Heat exchanger leakage
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Heat exchanger leaks are a problem that plants often encounter. In my facility, we usually inspect the heat exchangers after receiving feedback from the circulating water workshop. When diesel leaks, the circulating water becomes cloudy and contains a lot of foam; when gasoline leaks, the water also becomes cloudy. We typically use a measuring cup to collect the circulating water, examine it by smell and visual inspection, or directly check whether there are oil droplets in it. This method is not very efficient. Does anyone have any better suggestions? Please share them
My plant began operations in 1997; its original capacity was 300,000 tons, but it was later upgraded to 500,000 tons. Despite multiple upgrades, some of the equipment is still not fully compatible
Install an analytical instrument for monitoring.
Use a measuring cup to collect the circulating water, then check it by smelling, observing it, or simply draining it to see if there are any oil bubbles. Although it seems simple, the results should be quick to appear
The cost of installing the instruments is a bit high. For example, a simple way to inspect our reboiler is as follows: reduce the steam supply, close the drain valve, activate the bypass, and collect some of the condensed water to check if it has any unusual odor
There is only what the original poster mentioned; no other way exists.
It is recommended to install transparent bypasses on the circulating water return pipes, allowing direct observation of the quality of the returned water.
The so-called “home remedies” are often indeed the simplest and most effective solutions.
We are also rather naive, arranging the coagulation and setting the timing on-site, by feeling with our hands and smelling.
Our approach is to observe the changes in the tower; if significant changes occur, such as a drop in the temperature at the top of the tower, then samples are taken to analyze the components inside the tower. If a distinct water layer appears among the components at the tower top, it can be concluded that there is a leak in the reboiler
The method mentioned above seems too outdated; it would be possible to analyze all the heat exchangers in the plant, and to take samples from those that are more prone to leaks, thereby identifying leak points at an early stage
If it can be seen with the naked eye or if a smell is detected, it indicates that the leakage is severe. Condensate water can be used for oil analysis in water; if it’s not possible to determine which heat exchanger is leaking, water samples can be taken for extraction followed by chromatographic analysis.
“Generally, when diesel leaks into the circulating water, it causes the water to become turbid with a large amount of foam; gasoline leaks also cause the circulating water to become turbid. ” Not in this field; I studied * instead. I would like to ask everyone: to what extent can human judgment be relied on qualitatively? What is the error rate? Relatively speaking, I trust machines more.
The crude method has its advantages: it’s quick and simple. Increasing the detection devices necessarily increases costs.