Reduce your energy costs by improving the efficiency and reliability of your heat exchangers with improved control and continuous health monitoring.
Most chemical processing facilities have large numbers of heat exchangers of various types to heat and cool process fluids. They all depend on the absence of fouling, scaling, or corrosion to maximize heat transfer efficiency. A small number of field devices provide all the data necessary to measure efficiency and determine when maintenance is required.
To understand the efficiency of a heat exchanger, monitoring the energy balance across that unit is required. Using data from a few strategically placed measurement instruments will allow you to establish benchmarks and monitor process efficiency over time.
TopWorx D-Series Discrete Valve Controllers
The D-Series has been built to survive the most demanding applications and conditions, providing reliable service for a lifetime. With its microprocessor-based sensor-communication modules, it delivers position-sensing, bus network communications to facilitate predictive maintenance in On/Off valve applications.
Online Condition Monitoring Solutions for Mechanical Assets
Enhance chemical plant efficiency with real-time mechanical asset monitoring and advanced analytics.
Yarway Steam Traps
Emerson's Yarway steam traps that are suitable for a wide range of applications, with in-line repairable options.
Fisher MR95 Series Pressure Regulator
MR95 Series regulators are compact, large-capacity, direct-operated pressure regulators. They work well at maintaining constant feed of pressure to process to allow for better control of the fluid.
Level Measurement Solutions for Distillation Column Reboilers
Continuous and point level measurement and control solutions to eliminate overheating and optimize efficiency.
DeltaV Distributed Control System
The DeltaV DCS is an easy-to-use automation system that simplifies operational complexity and lowers project risk.
Fouling and scaling are the biggest enemies of heat exchanger efficiency. Once material builds up on the exchange surface, it serves as insulation which results in wasted energy. Fouling can happen with liquid-to-air heat exchangers if dust and other airborne solids are drawn into narrow air passages. Measuring flow with temperature or differential pressure across the heat exchanger provides a reliable indication that flow and heat transfer are being restricted. With a clear picture of how fouling is affecting all types of heat exchangers, a maintenance team can schedule cleanings for the right exchanger bundles at the right time, keeping costs low and ensuring optimal efficiency.
Rosemount Wireless Compact Conditioning Orifice Meter
Offering a best-in-class and cost-effective solution, the Rosemount 3051SFC Wireless Compact Conditioning Orifice Plate Flow Meter delivers accurate, multivariable measurements via a secure WirelessHART® network.
Rosemount™ 848T Wireless Temperature Transmitter
The Rosemount 848T Wireless Temperature Transmitter is the premier choice for high-density measurements via a WirelessHART® device.
Control Systems and Software for the Chemical Industry
Leveraging DeltaV advanced control systems, chemical producers will achieve higher product quality, more efficient tuning, more refined control, and better process visibility.
Yarway Steam Traps
Emerson's Yarway steam traps that are suitable for a wide range of applications, with in-line repairable options.
Liquid heat exchangers can develop internal leaks, allowing process liquids to infiltrate the circulating water, or vice versa, depending on the pressures involved. Process fluids may be toxic, flammable, reactive, or otherwise environmentally problematic. Once entrained in the cooling water circuit, they can be released into the environment. Similarly, cooling water might be forced into the process stream, contaminating the product. Emerson’s water-quality transmitters and monitoring solutions can sense a variety of chemicals, including liquid hydrocarbons, allowing maintenance teams to take corrective action before leaks become worse.
AMS Device Manager
Predictive maintenance helps plants avoid unplanned shutdowns and inefficient practices that eat away at profits. AMS Device Manager helps avoid these unnecessary costs with a window into the health of intelligent field devices.
Rosemount™ 400 Contacting Conductivity Sensor
The Rosemount 400 Sensor accurately measures electrolytic conductivity in a broad range of applications from high purity water to clean cooling water.
Rosemount 3900 General Purpose pH/ORP Sensor
To measure pH, the Rosemount 3900 pH Sensor is a good choice for most clean process fluids. For leak detection in ultra-pure water such as boiler feedwater, the combination of the 3900 sensor with a low flow panel is an excellent solution.
DeltaV Distributed Control System
The DeltaV DCS is an easy-to-use automation system that simplifies operational complexity and lowers project risk.
Heat exchangers are designed to operate within specific temperature and pressure limits, and their metallurgy is selected for its capability to tolerate specific chemical environments. Emerson’s flow, temperature, pressure, and corrosion instruments alert operators of sudden operating changes, helping to avoid potential safety and environmental incidents.
Temperature Measurement in Heat Exchangers
Monitoring the temperature of cooling water and process streams within heat exchangers allows users to better balance cooling loads and reduce total maintenance costs.
Online Condition Monitoring Solutions for Mechanical Assets
Enhance chemical plant efficiency with real-time mechanical asset monitoring and advanced analytics.
DeltaV Safety Instrumented Systems (SIS)
The proven DeltaV SIS continuously monitors your plant’s safety devices’ status and diagnoses the health of the entire safety loop–dramatically reducing your risk.
Hytork Excel (XL) Rack and Pinion Pneumatic Valve Actuator
Heavy-duty Hytork XL actuators have a variety of features that provide extra protection against aggressive environments.
Yarway Steam Traps
Emerson's Yarway steam traps that are suitable for a wide range of applications, with in-line repairable options.
Fisher Digital Isolation Solutions
Take the guesswork out of your safety instrumented system valve assemblies with our proven solutions and expertise.
Frequently Asked Questions about Heat Exchangers
To determine if a heat exchanger is leaking, conduct a visual inspection for signs of fluid or gas leakage, monitor for abnormal pressure drops or temperature variations, perform dye or tracer tests, consider visualizing techniques like UV light or thermal imaging, and utilize specialized leak detection analytical devices for detecting contamination such as conductivity or pH. Taking immediate action is important to address leaks, as they can reduce efficiency, increase energy consumption, and pose safety risks.
There are many types of heat exchangers, but the most common ones include shell and tube heat exchangers, plate heat exchangers, finned tube heat exchangers, and plate-fin heat exchangers. The type of heat exchanger used depends on the specific application and requirements.
Heat transfer in a heat exchanger is calculated using Q = M * Cp * ΔT, where Q is the heat transfer rate, M is the mass flow, Cp is the specific heat capacity, and dT is the temperature difference.
The heat transfer rate in a heat exchanger is typically calculated using the equation Q = U * A * ΔT, where Q is the heat transfer rate, U is the overall heat transfer coefficient, A is the surface area for heat exchange, and ΔT is the log mean temperature difference (LMTD) between the two fluids.
Fouling refers to the accumulation of unwanted material on the surfaces of the heat exchanger. This can reduce heat transfer efficiency, increase pressure drop, and lead to premature failure of the exchanger. Eliminating fouling helps reduce energy consumption.
