/Web Application For Necessary Actions. (110), Vibration Sensors (111), Heat Flux Sensors (112), Flow Meters (Hot & Cold Fluid ), Pump RPM Sensors ), Heat Exchanger Conductivity Sensors (115), Machine Run Time Meter (116), Ambient Temperature Sensor (117), Hot &Cold Fluid Temperature Sensors (118), Decibel Sensors (119), Keyboard (120), Control Unit (121), Power Supply (122), RF Modem (123), Local Controller (106), RF Modem (124), Microcontroller (125), Data Storage (126), Wi-Fi Modem (127), and Power Supply (128).
2. The system as claimed in claim 1, wherein [101- 105] Heat Exchanger Module are the integral part of the machine Monitoring Unit, where more than one sensor based on the variables that needs to be monitored as per the rated values by the equipment manufacturer; and Rotating Machine element / Component in service the following sensor used are [111] Vibration sensor, [112] Heat Flux Sensor,[113] Flow meters , [114] Pump RPM sensor, [115] Heat Exchanger Conductivity, [116] Machine Run Time, [117] Ambient Temperature Sensor, [118] Hot & Cold Fluid Temperature Sensor, and [119] Decibel Sensor.
3. The system as claimed in claim 1, wherein [120] Keyboard is a user interface used to feed the Rated Device values as per the prescribed values from the manufacturer; and said values are the values specific to the Machine / Structure component under test Like the Input / Output requirement for which the system is supposed to work, Types of load for which the system is designed, Materials specific to the test component.
4. The system as claimed in claim 1, wherein [121] Control Unit all the sensors employed give their respective inputs to this device. Along with the inputs from the sensors it also receives the data from a user entered Rated Values of the Device.
5. The system as claimed in claim 1, wherein [122] Power Supply is the power supply unit for the Machine Monitoring Unit which fulfils the power requirements of all the sensors, Keyboard, RF Modem as well as Computing unit.
6. The system as claimed in claim 1, wherein [123-124] RF Modem-1 is used to transmit data from the control unit to a Local Controller for further data processing.
7. The system as claimed in claim 1, wherein [125] Microcontroller are the units employed for multiple locations of the same machine/structure for a holistic analysis of the Machine/Structure. Each of these units consists parts from [111-119] which are the sensors or the input feeds.
8. The system as claimed in claim 1, wherein [106] Local Controller comprise of [124] RF Modem which receives the signals from the nearby machine monitoring units, [125] Microcontroller collects the data from RF Modem and stores in [126] Data Storage Device, then gives the modified output through a [127] Wi Fi Modem to Cloud Server.
9. The system as claimed in claim 1, wherein [128] Power Supply fulfills the power requirement of all the components of Local Controller [124], [125], [126] and [127].
10. The system as claimed in claim 1, wherein the data from the local Controller is feed to the [107] Cloud Server which in turn transmit the data to [108] Android based application and [109] Web based application so as to monitor the condition of the machine from a remote location and take the necessary action for the machine maintenance [110].