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Due to reduced energy efficiency and productivity loss caused by fouled heat exchangers in industrial plants there is an obvious need for detection of fouling formation. Based on continuously measured temperatures and flow rates collected from the refinery plant history database, a semi-empirical number of transfer units (NTU) model and neural network-based models are developed. In order to confirm the reliability of proposed fouling factor calculation, the entire procedure was performed by developing a dynamic nonlinear finite impulse response (NFIR) model. Developed models are intended for fouling detection for industrial shell and tube heat exchangers. The performance criteria of developed models together with residual monitoring indicate that not only neural networks but the NTU and NFIR models effectively detect fouling formation.

Fouling Detection in Industrial Heat Exchanger Using Number of Transfer Units Method, Neural Network, and Nonlinear Finite Impulse Response Models