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Journal of Mechanical Science and Technology 32 (1) (2018) 415~421


www.springerlink.com/content/1738-494x(Print)/1976-3824(Online)
DOI 10.1007/s12206-017-1242-6

Maximum allowable fouling detection in industrial fired heater furnaces†


Ali Chaibakhsh1,2,*, Reza Bahrevar1,2 and Nasim Ensansefat1,2
1
Faculty of Mechanical Engineering, University of Guilan, Rasht, Guilan 41938-33697, Iran
2
Intelligent System and Advanced Control Laboratory, University of Guilan, Rasht, Guilan 41938-33697, Iran

(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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Fired heaters are complicated nonlinear systems whose per-


1. Introduction
formance can be affected by many factors. Any change in
Oil refineries consume a significant amount of energy and related factors may cause fouling formation and increase foul-
heavily produce CO2 mainly due to the fouling formation in ing rate. For example, variations in inlet fuel flow rate or
the preheat exchangers of crude distillation units. These char- combustion characteristics will change the temperature distri-
acteristics lead to tremendous energy loss in refineries. Foul- bution inside fired heaters and cause coke formation [8, 9].
ing is an inevitable problem in fired heaters that may happen Hence, all the parameters that affect the performance of fur-
within a span of 1-3 years or even within several months; it naces can either directly or indirectly contribute to coke for-
considerably reduces the efficiency of heat exchangers [1-3]. mation.
This phenomenon is critical for systems, and it eventually Many studies have explored fouling and coke formation.
causes furnaces to shut down. The most sensible sign of foul- Various semi-empirical models have been developed and ap-
ing formation is the enhanced pressure drop that must be plied to predict the fouling behavior of crude oil. These mod-
compensated for to prevent the reduction of the thermal effi- els are useful in gaining a fundamental understanding of foul-
ciency of fired heaters. Hence, different methods are being ing and the effects of the properties and flow characteristics of
used to compensate for fouling, and they include bypassing crude oil on fouling rate [1, 10, 11]. They are also useful in
fouled units, increasing thermal surfaces, detecting fouling, generating accurate fouling/no-fouling operating zones [12]
mitigating fouling, and supervising fouling [2-4]. and designing heat exchangers. These models generally pre-
The thermal resistance of fouling is extremely high; thus, dict fouling rates in tubes based on various laboratory and
the heat transfer rate to the fluid inside the tubes decreases industrial datasets [10, 12]. Despite their high accuracy, these
significantly in the presence of fouling [5]. Consequently, tube models are unsuitable for designing control systems and for
temperature significantly increases, thereby causing the leak- troubleshooting.
ing, bursting, bulging, or cracking of tubes. Hot hydrocarbons Estimating the convection coefficient and fouling thickness
leak into the fired heater and cause widespread firing [6, 7]. [13] and numerical methods for determining fouling growth
These factors and conditions make monitoring furnace opera- are among the approaches used in the condition monitoring of
tion necessary to increase the safety and reliability of systems. fired heater furnaces.
*
Support vector machine (SVM) is a supervised learning
Corresponding author. Tel.: +98 13 33690270, Fax.: +98 13 33690271
E-mail address: chabakhsh@guilan.ac.ir method for classification and regression. Thus, it is a suitable

Recommended by Associate Editor Joon Ahn approach for fault diagnosis. Researchers have shown interest
© KSME & Springer 2018 in the prediction capability of SVM in fouling detection for
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416 A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421

heat exchangers [14, 15].


Fouling detection based on the modeling of a system in a
fuzzy representation is a detailed method that does not require
any specific sensor or special operating condition [8]. The
main deficiency of this method is that it is inapplicable to
complicated systems with numerous parameters.
An advantageous approach is to detect fouling according to
measurable and controllable variables, as well as by consider-
ing the parameters that affect furnace performance for an ap- Fig. 1. Fouling growth inside a tube.
propriate system diagnosis. The current study mainly aims to
determine the fouling rate and the maximum allowable fouling
inside the tubes of industrial fired heater furnaces. The predic- Increasing fouling rate enhances fouling resistance. Conse-
tion is based on recorded data from a dynamic model. Two quently, the heat transfer rate through the tube wall decreases
distinct approaches are used to solve this problem: Support significantly over time. This change causes a significant rise in
vector regression (SVR) and Artificial neural network (ANN). tube temperature and a drop in pressure. Fluid temperature
To achieve this objective, fouling rate is detected according to also decreases gradually.
independent furnace inputs, pressure drop through the tubes, A decrease in tube radius causes the fouling resistance to
tube temperature, and output oil temperature of the furnace. drop.
In the next section, a brief description of the nonlinear
model and data production is presented. The data are used in 1 æ r ö 1 ær ö
fouling detection in furnaces. In Sec. 3, a network is con- Rf = ln ç in ÷÷ = ln ç in ÷ , (2)
2p K c Lt çè rin - d ø 2p K L
c t è r ø
structed with input oil temperature, input oil flow rate, input
air flow rate, fuel flow rate, output oil temperature, tube tem-
perature, and output oil pressure as the inputs and fouling rate where Rf is the fouling resistance, Kc is the thermal conductiv-
as the output. The simulation results are presented in Sec. 4. ity of fouling, Lt is the tube length, rin is the tube inner radius,
The last section is devoted to the conclusion and suggestions and δ is the fouling thickness [8].
for future work. Finally, this increase continues until the tube wall reaches
its designed temperature. In this case, the furnace must be shut
down and cleaned. Coke formation can significantly influence
2. Data preparation the operating lifetime of furnace tubes. The critical point in a
A dynamic nonlinear model of a specific industrial fired tube in the combustion section is the site in which the tem-
heater furnace is used to simulate different operational condi- perature of the combustion gas is the highest. In such a case,
tions. This model considers the effects of different parameters, the heat flux to the tube will be at its maximum point, and the
such as velocity, pressure, and released heat from combustion, maximum allowable fouling in the tube will be the lowest.
on crude process temperature, tube temperature, and outlet Determining this critical location is necessary to effectively
pressure [8]. evaluate the run length of the radiant section. Under this con-
In general, fouling is built up on the inner surface of tubes dition, the maximum allowable fouling percentage inside the
over time due to the nature of the crude process. However, tubes is approximately 3 % or 4 %. The critical points are
excessive internal tube fouling occurs above certain tempera- located at the output tube of the furnace situated at the center
tures [16]. Coke formation is influenced by many factors and of the combustion section [16].
predicting its behavior under different operational conditions In this study, the independent inputs of the furnace are per-
is highly complicated; hence, any sudden or extreme change turbed over time, and fouling thickness inside the tube is in-
in furnace performance is disregarded in this study. An expo- creased to simulate furnace performance. However, applying
nential function is considered to approximate fouling inside the fouling rate presented in Fig. 1 is time-consuming, and the
the tubes [17, 18]. The time constant is assumed to be suffi- resultant dataset will be too large to handle. Thus, the datasets
ciently small to avoid unexpected changes that can affect foul- required for training and testing stages are selected randomly.
ing growth. In addition, coke formation reduces the inner radii Draft, fuel flow rate, combustion pressure, fuel temperature,
of the tubes. Thus, the function can be written as and temperature of combustion gases exiting the furnace are
among the operational parameters that affect furnace perform-
r = r0e -t t , (1) ance. Notably, any changes in the composition of the crude
process and fuel are disregarded in this research to simplify
where r0 is the initial radius of the tube, and τ is the time con- the problem. In this case, the inlet temperature of the crude
stant that is supposed to be sufficiently small to determine the process, fuel flow rate, inlet oil flow rate, inlet air flow rate,
effect of all the parameters on furnace outputs. Fouling growth and fuel flow are considered independent variables that affect
is presented in Fig. 1. the furnace. These parameters, as the inputs of the furnace,
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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

of these methods were examined and compared. The recorded Q ( w, b, x , x * ) = w + C å (x i p + x i* p ) . (3)


2 i =1
data with a sample time of 1 hr were used to develop a net-
work for fouling detection by implementing a simulated dy-
namic model. The inlet temperature of the crude process, fuel Subject to constraints,
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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

where C is the soft margin that determines the trade-off be-


tween the magnitude of the margin and the estimation error of
the training data, and p is typically considered 1 or 2 [15].
Parameter C has a pre-specified value, and it works as a
regularization factor that significantly affects the smoothness
of the regression function. This parameter serves as a con-
straint for Lagrange coefficients that prevents them from cov-
ering the outliers and affecting the accuracy of the model [21]. Fig. 4. NN structure.
The support vectors can be determined by solving the regres-
sion problem. Then, the weighted sum of the support vectors and function g(x) is the activation function for the output. The
is used in the prediction model [22]. type of activation function in this work is a sigmoid.
In this study, three types of kernels were used to map a Best weights can be determined with error propagation,
high-dimensional space: Linear, polynomial, and Radial-based which is computed by the root mean square of errors.
function (RBF) [23]. Approximately 29 % of the gathered data
were used as prediction samples, and 71 % of the data were 1 2 1
E= Exx = ( y - g (åWi , j X j )) 2 , (7)
utilized as training data. 2 2 j

Cross validation was utilized as the means to obtain the ker-


nel parameter and regularization factor. where y is the vector of the correct outputs.
The Backpropagation NN (BPNN) is a supervised training
Linear: ( )
K xi , x j = xiT x j algorithm. It is an efficient method for determining the rela-
d tion between input and output data. The error in the final layer
Polynomial: K ( x , x ) = (g x x + r ) , g > 0
T
(5)
i j i j
is used to update the weights in each layer. The BPNN per-
K ( x , x ) = exp ( -g x - x , g > 0 ) .
2
RBF: forms the task by proportioning the error of the output and
i j i j
propagating it backward into hidden layers. In case of one or
more hidden layers, the weights of the hidden layers are also
computed by minimizing errors with respect to weights. The
3.2 ANN
weights can be adjusted by calculating the changes in errors in
ANN has been used in various data processing problems response to changes in weights.
such as classification, function approximation, and clustering.
An ANN automatically learns the relationship between inputs Wk , j ¬ Wk , j + a ´ ak ´ D j , (8)
and outputs. The performance of the network improves
through a cost function, which overviews and feeds back nec- where the error gradient can be calculated as follows [24]:
essary changes to achieve an effective solution. Basically, an
ANN establishes an intricate and high-order connection be- ¶E ¶ai
= -å ( yi - ai ) = - ak D j , (9)
tween neurons to realize its objective [24]. ¶Wk , j i ¶Wk , j
The scheme for a Neural network (NN) pattern, as pre-
sented in Fig. 4, consists of one or more layers. Each layer where aj and ai are the activated inputs for the hidden and
includes neurons (Perceptrons) formed from input values. If output layers, respectively.
the scheme has more than one layer, then the layer between This method was also used in this study, and its predictive
the outputs and the input layer is called the hidden layer. In capability was compared with that of SVR.
case of an NN with only an input layer, every neuron is a The input and output vectors for the NN model are summa-
weighted function of inputs or perceptrons. Initially, all the rized as follows:
weights are presented randomly. With a weighted learning
function, the network should be able to calculate all the ìïinput = [ m& fuel m& input _ oil Tinput _ oil ]
weights and determine the outputs. ANN Model : í .
ïîoutput = [ Poutlet ] or [ Ttube ]or [ Toutlet _ oil ]

Neuron _ output = g (åW j X j ) , (6)


j
4. Results and discussion
The results of each method are provided in this section. The
where j indicates the perceptron that forms the next neuron, critical amount of fouling is set to be approximately 3 % in
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A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421 419

Table 1. Comparison between NN and SVR models.

e s (e) σ(e) MSE R2

Training NN 12.4621 8.4463 2.7279e-05 0.1829 0.9998


Prediction NN 10.6754 9.1951 1.5287 e-05 0.3247 0.9296
Training SVR 57.4553 8.6034 0.0024 3.8882 0.9950
Prediction SVR 39.5460 8.8540 0.0229 4.4555 0.9947

Fig. 5. Error histograms for the training and prediction of BPNN.

Fig. 8. Estimated fouling rate by SVR: (a) Training; (b) prediction.

Fig. 6. Estimated fouling rate by BPNN: (a) Training; (b) SVR.

Fig. 9. Estimated accelerated fouling rate: (a) BPNN; (b) SVR.

such that the results become tangible. This prediction is illus-


Fig. 7. Error histograms for training and prediction of SVR.
trated in Fig. 6 for training and prediction. High accuracy in-
dicates the capability of the proposed detector.
this research. That is, the maximum allowable fouling on the The error histograms of SVR are shown in Fig. 7. For train-
tube surface is approximately 0.06 inch because the tube ing and prediction, 71 % and 29 % of the data are used, re-
reaches its designed temperature, which is approximately 930 spectively. In most cases, the prediction error is zero or close
K. Error histograms for ANN are shown in Fig. 5. to zero.
For training and prediction, 71 % and 29 % of the data are To determine the fouling rate inside the tubes, we change
used, respectively. In most cases, the prediction error is zero the range of 0 %-3 % into the range of 0 %-100 %, such that
or close to zero. To determine the fouling rate inside the tubes, the results become tangible. This prediction is illustrated in
we change the range of 0 %-3 % into the range of 0 %-100 %, Fig. 8 for training and prediction. High accuracy indicates the
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420 A. Chaibakhsh et al. / Journal of Mechanical Science and Technology 32 (1) (2018) 415~421

capability of the proposed detector.


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(2008) 240-244. Ali Chaibakhsh is an Assistant Profes-


[15] S. Abe, Support vector machines for pattern classification, sor in mechanical engineering at the
Springer (2005). University of Guilan since 2009. He
[16] A. Cross, Direct-fired heaters: Evaluate thermal perform- obtained his B.Sc. in Mechanical Engi-
ance and the effects of fouling, Chemical Engineering, 116 neering from the University of Guilan,
(12) (2009) 47. Rasht, Iran in 2002 and his M.Sc. and
[17] T. R. Bott, To foul or not to foul-that is the question, Ph.D. from K.N. Toosi University of
Chemical Engineering Progress, 97 (11) (2001) 30-37. Technology, Tehran, Iran in 2004 and
[18] M. Z. Abedin and N.-H. Kim, An experimental study on 2009, respectively. His research interests include intelligent
accelerated fouling of aluminum oxide and ferric oxide par- systems, including neural networks, fuzzy logic, and soft com-
ticles in internally enhanced tubes, Journal of Mechanical puting techniques and their applications to industrial processes.
Science and Technology, 30 (12) (2016) 5707-5714.
[19] E. Osuna, R. Freund and F. Girosit, Training support vector Reza Bahrevar obtained his master
machines: an application to face detection, 1997 IEEE Com- degree in mechanical engineering from
puter Society Conference on Computer Vision and Pattern the University of Guilan. He obtained his
Recognition (1997) 130-136. B.Sc. and M.Sc. in Mechanical Engineer-
[20] C.-H. Wu, J.-M. Ho and D.-T. Lee, Travel-time prediction ing from the University of Guilan, Rasht,
with support vector regression, IEEE Transactions on Intel- Iran in 2012 and 2015, respectively. His
ligent Transportation Systems, 5 (4) (2004) 276-281. research interests are mainly in areas
[21] N. Cristianini and J. Shawe-Taylor, An introduction to pertaining to data mining, fault detection
support vector machines and other kernel-based learning and diagnosis, fault tolerant control, and system identification.
methods, Cambridge University Press (2000).
[22] V. Uslan and H. Seker, Quantitative prediction of peptide Nasim Ensansefat Masouleh obtained
binding affinity by using hybrid fuzzy support vector re- her B.Sc. and M.Sc. in Mechanical Engi-
gression, Applied Soft Computing, 43 (2016) 210-221. neering from the University of Guilan, Iran,
[23] N. Pooyan, M. Shahbazian and M. Hadian, Simultaneous in 2012 and 2015, respectively. She is
fault diagnosis using multi class support vector machine in a currently a Ph.D. student in mechanical
dew point process, Journal of Natural Gas Science and En- engineering at the University of Guilan.
gineering, 23 (2015) 373-379. Her research interests include industrial
[24] L. Fausett, Fundamentals of neural networks: Architectures, process modeling and control, fault
algorithms, and applications, Prentice-Hall, Inc. (1994). detection, and network-based control system design.

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