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(Manuscript Received February 17, 2017; Revised July 31, 2017; Accepted August 29, 2017)
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Abstract
Fouling is one the most serious problems in refineries that can have irreparable consequences. In this study, fouling detection inside the
tubes in the radiation section of an industrial fired heater furnace was investigated. The objective of this study is to identify the fouling
rate based on the independent inputs and outputs of the furnace. Therefore, the maximum allowable coke deposition thickness was con-
sidered the upper limit of the tolerance of the system for it to operate properly. A dynamic nonlinear mathematical model was used to
simulate different operational conditions and to record data. Then, fouling detection was performed based on support vector regression
and artificial neural network. Results were compared to achieve the best possible solution. In this work, the detection of critical fouling
was considered to immediately shut down furnaces and prevent irreversible damages.
Keywords: Dynamic model; Support vector regression; Artificial neural network
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416 A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421
A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421 417
Fig. 2. Furnace conditions during fouling: (a) Outlet oil pressure; (b) Fig. 3. Outlet oil temperature of the furnace: (a) Fouling in a single
tube temperature. tube; (b) fouling in several tubes.
together with the output oil temperature, tube temperature, and flow rate, inlet oil flow rate, inlet air flow rate, fuel flow, out-
output oil pressure, are used in fouling detection. Fouling can put oil temperature, tube temperature, and output oil pressure
only be studied under steady-state conditions. Thus, any ex- were used as the inputs of this network. Fouling rate served as
treme unexpected changes in the parameters are ignored. The the output. Then, the artificial model was utilized to predict
aforementioned parameters are changed between a minimum critical fouling and fouling intensity inside the tubes. The
of 2 % and a maximum of 1 %. critical point was deemed as the case in which the tube
The inner radius decreases by increasing fouling thickness reaches its designed temperature. This point should be de-
inside the tubes. Consequently, the heat transfer rate from the tected to shut down the furnace in time, thereby preventing
tubes to the inner fluid decreases significantly, and the tube irreparable damage. The following sections provide a brief
wall temperature and pressure drop improve (Fig. 2). description of the methods and their use in fouling detection.
The maximum designed temperature of the tube is 930 K,
and the maximum allowable fouling percentage is detected at 3.1 SVR
approximately 3 %. Crude oil is preheated inside the preheat-
ing furnace before entering the distillation tower. The combus- SVM is a machine learning algorithm with strong capabili-
tion section in the approached furnace comprises 4 passes with ties in many data processing problems [19]. This method is
24 tubes in each pass. The crude process temperature in this most known for its application to classification tasks, but it is
section increases from 562 K to 635 K. On average, the tem- also utilized in regression tasks, thereby making it suitable for
perature increases by approximately 3° in each tube in a single building the model for the continuous data in the current work.
pass. When coke is built up on the inner surface of the tubes, it The prediction capability of SVR has been tested in a variety
functions as an insulator and prevents the heating of the crude of research studies, and it has been proven to be successful
process. Consequently, the temperature decreases. [20].
However, if the fouling rate is only considered in a single SVR involves mapping the input data into a high-
tube, then this reduction becomes negligible because of the dimensional feature space through the kernel function; the
changes in parameters. If the fouling rate is considered in sev- output of the regression model can be determined by an opti-
eral tubes, then the temperature reduction becomes increas- mal hyper plane [21].
ingly sensible. The outlet temperature of the crude process is In the regression problem, the margin is considered a tube,
shown in Fig. 3. the data in which determine the pass of the regression pattern.
The piecewise linear function provides a robust solution for
discerning the best identifying function.
3. Fouling detection The regression problem is solved by minimizing
In this section, fouling was predicted based on two distinct
methods, namely, SVR and ANN. The prediction capabilities 1 2
M
418 A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421
yi - wT g ( xi ) - b £ e + xi for i = 1,..., M ,
w g ( xi ) + b - yi £ e + x
T
i
*
for i = 1,..., M , (4)
*
xi ³ 0, x ³ 0
i for i = 1,..., M
A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421 419
420 A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421
A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421 421