METHOD FOR MANAGING A PROCESS ENGINEERING FACILITY

Description

The invention relates to a method for managing a process engineering facility and a graphical user interface for managing a process engineering facility along with a computing system, a computer program and a machine-readable storage medium.

BACKGROUND OF THE INVENTION

Process engineering facilities are typically understood to mean facilities for performing substance changes and/or substance conversions with the aid of targeted physical and/or chemical and/or biological and/or nuclear action sequences. Such changes and conversions typically comprise crushing, sieving, mixing, heat transfer, rectification, crystallization, drying, cooling, filling and superimposed substance conversions, such as chemical, biological or nuclear reactions.

Heat exchangers, such as vacuum-brazed (aluminum) plate fin heat exchangers (PFHE) or coil-wound heat exchangers (CWHE), are often used in process engineering facilities based on a large number of advantages (heat integration, compactness, costs). For example, such a (plate) heat exchanger can comprise a plurality of separator plates or separating sheets arranged in parallel to one another and a plurality of lamellae (so-called fins) or structural sheets with lamellae, wherein one lamella each is arranged between two adjacent separator plates, so that a plurality of parallel channels are formed between adjacent plates, through which channels a medium can flow. Toward the sides, the lamellae are delimited by so-called sidebars, which are soldered to the adjacent plates. Through the interconnected structural sheets, sidebars, separating sheets and cover sheets, a heat exchanger block is formed as a whole. In this manner, a heat exchanger block is formed with a plurality of parallel heat transfer passages, so that media can, for example, be guided past one another in counterflow, in order to carry out an indirect heat exchange. A heat exchanger, in particular a plate heat exchanger (PFHE), can comprise a plurality of such heat exchanger blocks.

The aim is to be able to manage such a process engineering facility, for example to be able to operate the facility effectively.

DISCLOSURE OF THE INVENTION

Against this background, a method for managing a process engineering facility and a graphical user interface for managing a process engineering facility are proposed, along with a computing system, a computer program and a machine-readable storage medium with the features of the independent claims. Advantageous embodiments are the subject matter of the dependent claims and of the following description.

The process engineering facility comprises at least one heat exchanger. Each of these heat exchangers is in each case designed as a plate heat exchanger, e.g., as a vacuum-brazed (aluminum) plate fin heat exchanger (PFHE). Furthermore, each of these heat exchangers comprises a plurality of heat exchanger blocks. These individual heat exchangers are provided in the process engineering facility, in particular for heating or cooling a specific fluid or fluid flow. In addition to the plate heat exchangers, the process engineering facility can comprise other components, for example other heat exchangers of a different design (e.g., coil-wound heat exchangers, CWHE), columns (hollow, slim columns with internal structures), phase separation apparatuses (containers with internal structures), containers for phase separation, etc. For example, the process engineering facility can be a facility for separating and/or liquefying gases, for example an air separation facility, or generally a facility for separating mixtures of substances based on physical properties, a natural gas facility, a hydrogen and synthesis gas facility, an adsorption and membrane facility, e.g., a pressure swing adsorption facility, or a cryogenic facility, e.g., for cooling superconductors and cold neutron sources, MRIs, fusion and fission applications or in the liquefaction of helium and hydrogen.

Within the framework of the present method, sensor values or measured values or current actual values are received from sensors arranged on or in the at least one heat exchanger. These sensors can, for example, be installed on a surface of the particular heat exchanger or within the heat exchanger or protruding into the heat exchanger. In particular, the sensor values can characterize physical/chemical properties of the heat exchanger itself or its operation, e.g., its material or a fluid passing through the heat exchanger. The sensor values expediently describe the current temperature values of individual or all heat exchanger blocks of the particular heat exchanger.

On the basis of these received sensor values, parameters (or key figures) are determined, which identify or characterize the operation of the at least one heat exchanger. These parameters can, for example, directly describe a current state or current physical conditions of the at least one heat exchanger or at least allow conclusions to be drawn about such properties. One such parameter can be a key performance indicator (KPI), for example, using which, for example, progress or degrees of achievement with respect to predefined goals can be evaluated.

A temperature difference between heat exchanger blocks of the at least one heat exchanger is determined as such a parameter. For example, measured temperature values on the surface of the individual heat exchanger blocks or measured temperature values within the individual heat exchanger blocks can be taken into account for this purpose. Expediently, temperature differences are determined between immediately adjacent heat exchanger blocks that are mechanically connected to one another and/or are in fluid communication with one another. Expediently, a plurality of temperature differences between a plurality of adjacent heat exchanger blocks can also be determined as a parameter. Furthermore, it is expedient to determine additional parameters from other sensor values.

The received sensor values and/or the determined parameters are processed for a graphical display of the state of the at least one heat exchanger. In particular, this state can characterize the operation of the at least one heat exchanger, e.g., effectiveness, performance, etc. For example, the state can be a current state and thus in particular characterize the current operation of the particular heat exchanger. Furthermore, the state can also be a past state and in particular characterize the operation of the at least one heat exchanger in the past. Furthermore, the state can also be a future state, for example extrapolated from the current and/or past state.

The sensor values or parameters are processed in particular in such a way that (operationally) relevant information with respect to the state, which is important for the operation of the particular heat exchanger and also for the operation of the entire facility, can be extracted or recognized in a simple and clear manner. The display of the state can be an audiovisual display of the particular state, in particular a graphical or visual and/or an acoustic display. For example, the display can comprise a visual display of individual sensor values and/or parameters in a two-dimensional or multi-dimensional graph, e.g., as an image file or as an interactive, editable graphic. Furthermore, the display can comprise, for example, an acoustic display, e.g., with the aid of audio files, e.g., an acoustic output of individual sensor values or parameters, an output of warning tones, etc.

At least one service life or a remaining service life 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. Furthermore, a graphical display of this service life of the at least one heat exchanger is determined. For example, the service life can be determined or extrapolated from the sensor values or parameters with the aid of analytical, numerical or statistical methods, e.g., with the aid of theoretical simulations.

Temperature differences between heat exchanger blocks can have direct, immediate but also indirect effects on the service life of the particular heat exchanger. Large temperature differences between the individual heat exchanger blocks can lead to high loads on the material of the blocks, in particular to high mechanical stresses. For example, with large temperature differences, high loads can be placed on connecting pipes or connecting elements between individual heat exchanger blocks. Such high loads can lead to the deformation, wear, fatigue and weakening of the material of the blocks. Consistently high temperature differences and frequently changing temperature differences can further increase such loads. Thus, large or changing temperature differences between heat exchanger blocks of a particular heat exchanger can have a negative effect on the service life of the heat exchanger.

To determine the service life, for example, an original service life can be taken into account, which was determined, estimated or assessed after the heat exchanger was produced or commissioned for the first time, along with an operating time that has already elapsed since the heat exchanger was commissioned for the first time. on the basis of the current temperature differences between heat exchanger blocks, for example, corresponding mechanical stresses and loads on the heat exchanger material can be determined and corresponding effects on the service life or a corresponding reduction in the service life can be extrapolated, estimated or calculated. For example, analytical, numerical or statistical calculations and/or simulations can be performed for this purpose. In this manner, the current remaining service life of the heat exchanger can be determined as the state of the particular heat exchanger, expediently on the basis of the original service life, on the basis of the previous total operating time and on the basis of the effects of temperature differences.

The determined service life can be expediently processed for the graphical display in such a way that the remaining service life can be easily and traceably extracted or recognized. For example, in addition to the current determined service life, a history of the service life can also be displayed. Thus, it can particularly be easily traced how the estimated remaining service life has developed or changed during the previous operation. In this manner, it can be particularly easily traced which events, operating states and temperature differences significantly affect the remaining service life.

Due to this graphical display of the service life, for example, a service life tracker or service life monitor can be provided, which makes possible the display of service life consumption based on the operating conditions of the facility, a prediction of the remaining service life, and, for example, also a histogram display of the thermal and/or mechanical cycles and the thermal fatigue of the individual heat exchangers. For example, using such a service life monitor, recommendations for maintenance and/or replacement measures can be made, wherein, for example, delivery times for components to be replaced or installed can be taken into account.

The processed sensor values and/or parameters are output or displayed in a graphical user interface. In the course of this, the graphical display of the service life of the at least one heat exchanger is output in the graphical user interface. This graphical user interface represents in particular a human-machine interface, an input and output interface, a user interface or an (information management) dashboard. In particular, this user interface is a software tool for interacting with the facility in order to output information relevant to the operation and management of the facility and also to make it possible to influence the operation of the facility.

For example, the graphical user interface can be output by a computing unit, for example a PC, a laptop, a tablet, a control unit, etc. The graphical user interface is particularly expedient as a central, standardized interface. The graphical user interface or the software on which the graphical user interface is based is executed particularly expediently by a central computing unit or a central computing system, e.g., by a server or a computing system in the course of so-called “cloud computing.” Thus, the underlying software does not expediently have to be executed on the computing unit itself that displays or outputs the graphical user interface, but can instead be executed centrally by a remote computing unit. The graphical user interface can thus be displayed uniformly and independently of one another on a plurality of different computing units. For example, the graphical user interface can be streamed by the particular computing unit from the central computing unit or displayed in browser-based form, e.g., as a (web) dashboard.

On the basis of these output, processed sensor values and/or parameters, the operation of the at least one heat exchanger is managed, monitored or controlled in the graphical user interface. Relevant information characterizing the operation of the particular heat exchanger can be read in the user interface and, based on this information, the current operation can be monitored and changes can be developed and undertaken in order to improve operation.

In the course of this management, the determined (in particular remaining) service life of the at least one heat exchanger is monitored or analyzed. Due to the graphical display of the service life output in the graphical user interface, the effects or changes in the service life can expediently be recognized and monitored. A recognized, in particular non-linear (e.g., exponential) reduction in service life, e.g., based on high temperature differences between the heat exchanger blocks, can be counteracted expediently, e.g., by adjusting operating parameters or operating points of the heat exchanger or the entire facility. For example, the service life consumption of the heat exchangers during past operating states can be traced in the graphical user interface and improvements for operation to increase the remaining service life can be developed.

The invention also relates to a corresponding graphical user interface, wherein advantages and advantageous embodiments of this graphical user interface according to the invention and of the method according to the invention result in a corresponding manner from the present description. The graphical user interface comprises at least one display surface, which is configured to output sensor values and/or parameters that have been received or determined and processed in accordance with the present method. The display surface is configured to output the graphical display of the service life of the at least one heat exchanger. These display surfaces or display panels make it possible to display the information relevant to the operation of the particular heat exchanger in an intuitive and clear manner. For example, in each case one or more such display surfaces can be provided for each heat exchanger. Alternatively or additionally, for example, in each case one or more such display surfaces can be provided for all processed sensor values and/or parameters.

The present invention provides a way to visualize the operation of the individual heat exchangers in the process engineering facility and to monitor and manage them online. For this purpose, the graphical user interface provides a central, standardized interface in order to display information with respect to the operation or properties of the heat exchangers, and in order to influence the facility and its operation on the basis of this information, in particular to improve the operation or effectiveness or performance of the facility, in order to reduce wear on the facility. Furthermore, on the basis of the information displayed, recommendations can be made for maintenance work, e.g., repairs, cleaning, replacement of components, etc., and optimal maintenance work can be predicted (“predictive maintenance”). Particularly expediently, the invention makes it possible to monitor the remaining service life and, in particular, to increase it, or at least not unnecessarily reduce it or counteract potential reductions in service life.

With the aid of the graphical user interface, it is made possible to combine, consolidate or synthesize hardware installed in the facility, in particular in the form of sensors or measuring equipment, and management, analysis, simulation and/or control software.

Expediently, the corresponding operationally relevant information can be made available in the graphical user interface as a central (web) dashboard to individual or all parties involved in the operation of the facility, for example a manufacturer, owner, operator, plant manager, supervisory board, external experts, specialists for technical advice, etc. With the aid of the user interface and its functionalities, facility owners, for example, have the opportunity to evaluate and improve the performance and service life of the heat exchangers. For example, with the aid of the graphical user interface, it can be made possible for a heat exchanger manufacturer to provide different product concepts, such as leasing contracts, performance guarantee contracts, heat transfer contracts, deliveries with extended warranties, free trial periods, and data loggers with the aid of the heat exchanger as a recording device that automatically transmits data to the manufacturer.

In particular, the central, graphical user interface makes it possible to provide operationally relevant information to locally widely distributed parties over large distances. For example, the particular information can be provided via the user interface both to the operator or owner of the process engineering facility, who may be located in the facility itself or in the immediate vicinity of it, and to parties far away from the facility, e.g., the manufacturer or owner of the facility, who may be located at a great distance from the facility, for example at a distant company headquarters.

The corresponding information or data can be transferred or exchanged between locally networked and remote units, for example. For example, the sensor values detected by the sensors installed in or on the heat exchangers can be transmitted via a local network in the process engineering facility to a local, central computing unit, e.g., a server of the facility from which the user interface is also executed or which is directly connected via the local network to a computing unit executing the user interface. Furthermore, the sensor values of the sensors can, for example, also be transmitted to a remote computing unit, e.g., a (company) server, or a remote computing system, such as a distributed computing system in the course of so-called “cloud computing,” in which the user interface itself is executed or to which in turn a computing unit executing the user interface is connected. For example, the sensor values can be transmitted directly from the sensors to such a remote computing unit or such a remote computing system, or also indirectly, for example by initially transferring the values to a local computing unit of the facility, which then transmits the sensor values to the remote computing unit or the remote computing system. Furthermore, such a local computing unit can also perform calculations, for example determining the parameters and/or processing the sensor values or the parameters. The corresponding data can then be transferred from the local computing unit to the cloud system and output by it in the graphical user interface. Due to one or more computing units, which are in each case connected to the computing unit executing the user interface, e.g., via a local (facility) network or the Internet, the graphical user interface can then be output and displayed on a screen in each case. The centrally executed graphical user interface can thus be displayed uniformly by a plurality of different, possibly locally widely distributed computing units.

With the aid of the graphical user interface, it can, for example, be made possible to visualize and track a history, in particular a history of the service life, and/or the performance of the individual heat exchangers of the facility. Furthermore, the operation of the individual heat exchangers can be designed transparently and improved. In the user interface, it can, in particular, be made possible to consolidate all relevant information and the history of the individual heat exchangers, track the history and provide easy remote access to information. Furthermore, for example, predictive maintenance based on information about the service life of the heat exchangers, an assessment of risks for further operation based on such information about the service life and an improvement of the facility operation can be made possible in order to avoid critical (operating) states that can cause high service life consumption, in particular high temperature differences and frequently changing temperature differences between the heat exchanger blocks, and in order to maximize the performance of the heat exchanger. For example, automatic measures, control loops, control loop tuning, facility automation, automation of startups, restarts, load changes, etc. can be undertaken. In addition, the performance of the facility and options for increasing performance can be visualized and evaluated.

In accordance with one embodiment, the state of the at least one heat exchanger is further determined as a change in the service life of the at least one heat exchanger on the basis of the determined temperature difference between the heat exchanger blocks. Furthermore, a graphical display of this change in service life is determined and the graphical display of the change in service life is output in the graphical user interface. In particular, a correlation can be established and visualized as to how temperature differences affect the remaining service life. For example, the mechanical stresses and loads on the heat exchanger material caused by the temperature differences can be determined for this purpose and the effects of these stresses and loads on service life can be determined. Furthermore, for the graphical display it is possible, for example, to show graphically how past temperature differences have affected and changed the particular remaining service life at that time. Expediently, with the aid of the graphical user interface, it is possible to monitor and examine over the long term how temperature differences between individual heat exchanger blocks affect the remaining service life of the heat exchanger. With the aid of the graphical user interface, an (operating) strategy can be developed in particular in order to avoid temperature differences that reduce the service life and to increase the service life of the heat exchanger or to reduce it as slowly as possible in order to achieve the best possible service life of the heat exchanger.

In accordance with one embodiment, managing the operation of the at least one heat exchanger further comprises determining a maintenance interval of the at least one heat exchanger and/or a maintenance work to be performed on the at least one heat exchanger on the basis of the graphical display of the service life output in the graphical user interface. For example, such maintenance work or the repair or replacement of individual components can be scheduled on the basis of the service life consumption, for example, expediently in order to increase the remaining service life as much as possible. For example, such maintenance intervals and maintenance work can be determined for components of the heat exchanger that are exposed to high loads due to temperature differences between the heat exchanger blocks.

In accordance with one embodiment, managing the operation of the at least one heat exchanger further comprises determining hazards for an operation or for the service life of the at least one heat exchanger on the basis of the graphical display of the service life output in the graphical user interface. For example, by analyzing the current and past states along with the corresponding service life consumption in the user interface, it can be recognized which specific operating states or temperature differences lead to increased loads, wear and service life consumption. Such states can then be avoided or such states can be counteracted.

In accordance with one embodiment, managing the operation of the at least one heat exchanger further comprises determining control values or operating conditions or operating parameters of the at least one heat exchanger, on the basis of the graphical display of the service life output in the graphical user interface, in order to avoid critical states which lead to a shortening of service life. By monitoring and analyzing the states, service life, etc. displayed in the user interface, it is possible, for example, to develop the best possible control values in order to operate the heat exchangers in the best possible operating states, so that the maximum possible service life can be achieved.

In accordance with one embodiment, the state of the at least one heat exchanger is further determined as the performance or current performance of the at least one heat exchanger and/or a history or a temporal profile of the at least one heat exchanger. The current performance of the particular heat exchanger can, for example, be determined analytically or numerically from the sensor values and/or parameters with the aid of physical equations. Alternatively or additionally, the parameters can also already directly characterize the current performance. The corresponding sensor values and/or parameters can be processed in such a way that the current performance can be displayed visually and/or acoustically in an intuitive and clear manner. The history of the at least one heat exchanger can, in particular, comprise a history or a temporal profile of the sensor values and/or the parameters and/or the performance. With the aid of the graphical user interface, for example, it is possible to switch flexibly between current values and past values, or to flexibly compare current and past values. For example, the graphical user interface can comprise a start or overview page, in which the performance, service life and history or the corresponding sensor values and/or parameters are displayed and/or can be selected for display. For example, this overview page can comprise a list or button in order to quickly display the relevant information about the heat exchanger operation and to track or visualize the history of the heat exchanger.

In accordance with one embodiment, 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 or acoustic sensor and/or vibration sensor. The measured values detected by these sensors relate in particular to physical properties of the material of the heat exchanger and/or the fluid flows passing through the heat exchanger. With the aid of the temperature sensors, for example, the temperatures of the fluid flows and the heat exchanger walls can be measured. With the aid of the pressure and flow sensors, for example, the pressure and flow rate of the individual fluid flows can be detected. With the aid of the sound and vibration sensors, vibrations in the heat exchanger walls in particular can be monitored. Furthermore, with the aid of the sensors and their sensor values, mechanical stresses in the heat exchanger can be directly detected or indirectly derived. Further expedient sensors can also be used, e.g., optical sensors such as cameras etc.

In accordance with one embodiment, one or more of the following variables are also determined as a parameter: 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 (“cool-down” rate/“warm-up” rate), 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 and/or a thermal stress level of the at least one heat exchanger. In particular, such parameters can be determined from temperature sensor values that are detected at different points in the heat exchangers. With the aid of such parameters, temperature profiles of the heat exchangers in particular can be described, which allow conclusions to be drawn about the operation and effectiveness of the heat exchangers and which also characterize the loads acting on the heat exchangers during their operation, which in turn allows conclusions to be drawn about the remaining service life or service life consumption.

Alternatively or additionally, a deviation of the operation of the at least one heat exchanger from a predefined (safety) guideline for the operation of the at least one heat exchanger and/or a deviation from a (safety) specification for the at least one heat exchanger are determined as a parameter in accordance with one embodiment. For example, such deviations can comprise sensor values and/or parameters leaving predefined, permissible ranges or reaching, exceeding or falling below predefined, permissible limit or threshold values. The occurrence of such deviations from (safety) guidelines or specifications can often trigger the output of alarm messages. For example, such alarm messages can also be taken into account as a parameter, e.g., a frequency or specific points in time at which such alarm messages are output.

In accordance with one embodiment, the processing of the sensor values and/or the parameters further comprises determining a graphical display of a temporal profile of individual sensor values and/or individual parameters on the basis of points in time at which the particular sensor values were determined. In particular, changes or trends in the individual sensor values or parameters can be traced during the operation of the heat exchangers. For example, the processing can comprise a visualization of relevant time series data, e.g., process-related data or data with respect to properties of the heat exchanger. Furthermore, the processing can comprise, for example, determining correlations of data or trends and also, for example, determining a correlation matrix, an indicator for fluctuations and outliers, etc.

In accordance with one embodiment, the processing of the sensor values and/or the parameters further comprises 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. In particular, the processing comprises a visualization of a local profile of the particular data, and in particular of predefined, intended or specified operating conditions. In particular, this makes possible a comparison between the actual operation and the predefined operating conditions. For example, it can be explicitly displayed if the current operation is outside the specified operating conditions. For example, the processing or visualization can comprise providing a slider function. For example, the processing can comprise determining a temperature range display, e.g., a visualization of a local temperature profile of the individual heat exchangers and the predefined operating conditions.

In accordance with one embodiment, the processing of the sensor values and/or the parameters further comprises 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. In particular, the temporal and local profiles of individual sensor values or parameters are visualized as a three-dimensional plot on the basis of time and location. For example, the temperature profile and the temperature gradient of a particular heat exchanger can be visualized as a three-dimensional plot along the length of the heat exchanger and over time. For example, by means of such plots, mechanical and/or thermal stress levels or mechanical and/or thermal loads during the operation of the heat exchanger can be traced. Furthermore, deviations from predefined or recommended guidelines or specifications can be visualized in these multi-dimensional graphs, e.g., deviations from guidelines in accordance with an operating manual or in accordance with predefined standards. With the aid of such multi-dimensional graphs, for example, an evaluation and improvement of heat exchanger operation in terms of service life and performance can be undertaken. Furthermore, a report functionality for retrospective evaluation for a determined period of time can be made possible, for example.

In accordance with one embodiment, the processing of the sensor values and/or the parameters further comprises determining a graphical display of the performance of the at least one heat exchanger. For example, individual parameters can be displayed that characterize the current performance and operation of the individual heat exchangers, along with, in particular, any output alarm messages, so that (operationally) relevant information can be quickly recognized. For example, parameters can be processed and displayed for this purpose, which describe a heat transferability (e.g., on the basis of a heat transfer coefficient, on a surface on which a heat exchange takes place and on a thermal conductivity), along with, for example, contamination, pressure drops, temperature bottlenecks, options for improving performance, etc.

In accordance with one embodiment, the processing of the sensor values and/or the parameters further comprises determining a graphical display of a hazard analysis of the at least one heat exchanger. For example, such a hazard analysis (HAZAN) can be performed to minimize risks to the thermal conditions of the heat exchangers. Risk minimization measures, e.g., alarms, control loops, etc., are expediently provided in the facility. Due to the graphical display of the hazard analysis, for example, a HAZAN overview dashboard can be provided, in which alarm messages and measures implemented in the facility to minimize risks from thermal loads can be summarized, and furthermore, for example, a report functionality can also be made possible to retrospectively evaluate a determined period of time.

In accordance with one embodiment, the processing of the sensor values and/or the parameters also comprises determining a graphical display of cooling processes (“cool-down”) and/or warming processes (“warm-up,” “startup”) of the at least one heat exchanger. In this manner, an overview dashboard for cooling and warming processes can be provided in the graphical user interface. For example, such a graphical display can provide a comprehensive overview of the individual heat exchangers, so that cooling and cooling rates can be easily traced. With the aid of this graphical display, it can further be made possible, for example, to improve the operation of the heat exchangers, create a report functionality for the retrospective evaluation of the cooling process, and add information with respect to the startup procedure to an operating manual.

In accordance with one embodiment, the processing of the sensor values and/or the parameters further comprises determining a graphical display of a thermal expansion of heat exchanger blocks of the at least one heat exchanger. For example, a local or spatial profile of a temperature gradient of the particular block can be displayed along the three spatial directions. Thus, in particular, an overview of block expansions and thermal states can be displayed in the graphical user interface. For example, a live view and video functionality can be made possible.

In accordance with one embodiment, managing the operation of the at least one heat exchanger further comprises monitoring or analyzing a current state and/or a future state and/or a past state of the at least one heat exchanger. For example, the state displayed in the graphical user interface, its displayed history and the displayed extrapolated state can be compared with predefined safety or operating guidelines. Thus, using the graphical user interface, it can be assessed whether the operation of the individual heat exchangers complies with permissible specifications or if there is potential for improvement.

In accordance with one embodiment, managing the operation of the at least one heat exchanger further comprises determining control values or operating conditions or operating parameters of the at least one heat exchanger in order to increase the performance of the at least one heat exchanger. By monitoring and analyzing the states, service life, etc. displayed in the user interface, it is possible, for example, to develop the best possible control values in order to operate the heat exchangers in the best possible operating states, so that maximum performance and effectiveness can be achieved.

In accordance with one embodiment, inputs are received in the user interface and the at least one heat exchanger is controlled on the basis of the received inputs. In accordance with one embodiment, the graphical user interface comprises at least one control surface or at least one control panel for this purpose, which is configured to receive inputs. The graphical user interface is configured to control the at least one heat exchanger on the basis of these received inputs. In particular, the inputs can be manual inputs made by the facility operator or facility owner. Thus, the user interface provides the option of undertaking manual inputs and influencing the heat exchangers directly. For example, control values or target values can be input via the control surface, which can then be transferred from the user interface to a controller, for example, which converts these control values or target values and controls the heat exchangers accordingly. For example, the user interface can comprise a functionality to visualize and trace the effects of the inputs undertaken or the corresponding changes to control values on the state, effectiveness and/or service life of the particular heat exchanger.

In accordance with one embodiment, each heat exchanger block comprises interconnected structural sheets and/or sidebars and/or separating sheets and/or cover sheets. For example, such a heat exchanger block can comprise a plurality of separating sheets or separator plates arranged in parallel to one another and a plurality of structural sheets with lamellae (so-called fins), wherein a structural sheet is arranged between each two adjacent separating sheets, so that a plurality of parallel channels are formed between adjacent sheets, through which channels a medium can flow. Toward the sides, the lamellae are delimited by sidebars, which are soldered to the adjacent plates. Through the interconnected structural sheets, sidebars, separating sheets and cover sheets, a heat exchanger block is formed as a whole.

A computing system in accordance with the invention, e.g., a server of a process engineering facility or a remote, distributed computing system in the course of so-called “cloud computing,” is configured, in particular in terms of program technology, to perform a method according to the invention. For this purpose, the computing system has, in particular, a graphical user interface in accordance with the invention, in particular centrally and uniformly.

Furthermore, the implementation of a method according to the invention in the form of a computer program or computer program product with program code for performing all process steps is also advantageous, because this incurs particularly low costs, in particular if an executing control unit is also used for other tasks and is therefore present anyway. Finally, a machine-readable storage medium is provided with a computer program stored on it as described above. Suitable storage media or data carriers for providing the computer program are, in particular, magnetic, optical, and electrical storage units, such as hard drives, flash memories, EEPROMs, DVDs and the like. A download of a program via computer networks (Internet, intranet, etc.) is also possible. Such a download can be carried out via a wired or cable-based connection or wirelessly (e.g., through a WLAN network, a 3G, 4G, 5G, or 6G connection, etc.).

Further advantages and embodiments of the invention arise from the description and the accompanying drawings.

The invention is schematically represented in the drawing using exemplary embodiments and is described below with reference to the drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

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.

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

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

EMBODIMENT(S) OF THE INVENTION

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.

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 “aluminum”can also denote an aluminum alloy.

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.

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 formed—in each case for one of the process media A to E—and which can thereby come into heat exchange with one another.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.