阅读说明：本技术 热交换器和泄漏检测系统 (Heat exchanger and leak detection system ) 是由 布兰登·韦恩·米勒 尼古拉斯·泰勒·穆尔 丹尼尔·阿伦·尼亚尔加思 杰弗里·道格拉斯·兰博 于 2019-06-19 设计创作，主要内容包括：大体提供一种用于热交换和泄漏检测的系统,该系统包括热交换器,该热交换器包括限定包含第一流体的第一通道的第一壁。包含泄漏检测介质的泄漏检测外壳限定在第一壁和围绕第一壁的第二壁之间。(A system for heat exchange and leak detection is generally provided that includes a heat exchanger including a first wall defining a first passage containing a first fluid. A leak detection housing containing a leak detection medium is defined between the first wall and a second wall surrounding the first wall.)

1. A system for heat exchange and leak detection, the system comprising:

a heat exchanger comprising a first wall defining a first channel containing a first fluid, wherein a leak detection housing containing a leak detection medium is defined between the first wall and a second wall, the second wall surrounding the first wall.

2. The system of claim 1, wherein the leak detection medium comprises a fluid, and wherein the fluid defines a pressure greater than the first fluid or a second fluid surrounding the second wall.

3. The system of claim 1, further comprising:

a sensor disposed on the leak detection housing.

4. The system of claim 3, wherein the sensor defines a resistance sensor or a conductivity sensor.

5. The system of claim 3, wherein the sensor defines a pressure sensor.

6. The system of claim 5, wherein the sensor is coupled to a valve at the first channel, wherein the valve defines a first position at or above a pressure threshold of the leak detection housing and a second position below the pressure threshold of the leak detection housing.

7. The system of claim 5, wherein the sensor is coupled to a valve at a second channel defined between a third wall and the second wall, wherein the valve defines a first position at or above a pressure threshold of the leak detection enclosure and a second position below the pressure threshold of the leak detection enclosure.

8. The system of claim 3, wherein the sensor defines a vibration measurement sensor at the leak detection housing.

9. The system of claim 1, wherein the leak detection medium defines approximately 3.50 x 10⁷Or greater electrical conductivity.

10. The system of claim 1, wherein the leak detection medium defines a fluid.

Technical Field

The present subject matter generally relates to heat exchangers and leak detection systems for heat exchangers.

Background

Heat exchanger systems typically function using two or more working fluids in thermal communication. However, the working fluid may require fluid separation. In general, the working fluids may be incompatible, volatile, or undesirable if mixed. The inability to separate the fluids may significantly degrade or damage the heat exchanger system or the system to which the heat exchanger is attached. Accordingly, there is a need for a heat exchanger and leak detection system that can detect leaks or mitigate mixing of working fluids.

Disclosure of Invention

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

One aspect of the present disclosure relates to a system for heat exchange and leak detection. The system includes a heat exchanger including a first wall defining a first channel containing a first fluid. A leak detection housing containing a leak detection medium is defined between the first wall and a second wall surrounding the first wall.

In one embodiment, the leak detection medium comprises a fluid. The fluid defines a pressure greater than the first fluid or the second fluid surrounding the second wall.

In various embodiments, the system further comprises a sensor disposed at the leak detection housing. In one embodiment, the sensor defines a resistance sensor or a conductivity sensor. In other various embodiments, the sensor defines a pressure sensor. In one embodiment, the sensor is coupled to the valve at the first channel. The valve defines a first position at or above a pressure threshold of the leak detection housing and a second position below the pressure threshold of the leak detection housing. In another embodiment, the sensor is coupled to the valve at a second channel defined between the third wall and the second wall. The valve defines a first position at or above a pressure threshold of the leak detection housing and a second position below the pressure threshold of the leak detection housing. In yet another embodiment, the sensor defines a vibration measuring sensor at the leak detection housing.

In one embodiment, the leak detection medium defines about 3.50 x 10⁷Or greater electrical conductivity.

In various embodiments, the leak detection medium defines a fluid. In one embodiment, the system further comprises a sensor disposed at one or more of the first channel or the second channel. The sensor is configured to detect a leak detection medium at the first fluid at the first passage or at the second fluid at the second passage. In one embodiment, the leak detection medium comprises an inert gas or liquid.

Another aspect of the present disclosure relates to a heat exchanger and a leak detection system. The system includes a first wall defining a first channel containing a first fluid and a second wall surrounding the first wall. The leak detection medium is located in a leak detection enclosure defined between the first wall and the second wall. The system also includes one or more controllers configured to perform operations. The operations include flowing a first fluid through a first channel; flowing a second fluid in thermal communication with the second wall; and acquiring, via a sensor at the leak detection housing, a signal indicative of fluid communication between the leak detection medium and one or more of the first fluid or the second fluid.

In various embodiments, the operations further comprise: acquiring, via a sensor, a first leak detection value at a leak detection enclosure; acquiring, via the sensor, a second leak detection value at the leak detection housing; determining, via the controller, a change in the leak detection value at the leak detection housing based at least on the acquired first and second leak detection values; determining, via the controller, a leak at the leak detection housing based at least on the acquired first and second leak detection values.

In one embodiment, determining a change in the leak detection value at the leak detection housing includes comparing the second leak detection value to the first leak detection value over a period of time.

In another embodiment, the operations further comprise pressurizing the leak detection medium to a pressure at the leak detection housing that is greater than a pressure at the first passage and the second passage.

In one embodiment of the system, the operations further comprise: acquiring a first leak detection value at the first passage via a first passage sensor provided at the first passage; acquiring a second leak detection value at the second channel via a second channel sensor provided at the second channel; acquiring, via a leak detection sensor, a change in a leak detection value at a leak detection housing; determining, via the controller, a leak at one or more of the first passage, the second passage, and the leak detection housing based at least on a difference between the first leak detection value and the second leak detection value, each difference being a change in the leak detection value at the leak detection housing.

In another embodiment, obtaining a signal indicative of leakage of the leak detection medium into the first channel and/or the second channel comprises measuring a change in resistance or conductivity at the leak detection medium.

In yet another embodiment, obtaining a signal indicative of leakage of the leak detection medium into the first channel and/or the second channel comprises measuring a change in a vibration measurement at the leak detection medium.

In yet another embodiment, the operations further comprise adjusting an operating condition of the heat exchanger based on the signal obtained from the sensor.

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.

Drawings

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

1-7 are schematic cross-sectional views of exemplary embodiments of a heat exchanger and leak detection system;

FIG. 8 is a schematic diagram of an exemplary embodiment of the system shown and described with respect to FIGS. 1-7;

FIGS. 9-10 are cutaway perspective views of exemplary embodiments of heat exchangers according to the systems of FIGS. 1-8;

FIG. 11 is a flowchart outlining exemplary steps of a method for leak detection at a heat exchanger system; and

FIG. 12 is an exemplary embodiment of a heat engine at which exemplary embodiments of the systems and methods shown and described with respect to FIGS. 1-11 may be disposed.

Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.

Detailed Description

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one element from another, and are not intended to denote the position or importance of the various elements.

The terms "upstream" and "downstream" refer to relative directions with respect to fluid flow in a fluid path. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction to which the fluid flows.

The approximation term described herein may include a margin based on one or more measurement devices used in the art, such as, but not limited to, a percentage of the full-scale measurement range of a measurement device or sensor. Alternatively, approximations described herein may include a margin that is greater than 10% of the upper value or less than 10% of the lower value.

Embodiments of heat exchangers and leak detection systems, and methods for leak detection, are generally provided that may detect leaks or mitigate mixing of working fluids. The system generally includes a leak detection medium disposed between the working fluids in the heat exchanger. A crack, break, or other failure at one or more of the first or second walls enclosing the leak detection medium may mitigate leakage or fluid communication between the working fluids. The leak detection medium may generally detect a leak of the working fluid and/or a failure of the first wall or the second wall via one or more sensors that detect a change in pressure, resistivity or conductivity, vibration or acoustics, or one or more other suitable measurement parameters.

Referring now to the drawings, FIG. 1 is a schematic diagram of an exemplary heat exchanger and leak detection system 90 (hereinafter, "system 90") according to aspects of the present disclosure. The system 90 may be part of a heat engine or heat exchanger system for a land-based, space-based, or sea-based system or facility. Such systems or facilities may include, but are not limited to, liquid or gas heat exchangers, including fuel, air, lubricants, hydraulic fluids or gaseous working fluids for aviation, aerospace or aerospace systems, power generation systems, nuclear systems, medical systems and scientific equipment measurement systems (e.g., magnetic resonance imaging, spectroscopy, cryology, etc.), or other heat exchanger safety critical systems.

Referring to fig. 1, the system 90 includes a heat exchanger 100, the heat exchanger 100 including a first wall 110, the first wall 110 defining a first channel 105 containing a first fluid 101. A leak detection housing 115 containing a leak detection medium 103 is defined between the first wall 110 and a second wall 120 surrounding the first wall 110. The second fluid 102 at least partially surrounds the second wall 120. The second fluid 102 is in thermal communication with the first fluid 101 through a leak detection medium 103. The first fluid 101 and the second fluid 102 each define a working fluid enabling heat exchange with each other.

Referring now to fig. 2, in various embodiments, the heat exchanger 100 generally depicted with respect to fig. 1 may further include a third wall 130 surrounding the second wall 120. The third wall 130 and the second wall 120 may together define a second channel 125 therebetween that at least partially contains the second fluid 102. The member 135 may couple the third wall 130 and the second wall 120 together. For example, the member 135 may define a substantially rectangular, circular, oval, polygonal, etc. column or post extending between the third wall 130 and the second wall 120. As another example, the member 135 can define a wall that extends at least partially circumferentially around the second wall 120 (fig. 9-10). The member 135 may define the second channel 125 as a plurality of chambers (e.g., as shown with respect to fig. 9-10) extending generally circumferentially around the second wall 120. The member 135 may extend substantially circumferentially around the second wall 120 and further extend at least partially in the longitudinal direction so as to define a helical second channel 125 (fig. 9-10) around the second wall 120.

Referring to fig. 1-2, during normal operation (i.e., no leakage) of the system 90, the first wall 110 encloses the first fluid 101 within the first channel 105, the first fluid 101 being fluidly separated from the leakage detection housing 115, the leakage detection medium 103 therein, and/or the second fluid 102. Additionally, during normal operation, the first wall 110 and the second wall 120 together enclose the leak detection medium 103 within the leak detection housing 115 so as to be separated from the first fluid 101 and the second fluid 102. Further, during normal operation, the second wall 120 separates the second fluid 102 from the leak detection medium 103 and the leak detection housing 115.

In various embodiments, the leak detection medium 103 defines a fluid. In one embodiment, the fluid-defining leak detection medium 103 is enclosed within the leak detection housing 115 at a pressure greater than the first fluid 101, the second fluid 102, or both. In another embodiment, the fluid-defining leak detection medium 103 is capable of flowing in a circuit at least partially defined by the leak detection housing 115 at a pressure greater than the first fluid 101, the second fluid 102, or both. Thus, during adverse operation of system 90, such as fluid communication between first fluid 101 and leak detection medium 103 or fluid communication between second fluid 102 and leak detection medium 103 (e.g., a rupture, breakage, or other failure of first wall 110 and/or second wall 120), leak detection medium 103 may generally flow from high pressure leak detection housing 115 into first channel 105 or second channel 125.

2-3, the various embodiments of the system 90 depicted with respect to FIGS. 1-2 also include a sensor 140 disposed at the leak detection housing 115. The sensor 140 typically measures, calculates, meters, or otherwise acquires and/or transmits a signal, shown graphically at 150, indicative of fluid communication between the leak detection medium 103 and one or more of the first fluid 101 or the second fluid 102. The system 90 also determines whether a leak is present at the leak detection housing 115 (e.g., via a leak, break, damage, crack, etc. at the first wall 110 or the second wall 120) based at least on a change or difference in the signals acquired from the sensors 140.

In one embodiment, sensor 140 defines a pressure sensor. For example, the sensor 140 defining the pressure sensor typically determines, measures, calculates, meters, or otherwise obtains and/or transmits a pressure value of the leak detection medium 103 defining the fluid. The sensor 140, which defines a pressure sensor, obtains a plurality of pressure values at the leak detection housing 115.

In various embodiments, the sensors 140 defining the pressure sensors each acquire a first pressure value and a second pressure value at the leak detection housing 115. The system 90 determines a change in pressure or delta pressure at the leak detection housing 115 based at least on the acquired first and second pressure values. In one embodiment, the second force value is obtained within a time period from the first force value obtained. The second pressure value and the first pressure value are compared against the time period to determine a change in pressure over the time period. For example, a leak at the first wall 110 and/or the second wall 120 may be indicated via a pressure decrease at the second pressure value over the period of time relative to the first pressure value. As another example, the leak detection medium 103 may generally be contained within the leak detection housing 115 as a substantially stationary fluid. The sensor 140 may acquire the static pressure value of the leak detection medium 103 in the leak detection housing 115 and compare the change in pressure value over the time period.

Referring now to fig. 4-5, in another embodiment of the system 90 generally described with respect to fig. 1-3, the second and first pressure values are obtained via a plurality of sensors 140 disposed at the upstream and downstream ends 99, 98 of the system 90. For example, the system 90 may include an upstream sensor 141 disposed proximate the upstream end 99 and a downstream sensor 142 disposed proximate the downstream end 98.

Referring to FIG. 4, sensors 141,142 may be provided at the leak detection housing 115 to obtain delta pressure values of the leak detection medium 103 defining the fluid flowing through the leak detection housing 115. For example, the system 90 may acquire a second pressure value via the downstream sensor 142 over a distance relative to a first pressure value via the upstream sensor 141 to determine a pressure loss between the sensors 141,142 across the distance. The system 90 also acquires the second pressure value and the first pressure value over a period of time, such as a continuous or intermittent acquisition, or tends to determine whether the delta pressure between the second pressure value and the first pressure value varies over the period of time.

Referring to fig. 5, the system 90 is constructed substantially similar to the system shown and described with respect to fig. 1-4. In fig. 5, a plurality of sensors 140 are disposed at one or more of the first channel 105 or the second channel 125. For example, system 90 may include an upstream first channel sensor 143 and a downstream first channel sensor 144, each disposed at first channel 105. As another example, the system 90 may include an upstream second channel sensor 145 and a downstream second channel sensor 146, each disposed at the second channel 125. First channel sensors 143,144 obtain delta pressure values for first fluid 101 that define the fluid flowing through first channel 105. The second channel sensors 145,146 obtain delta pressure values for the second fluid 102 that define the fluid flowing through the second channel 125. For example, system 90 may acquire a second pressure value via downstream sensors 144,146 over a distance relative to a first pressure value via upstream sensors 143,145 to determine a pressure loss between each pair of first channel sensors 143,144 and second channel sensors 145,146 across the distance. The system 90 also acquires the second pressure value and the first pressure value over a period of time, such as a continuous or intermittent acquisition, or tends to determine whether the delta pressure between the second pressure value and the first pressure value varies over the period of time.

In various embodiments, sensors 140,141,142,143,144,145,146 may be disposed at one or more of first channel 105, second channel 125, or leak detection housing 115 via member 135 extending to second wall 120. Referring to FIG. 5, in one embodiment, the member 135 may further extend to the first wall 110 to dispose the sensors 140,141,142,143,144,145,146 to the first channel 105. The member 135 may generally pass a wire or other communication device from the sensor 140 to a controller configured to receive and/or transmit signals from the sensor 140 and perform an operation.

Referring now to fig. 1-5, in various embodiments, the leak detection medium 103 may be defined at about 3.50 x 10 at about 20 degrees celsius⁷Or greater electrical conductivity. For example, the leak detection medium 100 may define one or more materials including, but not limited to, aluminum, gold, copper, silver, or combinations thereof. It should be understood that the measured value of conductivity may be increased or decreased based on different temperatures. In one embodiment, the sensor 140 defines a resistance sensor or a conductivity sensor. For example, during normal operation of the system 90, the sensor 140 acquires a signal indicative of a first resistance or conductivity of the leak detection medium 103. During adverse operation of the system 90, the sensor 140 acquires a signal indicative of a second resistance or conductivity of the leak detection medium 103. The second resistance or conductivity may generally indicate that the first fluid 101 or the second fluid 102 leaks into the leak detection housing 115 to change the resistance or conductivity of the leak detection medium 103.

Still referring to fig. 1-5, in further embodiments, the sensor 140 may define a vibration measuring sensor at the leak detection housing 115. For example, the sensor 140 may define an accelerometer or an acoustic measurement device. During normal operation of the system 90, the sensor 140 acquires a signal indicative of a first vibration measurement at the leak detection housing 115. During adverse operation of the system 90, the sensor 140 acquires a signal indicative of a second vibration measurement at the leak detection housing 115. A second vibration measurement at the leak detection housing 115 may generally indicate a leak of the leak detection medium 103 from the leak detection housing 115 into one or more of the first channel 105 or the second channel 125.

Additionally or alternatively, a second vibration measurement at the leak detection housing 115 may generally indicate that the first fluid 101 or the second fluid 102 is leaking into the leak detection housing 115. Further, the sensor 140 may acquire a signal at the first channel 105, the second channel 125, or both based on a leak between the upstream end 99 and the downstream end 98 to indicate a change in the vibration measurement. For example, one or more of the upstream sensors 141,143,145 may acquire a first vibration measurement and one or more of the downstream sensors 142,144,146 may acquire a second vibration measurement, such as shown and described with respect to FIG. 5. The system 90 may compare the second measurement to the first measurement to determine whether the leak detection housing has a leak. The system 90 may further compare the second measurement to the first measurement to determine whether the leak is in the first passage 105, the second passage 125, or both.

Referring to fig. 5, in one embodiment, a sensor 140 may be disposed at one or more of the first channel 105 or the second channel 125 to acquire a signal indicative of a leak of the leak detection medium 103 into the first channel 105 or the second channel 125. In one embodiment, the sensor 140 may define a gas detection sensor disposed at one or more of the first channel 105 or the second channel 125 to indicate a leak of the leak detection medium 103 into the first channel 105 or the second channel 125. For example, the sensor 140 defining the gas detector may more specifically define an electrochemical gas detector. The sensor 140 defining the electrochemical gas detector may comprise a chemically reactive semiconductor sensor. The chemically reactive semiconductor may comprise a tin oxide based sensor in which the resistance changes due to the presence of the leak detection medium 103 mixed with the first fluid 101 in the first channel 105 or the second fluid 102 in the second channel 125.

As another example, in one embodiment, the sensor 140 defining the gas detection sensor may further define one or more types of spectrometers. The sensor 140 defining a spectrometer may further define one or more of a mass spectrometer, an optical spectrometer, an imaging spectrometer, or another spectrometer suitable for detecting the leak detection medium 103 in the fluid 101, 102.

In various embodiments, the leak detection medium 103 may define a fluid that substantially includes an inert or noble gas or an inert gas in liquefied form. The inert or noble gas may include argon, helium, xenon, neon, krypton, radon or gas oxygen (Oganesson), or combinations thereof. The sensor 140 may define an inert or noble gas sensor to detect the amount of the leak detection medium 103 in the first channel 105 or the second channel 125, such as one or more of the previously described embodiments of the sensor 140.

Referring now to fig. 6-7, the system 90 shown and described with respect to fig. 1-5 may also include a valve 160 coupled to the sensor 140. The valve 160 defines a first position at or above a pressure threshold of the leak detection housing 115. The valve 160 also defines a second position at the leak detection housing 115 below a pressure threshold. In one embodiment, such as shown with respect to fig. 6, a valve 160 is disposed at the first passage 105. In another embodiment, such as shown with respect to fig. 7, a valve 160 is disposed at the second passage 125. In other embodiments, the valve 160 may be disposed at the first and second passages 105, 125. The valve 160 receives a signal from the sensor 140 indicating the amount of pressure at the leak detection housing 115. When the pressure value is greater than or equal to the predetermined pressure threshold, the valve 160 defines a first position (e.g., an open position) to enable the first fluid 101 to flow through the first channel 105, or to enable the second fluid 102 to flow through the second channel 125, or both. When the pressure value is less than the predetermined pressure threshold, the valve 160 defines a second position (e.g., a closed position) to reduce or inhibit the flow of the first fluid 101 through the first passage 105, or the flow of the second fluid 102 through the second passage 125, or both.

Referring now to fig. 1-7, the system 90 may further pressurize the leak detection housing 115. For example, the system 90 may pressurize the leak detection housing 115 to or above a pressure threshold to enable the system 90 to detect a leak of the leak detection medium 103, such as described with respect to fig. 1-7. The system 90 may further pressurize the leak detection housing 115 to or above a pressure threshold to enable flow of the first fluid 101 and/or the second fluid 102, such as described with respect to fig. 6-7. In various embodiments, the pressure threshold may define a predetermined pressure value at the leak detection housing 115. In other embodiments, the pressure threshold may define a predetermined pressure differential that is higher than the pressure value at the first channel 105 or higher than the pressure value at the second channel 125. For example, the predetermined pressure differential may be 1 megapascal (Mpa) or greater (e.g., or 5Mpa, or 10Mpa, or 100Mpa, etc.) that is greater than the greater of the pressure value at the first channel 105 or the pressure value at the second channel 125. As another example, the predetermined pressure differential may be greater than a predetermined percentage (e.g., 1% greater, or 5% greater, or 10% greater, or 20% greater, etc.) of one or more of the first channel 105 or the second channel 125. In other various embodiments, the predetermined pressure threshold may be based on a curve, graph, function, schedule, regression, or transfer function based on one or more pressure values at the first channel 105, the second channel 125, or both.

Referring now to fig. 8, a schematic diagram of a system 90 generally shown and described with respect to fig. 1-7 is provided. It should be understood that although the schematic diagram provided generally in relation to fig. 8 includes features illustrated or described in relation to one or more of the embodiments illustrated and described in relation to fig. 1-7, the system 90 may include arrangements or embodiments that are specific to one or more of the embodiments illustrated in relation to fig. 1-7.

The system 90 may also include one or more bypass conduits 111,121 that enable one or more fluids 101,102 to bypass all or a portion of the heat exchanger 100. The bypass conduits 111,121 may enable one or more fluids 101,102 to bypass based at least on a determined leak at the heat exchanger 100 as described above. In one embodiment, when the valve 160 defines the second position, the fluids 101,102 may bypass the heat exchanger 100 via the bypass conduits 111,121, such as described with respect to fig. 6-7. The first bypass conduit 111 may enable the first fluid 101 to bypass the first pass 105 into the heat exchanger 100. The second bypass conduit 121 may enable the second fluid 102 to bypass the second channel 125 entering the heat exchanger 100. During adverse operation of the system 90, such as indicating a leak, the system 90 may reduce or inhibit one or more of the fluids 101,102 from flowing into the heat exchanger 100 in order to reduce, mitigate, or eliminate undesired mixing of the fluids 101,102 due to the leak.

The embodiments shown and described with respect to fig. 1-8 may define a passive arrangement, such as the sensor 140 providing a signal to the valve 160 and the valve 160 adjusting position, as described above. Additionally or alternatively, the system 90 may define an active arrangement, which further comprises a controller 210, such as schematically depicted in fig. 8.

In general, controller 210 may correspond to any suitable processor-based device, including one or more computing devices. For example, FIG. 8 illustrates one embodiment of suitable components that may be included within controller 210. As shown in fig. 8, the controller 210 may include a processor 212 and associated memory 214 configured to perform various computer-implemented functions. In various embodiments, the controller 210 may be configured to operate the system 90, for example, according to one or more steps of a method for leak detection at a heat exchanger system (hereinafter, "method 1000") as generally described herein with respect to fig. 1-10, and as outlined with respect to fig. 11.

As used herein, the term "processor" refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to controllers, microcontrollers, microcomputers, Programmable Logic Controllers (PLCs), Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs), and other programmable circuits. Additionally, memory 214 may generally include memory elements including, but not limited to, computer-readable media (e.g., Random Access Memory (RAM)), computer-readable non-volatile media (e.g., flash memory), compact disc read only memory (CD-ROM), magneto-optical disks (MOD), Digital Versatile Discs (DVD), and/or other suitable memory elements or combinations thereof. In various embodiments, the controller 210 may define one or more of a Full Authority Digital Engine Controller (FADEC), a Propeller Control Unit (PCU), an Engine Control Unit (ECU), or an Electronic Engine Control (EEC).

As shown, the controller 210 may include control logic 216 stored in the memory 214. The control logic 216 may include instructions that, when executed by the one or more processors 212, cause the one or more processors 212 to perform operations such as those described with respect to the method 1000.

In addition, as shown in fig. 12, the controller 210 may further include a communication interface module 230. In various embodiments, the communication interface module 230 may include associated electronic circuitry for transmitting and receiving data. As such, the communication interface module 230 of the controller 210 may be used to receive data from the system 90 (e.g., the sensors 140,141,142,143,144,145,146) that provides pressure, flow or temperature values, vibration or acoustic measurements, resistivity or conductivity measurements, or gas detection, or a combination thereof. In addition, the communication interface module 230 may also be used to communicate with any other suitable component of the system 90, including any number of valves 160 or bypass conduits 111,121 configured to enable, disable, or alter the flow of fluids 101,102,103 through the system 90.

It should be appreciated that the communication interface module 230 may be any combination of suitable wired and/or wireless communication interfaces and, thus, may be communicatively coupled to one or more components of the system 90 via a wired and/or wireless connection. As such, the controller 210 may operate, adjust or tune the operation of the system 90, acquire or send signals via the sensors 140, or determine a leak at the leak detection housing 115, or other steps such as described with respect to the method 1000.

Referring now to fig. 9-10, perspective cross-sectional views of exemplary embodiments of the heat exchanger 100 of the system 90 are provided generally in accordance with one or more embodiments shown and described with respect to fig. 1-8. All or part of the system 90, including the heat exchanger 100, may be part of a single, unitary component and may be manufactured by any number of processes. These manufacturing processes include, but are not limited to, manufacturing processes known as "additive manufacturing" or "3D printing. Additionally, the heat exchanger 100 may be constructed using any number of casting, machining, welding, brazing, or sintering processes, or any combination thereof, including, but not limited to, the first wall 110, the second wall 120, the third wall 130, the member 135, channels, cavities, openings, or outlets for the sensor 140 and/or the valve 160, or combinations thereof. Further, the system 90 may constitute one or more separate components mechanically joined (e.g., via bolts, nuts, rivets or screws, or a welding or brazing process, or a combination thereof), or positioned in space to achieve substantially similar geometric, aerodynamic, or thermodynamic results as if fabricated or assembled into one or more components. Non-limiting examples of suitable materials include high strength steel, titanium and titanium based alloys, nickel and cobalt based alloys, aluminum and/or metals, polymer or ceramic matrix composites, or combinations thereof.

Referring to fig. 1-10, in various embodiments, one or more of the fluids 101,102,103 define a liquid or gaseous fuel, compressed air, a refrigerant, a liquid metal, a noble gas, a supercritical fluid, compressed air, or a combination thereof. Various embodiments of the fluid 101,102,103 that define a supercritical fluid may include, but are not limited to, carbon dioxide, water, methane, ethane, propane, ethylene, propylene, methanol, ethanol, acetone, or nitrous oxide, or combinations thereof.

In various embodiments, the refrigerant-defining fluid 101,102,103 may include, but is not limited to, an alkyl halide, a perchloroalkene, a perchlorocarbon, a perfluoroolefin, a perfluorocarbon, a hydrogenated olefin, a hydrocarbon, a hydrochloroolefin, a hydrochlorohydrocarbon, a hydrofluoroolefin, a hydrofluorocarbon, a hydrochloroolefin, a hydrochlorofluorocarbon, a chlorofluorocarbon, or a chlorofluorocarbon refrigerant, or a combination thereof.

Further various embodiments of the fluids 101,102,103 defining the refrigerant may include methylamine, ethylamine, hydrogen, helium, ammonia, water, neon, nitrogen, air, oxygen, argon, sulfur dioxide, carbon dioxide, nitrous oxide, or krypton, or combinations thereof.

Various embodiments of the system 90 may adjust the operating conditions of the heat exchanger 100 based on the signals obtained from the sensors 140. Adjusting the operating conditions of the system 90 may include adjusting the pressure, flow rate, and/or temperature of the fluids 101,102 at the heat exchanger 100. Additionally or alternatively, adjusting the operating state of the system 90 may include bypassing one or more of the fluids 101,102 via one or more of the bypass conduits 111, 121. Additionally or alternatively, adjusting the operating state of the system 90 may include adjusting or modulating the valve 160 to adjust the pressure, flow rate, and/or temperature of one or more of the fluids 101,102 at the heat exchanger 100.

Referring now to FIG. 11, a flowchart outlining exemplary steps of a method for leak detection at a heat exchanger system (hereinafter, "method 1000") is generally provided. Although generally shown and described with respect to fig. 1-10, method 1000 may be performed or utilized in other structures or systems not generally provided herein. In addition, although the steps outlined herein are presented in a particular order, the steps may be rearranged, reordered, omitted, added, or otherwise altered without departing from the scope of the present disclosure.

The method 1000 may include flowing a first fluid through a first channel at 1010; flowing a second fluid in thermal communication with the second wall at 1020; and acquiring a signal indicative of fluid communication between the leak detection medium and one or more of the first fluid or the second fluid at 1030, such as shown and described with respect to system 90 in fig. 1-10.

In various embodiments, method 1000 may further include, at 1040, obtaining a first leak detection value at the leak detection enclosure; at 1050, obtaining a second leak detection value at the leak detection housing; and determining a change in the leak detection value at the leak detection housing based at least on the acquired first and second leak detection values at 1060.

In other various embodiments, a leak detection value may be obtained via a sensor (e.g., sensors 140,141,142,143,144,145,146) at step 1030. The sensor may obtain a leak detection value indicative of a pressure value, resistivity or conductivity, vibration or acoustic measurement. In one embodiment, acquiring a signal indicative of leakage of the leak detection medium into the first channel and/or the second channel includes measuring a change in resistance or conductivity of the leak detection medium at 1030. In another embodiment at 1030, acquiring a signal indicative of leakage of the leak detection medium into the first channel and/or the second channel includes measuring a change in a vibration measurement at the leak detection housing, the first channel, or the second channel.

In one embodiment at 1060, determining a change in the leak detection value at the leak detection housing includes comparing the second leak detection value to the first leak detection value over a period of time. In various examples, such as those described with respect to fig. 1-10, comparing the leak detection value may include comparing static pressure measurements at the leak detection housing over a period of time to determine a change (e.g., a decrease) indicative of a leak of the leak detection medium to the first passage, the second passage, or both. As another example, comparing the leak detection value may include comparing a change in a difference between the downstream leak detection value and the upstream leak detection value over a period of time. In yet another example, comparing the leak detection value may include comparing a change in the presence of the leak detection medium in the first fluid or the second fluid (e.g., indicating a change in the presence of the leak detection medium defining an inert gas in the first fluid or the second fluid). In further examples, comparing leak detections includes comparing vibration measurements, pressure, or changes in resistance or conductance.

In various embodiments, method 1000 further comprises: at 1071, obtaining a first leak detection value change at the first channel; at 1072, a second leak detection value change at the second channel is obtained; at 1073, a change in the leak detection media value at the leak detection housing is obtained; at 1074, a leak is determined at one or more of the first channel, the second channel, and the leak detection housing based at least on a difference between the first leak detection value change and the second leak detection value change, each of the first leak detection value change and the second leak detection value change being a change in the leak detection media value at the leak detection housing.

In yet another embodiment, the method 1000 can further include adjusting an operating condition of a heat exchanger (e.g., the heat exchanger 100) based on the signal obtained from the sensor at 1080. In various embodiments, adjusting the operating condition may include adjusting a pressure, a flow rate, and/or a temperature of the fluids (e.g., fluids 101,102) entering and/or exiting the heat exchanger 100 via a valve (e.g., valve 160). In another embodiment, adjusting the operating condition of the heat exchanger includes at least partially bypassing one or more of the first fluid or the second fluid from the first channel or the second channel. For example, the method 1000 at 1080 may be instantiated such as shown and described with respect to fig. 8 (e.g., bypass conduits 111, 121).

Method 1000 may further include determining a leak at the leak detection enclosure based at least on the acquired first and second leak detection values at 1090. For example, the method 1000 at 1090 may be instantiated, such as shown and described with respect to fig. 1-10.

The method 1000 may also include pressurizing the leak detection medium at 1005 such that a pressure at the leak detection housing is greater than a pressure at the first channel and the second channel. For example, the method 1000 at 1005 may be illustrated, such as shown and described with respect to fig. 1-10.

Referring now to FIG. 12, a schematic partial cross-sectional side view of an exemplary heat engine 10 (referred to herein as "engine 10") that may incorporate various embodiments of the system 90 is generally provided. It should be understood that fig. 12 is provided as an example, and that in various embodiments, the system 90 may be incorporated into power generation systems, nuclear systems, medical systems and scientific equipment measurement systems (e.g., magnetic resonance imaging, spectroscopy, cryosurgery, etc.), or other heat exchanger safety critical systems.

Although further described herein as a gas turbine engine, engine 10 may generally define a steam turbine engine or turbomachine, including a turbofan, turbojet, turboprop or turboshaft gas turbine engine configuration, or a combined cycle engine. As shown in FIG. 12, the engine 10 has a longitudinal or axial centerline axis 12 extending therethrough for reference purposes. Generally, engine 10 may include a fan assembly 14 and a core engine 16 disposed downstream of fan assembly 14.

Core engine 16 may generally include a substantially tubular housing 18, with housing 18 defining an annular inlet 20 into a core flow path 19 defined through core engine 16. The housing 18 encloses or is at least partially formed in serial flow relationship: a compressor section 21, for example having a supercharger or Low Pressure (LP) compressor 22 and a High Pressure (HP) compressor 24; a combustion section 26; and an expansion section or turbine section 31, including, for example, a High Pressure (HP) turbine 28 and a Low Pressure (LP) turbine 30. The turbine or expansion section 31 also includes an injection exhaust nozzle section 37 through which combustion gases 86 are discharged from the core engine 16 through the injection exhaust nozzle section 37. In various embodiments, the injection exhaust nozzle section 37 may further define an afterburner chamber. The core engine 16 also defines a hot section 33, the hot section 33 including a combustion section 26, a turbine or expansion section 31, and an injection exhaust nozzle section 37, with combustion gases 86 formed and flowing through the hot section 33. A High Pressure (HP) spool shaft 34 drivingly connects the HP turbine 28 to the HP compressor 24. A Low Pressure (LP) rotor shaft 36 drivingly connects the LP turbine 30 to the LP compressor 22. LP rotor shaft 36 may also be connected to a fan shaft 38 of fan assembly 14. In particular embodiments, as shown in FIG. 1, LP rotor shaft 36 may be connected to fan shaft 38 via a reduction gear 40, for example, in an indirect drive or geared configuration.

As shown in fig. 12, fan assembly 14 includes a plurality of fan blades 42, fan blades 42 coupled to fan shaft 38 and extending radially outward from fan shaft 38. An annular fan casing or nacelle 44 circumferentially surrounds at least a portion of fan assembly 14 and/or core engine 16. It should be appreciated by those of ordinary skill in the art that the nacelle 44 may be configured to be supported relative to the core engine 16 by a plurality of circumferentially spaced outlet guide vanes or struts 46. Further, at least a portion of nacelle 44 may extend on an exterior of casing 18 of core engine 16 to define a fan bypass airflow passage 48 therebetween.

During operation of engine 10, a volume of air, schematically indicated by arrow 74, enters engine 10 through fan casing or nacelle 44 and/or an associated inlet 76 of fan assembly 14. As air 74 passes through fan blades 42, a portion of the air is channeled or directed into bypass airflow passage 48 as schematically represented by arrows 78, and another portion of the air is channeled or directed into core flow path 19 of core engine 16 at LP compressor 22 as schematically represented by arrows 80. As the air 80 flows through the core flow path 19 across the LP and HP compressors 22,24 toward the combustion section 26, the air 80 is progressively compressed, as schematically illustrated by, for example, arrows 81 and 82, the arrow 81 depicts an increased pressure and temperature of the compressed air flow, and the arrow 82 depicts an outlet temperature and pressure from the compressor section 21 (e.g., defining an inlet temperature and pressure to the combustion section 26). The now compressed air 82 flows into the combustion section 26 to mix with liquid or gaseous fuel and combust to produce combustion gases 86. Combustion gases 86 generated in combustion section 26 flow downstream through core flowpath 19 into HP turbine 28, thereby rotating HP rotor shaft 34, thereby supporting operation of HP compressor 24. Combustion gases 86 are then channeled through core flow path 19 over LP turbine 30, thereby rotating LP rotor shaft 36, thereby supporting operation of LP compressor 22 and/or rotation of fan shaft 38 and fan blades 42. The combustion gases 86 are then discharged through the jet exhaust nozzle section 37 of the core engine 16 to provide propulsion.

In the embodiment generally provided in FIG. 12, engine 10 also defines a third flow bypass airflow passage 49. A third flow bypass airflow passage 49 is at least partially defined through casing 18 from a compressor (e.g., LP compressor 22) of compressor section 21 to fan bypass airflow passage 48. Third flow bypass airflow passage 49 selectively allows compressed air 80,81 (schematically shown by arrows 79) to flow from the compressor of compressor section 21 (e.g., from LP compressor 22) to mix with air portion 78 in fan bypass airflow passage 48. Engine 10 enables third flow bypass airflow passage 49 to completely or substantially close off flow of compressed air 79 to fan bypass airflow passage 48 based on operating conditions of engine 10 (e.g., high power conditions) to increase thrust output of engine 10. The engine 10 also enables the third flow bypass airflow passage 49 to at least partially open the compressed airflow 79 to flow out to the fan bypass airflow passage 48 based on operating conditions of the engine 10 (e.g., low or medium power conditions) in order to reduce fuel consumption.

It should be appreciated that although the exemplary embodiment of engine 10 generally provided in FIG. 12 is presented in a three-flow turbofan configuration, engine 10 may define a two-flow (e.g., fan bypass airflow passage 48 and core flow path 19) or a one-flow hot engine configuration (e.g., core flow path 19). It should be further appreciated that, although the exemplary embodiment of engine 10 generally provided in FIG. 1 is presented in a dual spool turbofan configuration, engine 10 may define a third or more spool configurations wherein LP compressor 22 defines an Intermediate Pressure (IP) compressor coupled to an IP shaft and an IP turbine, each of which is disposed in serial flow relationship between a respective fan assembly 14, HP compressor 24, HP turbine 28 and LP turbine 30. Still further, the tri-spool configuration may also mechanically couple the fan assembly 14 to the LP turbine 30 independent of the LP/IP compressor 22 and the IP turbine. In other words, the engine 10 may define three mechanically independent spools, including respective combinations of the fan assembly and the LP turbine, the IP compressor and the IP turbine, and the HP compressor and the HP turbine.

Referring now to fig. 1-12, in various embodiments, one or more of the fluids 101,102,103 may define a liquid or gaseous fuel at the engine 10. The fuel may include, but is not limited to, gasoline, propane, ethane, hydrogen, diesel, kerosene, or one or more Jet fuel formulations (e.g., Jet a, JP1, etc.), coke oven gas, natural gas, or syngas, or combinations thereof. The fluids 101,102,103 or air generally defining the oxidant may include bypass air streams 78,79 from the fan assembly 14 or compressor section 21, such as described with respect to FIG. 12, bypassing the combustion section 26 and flowing through the fan bypass airflow passage 48 and/or the third flow bypass airflow passage 49.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

The various features, aspects, and advantages of the present invention may also be embodied in the various aspects described in the following clauses, which may be combined in any combination:

1. a system for heat exchange and leak detection, the system comprising:

a heat exchanger comprising a first wall defining a first channel containing a first fluid, wherein a leak detection housing containing a leak detection medium is defined between the first wall and a second wall, the second wall surrounding the first wall.

2. The system of clause 1, wherein the leak detection medium comprises a fluid, and wherein the fluid defines a pressure greater than the first fluid or a second fluid surrounding the second wall.

3. The system of clause 1, further comprising:

a sensor disposed on the leak detection housing.

4. The system of clause 3, wherein the sensor defines a resistance sensor or a conductivity sensor.

5. The system of clause 3, wherein the sensor defines a pressure sensor.

6. The system of clause 5, wherein the sensor is coupled to a valve at the first channel, wherein the valve defines a first position at or above a pressure threshold of the leak detection housing and a second position below the pressure threshold of the leak detection housing.

7. The system of clause 5, wherein the sensor is coupled to a valve at a second channel defined between a third wall and the second wall, wherein the valve defines a first position at or above a pressure threshold of the leak detection enclosure and a second position below the pressure threshold of the leak detection enclosure.

8. The system of clause 3, wherein the sensor defines a vibration measuring sensor at the leak detection housing.

9. The system of clause 1, wherein the leak detection medium defines about 3.50 x 10⁷Or greater electrical conductivity.

10. The system of clause 1, wherein the leak detection medium defines a fluid.

11. The system of clause 10, further comprising:

a sensor disposed at one or more of the first channel or second channel, wherein the sensor is configured to detect the leak detection medium at the first fluid at the first channel or at a second fluid at the second channel.

12. The system of clause 10, wherein the leak detection medium comprises an inert gas or liquid.

13. A heat exchanger and leak detection system, the system comprising a first wall defining a first channel containing a first fluid and a second wall surrounding the first wall, wherein a leak detection medium is in a leak detection enclosure defined between the first wall and the second wall, the system further comprising one or more controllers configured to perform operations comprising:

flowing the first fluid through the first channel;

flowing a second fluid in thermal communication with the second wall; and

obtaining, via a sensor at the leak detection housing, a signal indicative of fluid communication between the leak detection medium and one or more of the first fluid or the second fluid.

14. The system of clause 13, wherein the operations further comprise:

obtaining a first leak detection value at the leak detection housing via the sensor;

obtaining a second leak detection value at the leak detection housing via the sensor;

determining, via the controller, a change in a leak detection value at the leak detection housing based at least on the acquired first and second leak detection values; and

determining, via the controller, a leak at the leak detection enclosure based on at least the acquired first and second leak detection values.

15. The system of clause 14, wherein determining a change in the leak detection value at the leak detection enclosure comprises comparing the second leak detection value to the first leak detection value over a period of time.

16. The system of clause 14, wherein the operations further comprise:

pressurizing the leak detection medium to a pressure at the leak detection housing that is greater than a pressure at the first passage and the second passage.

17. The system of clause 13, wherein the operations further comprise:

acquiring a first leak detection value at the first passage via a first passage sensor provided at the first passage;

acquiring a second leak detection value at the second channel via a second channel sensor provided at the second channel;

acquiring, via the leak detection sensor, a change in a leak detection value at the leak detection housing; and

determining, via the controller, a leak at one or more of the first passage, the second passage, and the leak detection housing based at least on a difference between the first leak detection value and the second leak detection value, each of the differences being a change in a leak detection value at the leak detection housing.

18. The system of clause 13, wherein obtaining a signal indicative of the leak detection medium leaking into the first channel and/or the second channel comprises measuring a change in resistance or conductivity at the leak detection medium.

19. The system of clause 13, wherein obtaining a signal indicative of leakage of the leak detection medium into the first channel and/or the second channel comprises measuring a change in a vibration measurement at the leak detection medium.

20. The system of clause 13, wherein the operations further comprise:

adjusting an operating state of the heat exchanger based on the signal obtained from the sensor.