Patent Description:
In fluid handling systems, maintaining surfaces in contact fluid free of deposits and cleaning such surfaces can be essential to providing desired operation and efficiency of associated equipment. For example, maintaining deposit-free heat exchange surfaces in water systems, particularly in industrial water systems, e.g., cooling water systems and heating water systems, is important to optimizing energy efficiency. Mineral deposit, particularly calcium salts, and more particularly calcium carbonate, may be in the form of scaling or fouling. Generally, scaling is the precipitation of inorganic salts on equipment surfaces, and fouling results from deposit of insoluble particles suspended in a liquid. Biofilm fouling on heat exchange surfaces can also cause inefficiency in industrial water systems. For example, compared to mineral deposit, biofilm fouling is generally a <NUM> to <NUM> times better insulator than mineral deposit. Generally, biofilms are slimy, and the microorganisms causing the formation of biofilm fouling may represent merely a small fraction of the biofilm's content.

Monitoring industrial water systems to reduce or prevent deposit (biofilm, mineral, corrosion, or otherwise) onto heat exchange surfaces can provide information that can be utilized to improve, or at least maintain, efficiency in an industrial water system's operation and/or treatment program. In order to achieve optimum performance of the system, the chemical treatment products may be introduced into an industrial water system as a preventative measure in order to minimize the accumulation of biofouling. Should deposits accumulate on surfaces, however, chemical treatment products introduced in the system may require alteration or adjustment. Further, actions may be required in order to reduce or eliminate such deposits. Possible actions to be taken will be dependent upon the type of deposit accumulated. For example, the introduction of a chemical treatment program may be utilized to treat an accumulation of biofilm, while another chemical treatment program or physical intervention may be required in order to treat deposit such as mineral scale.

<CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and <CIT> disclose relevant background information.

The disclosed systems and method utilize the autofluorescence, optic imaging, and heat transfer resistance technologies to concurrently monitor the same simulated surface area for deposits. The systems and methods may provide continuous monitoring, detection, characterization and quantification of deposits. Utilizing this information, an associated control system may initiate alarms, initiate a chemical treatment or physical intervention operation, and adjust corresponding treatment chemicals and preventive protocols to minimize and/or eradicate the issue.

The invention is directed, in one aspect, to a system for analyzing deposit within a fluid handling system as defined in claim <NUM>. The system for analyzing deposit includes a conduit that is adapted to be fluidly coupled to the fluid handling system to receive a flow of representative fluid from the fluid handling system. Contained within the conduit is a substrate that includes a surface disposed to contact the flow of representative fluid. The substrate is representative of a system surface within the fluid handling system. A temperature modification element is disposed to modify the temperature of the substrate. At least one temperature sensor is disposed to measure a temperature transmitted through the substrate in order to determine heat transfer resistance of the substrate. At least one fluorometer is disposable or is disposed to monitor fluorescence of the surface of the substrate at a plurality of fluorometer locations along the substrate, and at least one camera is disposable or is disposed to provide optical images of the surface of the substrate at a plurality of camera locations. The resultant heat transfer data, fluorescence and optical images may be analyzed in order to identify what, if any deposit has accumulated. In at least one embodiment, the system for analyzing deposit includes multiple cameras and/or multiple fluorometers disposed at a plurality of locations in order to acquire data along the substrate.

In at least one embodiment, the determination of the type of deposit may be utilized to determine what, if any, action should take place. For example, the data may be utilized in order to initiate an appropriate chemical treatment program to the representative fluid flow into the system for analyzing. Alternatively or additionally, such chemical treatment program may be provided to the fluid handling system, and/or an additive introduced to the fluid handling system may be modified. In another example, steps may be taken to introduce a cleaning treatment or physically clean the substrate in order to remove mineral deposits.

In at least one embodiment, the system for analyzing deposit includes a moveably mounted fluorometer and/or a movably mounted camera in order to acquire data along the substrate.

In at least one embodiment, the system for analyzing deposit includes a motor adapted to move at least one of the camera to the plurality of camera locations and/or the fluorometer to the plurality of fluorometer locations.

In at least one embodiment, the system for analyzing deposit includes a controller configured to receive data from the at least one temperature sensor, the fluorometer and the camera, determine a level of heat transfer resistance through the substrate, and determine at least one of a nature of the deposit and a level of the deposit based upon data from at least one of the fluorometer, the camera, and the temperature sensor, the controller further being configured to control operation of the motor.

In at least one embodiment, the system for analyzing includes a plurality of temperature sensors, the plurality of temperature sensors including a substrate temperature sensor.

In at least one embodiment, the system for analyzing deposit includes at least one of an ambient temperature sensor, a representative fluid inflow temperature sensor, and a representative fluid outflow temperature sensor.

In at least one embodiment of the system for analyzing deposit, the conduit is adapted to be fluidly coupled to a supply of a chemical treatment for selectively supplying a flow of the chemical treatment to the substrate.

In at least one embodiment, the system for analyzing deposit includes a supply of the chemical treatment fluidly coupled to selectively supply a flow of the chemical treatment to the substrate.

In at least one embodiment of the system for analyzing deposit, the conduit includes an inside surface, the inside surface including the substrate.

In at least one embodiment of the system for analyzing deposit, at least a portion of the conduit is transparent.

In at least one embodiment, the system for analyzing deposit further includes a control system including at least one controller. The controller is configured to receive data from the at least one temperature sensor, the at least one fluorometer and the at least one camera, determine a level of heat transfer resistance through the substrate based upon at least one of temperature data received from the at least one temperature sensor, and at least one of characterize deposits or determine a level of deposits based upon at least one of fluorescence data from the fluorometer, optical data images received from the camera, and heat transfer resistance.

In at least one embodiment of the system for analyzing deposit, the controller is further configured to send out an alarm when at least one of a threshold type and level or preset type and level of deposit is identified on the surface of the substrate.

In at least one embodiment, the system for analyzing deposit is configured to initiate a chemical treatment when at least one of a threshold type and level or preset type and level of deposit is identified on the surface of the substrate.

In at least one embodiment of the system for analyzing, the controller is configured to adjust a deposit and scale control program based upon data received from at least one of the at least one temperature sensor, the fluorometer and the camera, and the type of and level of deposit identified.

In at least one embodiment of the system for analyzing deposit, the controller is configured to adjust at least one of a biocide program for preventative treatment and biofilm inhibition treatment program based upon data received from at least one of the at least one temperature sensor, the fluorometer and the camera and the type and level of deposit identified.

In at least one embodiment, the controller of the system for analyzing deposit is configured to determine a type of deposit based upon at least one of (<NUM>) where both fluorescence data received from the fluorometer and optical data images received from the camera are positive, then determining that biofouling exists; (<NUM>) where optical data images received from the camera are positive, and fluorescence data received from the fluorometer is negative, then determining that mineral scale or fouling exists; and (<NUM>) determining a treatment program specific to the type of deposit identified for corrective action.

In at least one embodiment of the system for analyzing the fluid handling system is an industrial water system.

The invention is also directed, in another aspect, to a method of determining deposit within a fluid handling system as defined in claim <NUM>. The method includes providing a flow of the representative fluid from the fluid handling system to a surface of a substrate representative of a system surface within the fluid handling system, providing temperature altering conditions to an opposed surface of the substrate, measuring heat transfer resistance through the substrate to the representative fluid, monitoring fluorescence of the surface of the substrate at a plurality of locations along the substrate using at least one fluorometer, acquiring optical images of the surface at a plurality of locations along the substrate using at least one camera, wherein monitoring fluorescence and acquiring optical images of the surface of the substrate includes monitoring fluorescence of the surface of the substrate at a plurality of fluorometer locations and acquiring optical images of the surface of the substrate at a plurality of camera locations, and characterizing a nature of a deposit on the surface of the substrate based upon at least one of the monitored fluorescence, the optical images, and the heat transfer resistance. In at least on embodiment the method includes both characterizing the nature of a deposit on the surface of the substrate and the level of deposit on the surface of the substrate based upon at least one of the monitored fluorescence, the optical images, and the heat transfer resistance. In at least one embodiment, the method of determining deposit within a fluid handling system includes both characterizing the nature of a deposit on the surface of the substrate and the level of deposit on the surface of the substrate based upon at least one of the monitored fluorescence, the optical images, and the heat transfer resistance.

In at least one embodiment of the method of determining deposit within a fluid handling system, providing a flow of the representative fluid from the fluid handling system to a surface of a substrate representative of a system surface within the fluid handling system includes providing a substrate that includes a similar material and surface roughness as the system surface within the fluid handling system.

In at least one embodiment of the method of determining deposit within a fluid handling system, providing the flow of the representative fluid from the fluid handling system includes providing the flow of representative fluid to a conduit including the substrate.

In at least one embodiment, the method of determining deposit within a fluid handling system includes fluidly coupling the conduit to the fluid handling system.

In at least one embodiment of the method of determining deposit within a fluid handling system, providing a flow or representative fluid includes providing a flow of representative fluid that simulates a shear stress experienced by fluid within the fluid handling system.

In at least one embodiment of the method of determining deposit within a fluid handling system, providing temperature altering conditions to an opposed surface includes providing temperature altering conditions that simulate temperature conditions representative of temperatures experienced by the system surface within the fluid handling system.

In at least one embodiment of the method of determining deposit within a fluid handling system, measuring heat transfer resistance through the substrate to the representative fluid includes measuring a representative fluid outflow temperature.

In at least one embodiment of the method of determining deposit within a fluid handling system, measuring heat transfer resistance through the substrate includes measuring at least one of an ambient temperature, a temperature of representative fluid flowing to the substrate, a temperature of the surface of the substrate, and a temperature of the temperature modification element.

In at least one embodiment of the method of determining deposit within a fluid handling system, measuring the fluorescence includes moving a fluorometer to a plurality of fluorometer locations along the substrate and measuring the fluorescence of the surface of the substrate at the plurality of fluorometer locations.

In at least one embodiment of the method of determining deposit within a fluid handling system, acquiring optical images includes moving a camera to a plurality of camera locations along the substrate and providing optical images of the surface of the substrate at a plurality of camera locations.

In at least one embodiment of the method of determining deposit within a fluid handling system, measuring the fluorescence includes acquiring measuring fluorescence with a plurality of fluorometers disposed at a plurality of fluorometer locations.

In at least one embodiment of the method of determining deposit within a fluid handling system, acquiring optical images includes acquiring optical images from a plurality of cameras at a plurality of camera locations.

In at least one embodiment, the method of determining deposit within a fluid handling system further includes performing a mechanical cleaning of the surface of the substrate when at least one of a predetermined type of deposit and a predetermined level of deposit is determined.

In at least one embodiment, the method of determining deposit within a fluid handling system further includes selectively supplying a flow of a chemical treatment to the substrate.

In at least one embodiment, the method of determining deposit within a fluid handling system further includes supplying a flow of the chemical treatment to the substrate when at least one of a predetermined type of deposit and a predetermined level of deposit is determined.

In at least one embodiment, the method of determining deposit within a fluid handling system further includes stopping a flow of the chemical treatment to the substrate, and restarting at least one of measuring heat transfer resistance through the substrate to the representative fluid; monitoring fluorescence of the surface of the substrate; acquiring optical images of the surface of the substrate; and determining at least one of a type of and a level of deposit on the surface of the substrate based upon at least one of the monitored fluorescence, the monitored optical images, and heat transfer resistance.

In at least one embodiment of the method of determining deposit within a fluid handling system, monitoring fluorescence of the surface of the substrate includes monitoring the surface of the substrate through a transparent conduit, and acquiring optical images of the surface of the substrate includes acquiring optical images of the surface of the substrate through the transparent conduit.

In at least one embodiment, the method of determining deposit within a fluid handling system further includes providing data from at least one temperature sensor, at least one fluorometer and at least one camera to a control system including at least one controller.

In at least one embodiment, the method of determining deposit within a fluid handling system further includes sending out an alarm when a predetermined type and level of deposit are determined.

In at least one embodiment, the method of determining deposit within a fluid handling system further includes adjusting a deposit and scale control program based upon data received from at least one of the at least one temperature sensor, the fluorometer and the camera, and the type and level of deposit identified.

In at least one embodiment, the method of determining deposit further includes adjusting at least one of a biocide program for preventative treatment and biofilm inhibition treatment program based upon data received from at least one of the at least one temperature sensor, the fluorometer and the camera and the type and level of deposit identified.

In at least one embodiment, the method of determining deposit further includes determining basic deposit based upon at least one of (<NUM>) where both fluorescence data received from the fluorometer and optical data images received from the camera are positive, then determining that biofouling exists; and (<NUM>) where optical data images received from the camera is positive, and fluorescence data received from the fluorometer is negative, and the level of heat transfer resistance does not indicate corrosion, then determining that general deposits or scale exist.

In at least one embodiment of the method of determining deposit, the fluid handling system is an industrial water system.

In at least one embodiment, the method of determining deposit further includes at least one of chemically treating and cleaning the surface of the substrate to create a cleaned surface, acquiring optical images of the cleaned surface of the substrate, and comparing the optical images of the cleaned surface of the substrate with a previously acquired digital image of the substrate, and identifying if corrosion changes have occurred to the cleaned surface of the substrate.

In at least one embodiment, the method of determining deposit further includes draining the representative fluid from the surface of the substrate prior to monitoring fluorescence of the surface of the substrate and acquiring optical images of the surface of the substrate.

In at least one embodiment, the method of determining deposit further includes performing an image analysis to characterize corrosion as general or local, combining analyzed results with process monitoring data, and adjusting a corrosion inhibitor treatment program based on corrosion level and type.

For purposes of this disclosure, the following terms have the definitions set forth below:.

"Deposit" means foreign substances on a surface that may result from suspended solids and/or process contamination, or reaction of a fluid with the surface. "Deposit" includes mineral deposits, corrosion, biofilm fouling, and combined types. Mineral deposits may include, for example, calcium salts, iron, and magnesium, which may be in the form of scaling or fouling. Generally, scaling is the precipitation of inorganic salts on surfaces, and fouling results from deposit of insoluble particles suspended in a liquid. Suspended solids may include, for example, soil particles such as silt, sand, or clay introduced by water and air scrubbing, pollen, and particles, etc., carried by those media. Process contamination may include, for example, any contamination of water or primary process fluids by other process fluids like organic contaminations. Generally, biofilms or biofilm fouling arises from contamination in the fluid of fluid systems that can result in microbial growth on wetted surfaces. Microbial growth may start with a few cells depositing on a surface, which may increase over time into fully formed biofilms-- a population of microbial organisms in a matrix of organic materials produced by the microbial organisms' contamination in the fluid of fluid systems can result in microbial growth on themselves.

"Fluid" means a liquid or flowable substance.

"Fluid handling system" means any system wherein a fluid is circulated. An example of a fluid handling system is an industrial water system.

"Industrial water system" means any system that circulates water as its primary ingredient. Examples of "industrial water systems" may include cooling systems, heating systems, membrane systems, paper making process or any other system that circulates water as defined above.

"Protocol" means a set of instructions that may include concentrations, flow rates, mixing rates, temperatures, volumes, masses, or any number of other criteria known to those skilled in the art. As related to this invention, a "protocol" may control the mixing and/or injection of treatment into the water of an industrial water system. A "protocol" can be created and/or stored using an electronic input-output device, which may be a computer, a programmable logic controller (PLC), or any input-output device programmed with the appropriate software and/or firmware, which communicates the instructions to carry out the "protocol" in an automated fashion. Additionally, the "protocol" includes optimization methods and techniques based on physical models, empirical models, semi-empirical models, or a combination of models to develop a set of instructions.

"Sensor" means a measurement device that measures a parameter and is capable of outputting the measured parameter.

"Water" means any substance that has water as a primary ingredient. Water may include pure water, tap water, fresh water, brine, steam, and/or any chemical, solution, or blend that is circulated in an industrial water system.

Turning to <FIG> there is illustrated an exemplary fluid handling system <NUM>. While the details are the exemplary fluid handling system <NUM> are not illustrated in detail, those of skill in the art will appreciate that such a fluid handling system <NUM> may include an industrial water system <NUM> what circulates water as its primary ingredient. While not illustrated in detail, industrial water systems may include, for example, cooling systems, heating systems, membrane systems, paper making process or any other system that circulates water.

In accordance with the disclosure, there is provided a system for analyzing deposit <NUM> within a fluid handling system <NUM>. The system for analyzing deposit <NUM> may be disposed as a separate arrangement that includes a fluid connection <NUM> or the like fluidly coupling the system for analyzing deposit <NUM> to the fluid handling system <NUM>, or the system for analyzing deposit <NUM> may be incorporated into the fluid handling system <NUM>. The system for analyzing deposit <NUM> may be selectively fluidly coupled to or within the fluid handling system <NUM> by any appropriate arrangement.

The system for analyzing deposit <NUM> includes a conduit <NUM> housing a substrate <NUM>. The substrate <NUM>, and, more specifically, the substrate surface <NUM> may be formed of any appropriate material representative of the surface within the fluid handling system <NUM>. The surface <NUM> of the substrate <NUM> is preferably of the same material type and surface characteristics, as well as held at the same surface temperature as surfaces within the fluid handling system <NUM> such that representative fluid flow across the surface <NUM> at a rate similar to that exhibited within the fluid handling system <NUM> will result in similar shear stress on the surface <NUM>.

By way of example only, the surface <NUM> may be a metal surface, such as type <NUM> stainless steel, type <NUM> stainless steel, low carbon steel (Grades <NUM> to <NUM>), admiralty brass, copper, <NUM>:<NUM> copper nickel, <NUM>:<NUM> copper nickel, aluminum <NUM>, Monel®, titanium, titanium alloys, aluminum bronze, and galvanized steel. The surface <NUM> may alternatively be formed of a nonmetal surface, such as wood, or a polymeric material such as polyvinylchloride (PVC) or polypropylene.

The surface <NUM> of the substrate <NUM> additionally preferably presents a surface roughness such that the shear stress of representative fluid flowing across the surface <NUM> is representative of the surface within the fluid handling system <NUM>. By way of example only, the surface roughness may be presented as Grade Ra range [<NUM> to <NUM>] um (ISO grade numbers [Nl - N12]), and yield a shear stress as liquid linear velocity of [<NUM>-<NUM>] ft/s at a surface temperature range of -<NUM>°F - <NUM>°F (-<NUM> - <NUM>). In a more specific example, the surface roughness may be presented as Grade Ra range <NUM>-<NUM> (ISO grade numbers N4-N7), and yield a shear stress as liquid linear velocity of <NUM>-<NUM> ft/s at a surface temperature range of <NUM>°F - <NUM>°F (<NUM> - <NUM>°).

The conduit <NUM> is fluidly coupled to the fluid handling system <NUM> to receive a flow of representative fluid from the fluid handling system <NUM>. Preferably, flow through the conduit <NUM> substantially simulates flow through the fluid handling system <NUM> itself. In this regard, a flow meter <NUM> may be provided to monitor the flow to the conduit <NUM>. In the exemplary embodiment of <FIG>, an inlet valve <NUM> is provided in a fluid connection <NUM> that is fluidly coupled to flow within the fluid handling system <NUM>. In the embodiment of <FIG>, the inlet valve <NUM> may be a flowrate controlled valve. In this way, fluid flowing across the surface <NUM> substantially simulates the conditions of fluid flowing across the surface within the fluid handling system <NUM>, including shear stresses.

The inlet valve <NUM> may be selectively operated to provide or prevent flow from the fluid handling system <NUM> to the system for analyzing deposit <NUM>. In at least one embodiment, there is further provided an inlet side drain valve <NUM> that may be utilized in concert with valve <NUM>, for example, to drain the system for analyzing deposit <NUM> or cleaning the surface <NUM>.

Flow from the system for analyzing deposit <NUM> may be directed as appropriate. For example, as illustrated in <FIG>, flow may be directed back to the fluid handling system <NUM> in some embodiments (see fluid connection <NUM>). In order to selectively direct flow to a drain <NUM>, however, an outlet valve <NUM> may be provided. In this way, if it is undesirable to direct flow back to the fluid handling system <NUM>, the outlet valve <NUM> may direct the flow to a drain <NUM>. In at least one embodiment, such as the embodiment of <FIG>, the representative fluid flowing from the system for analyzing deposit <NUM> may be directed to the fluid handling system <NUM>. In <FIG>, the reference numbers of <FIG> are utilized for the same or similar components, adding a "<NUM>" prior to the number, that is "1xx".

The conduit <NUM> may likewise be of any appropriate design. For example, the conduit <NUM> may be a tube through which fluid flows, or a tank through which fluid is directed. In at least one embodiment, the conduit <NUM> is a quartz glass tube, and the substrate <NUM> is a separate element that is disposed within the conduit <NUM>. The substrate <NUM> may be, for example, at least a portion of a tubular structure <NUM> extending within the conduit <NUM>. In at least one embodiment, the conduit <NUM> itself includes at least a section that forms the substrate <NUM> and presents the surface <NUM> within the conduit <NUM>. The surface <NUM> may include a single surfaces or a plurality of surfaces, and may have any surface contour. For example, the surface <NUM> may be convex, concave, or flat, or any combination of the same.

The system for analyzing deposit <NUM> further includes a temperature modification element <NUM> disposed to modify the temperature of the substrate <NUM>, wherein modification of the temperature of the substrate is to be understood as an application of a temperature other than the temperature of the representative fluid flowing past the substrate <NUM>. The temperature modification element <NUM> may be, for example, a heating element or a cooling element.

The temperature modification element <NUM> may be of any appropriate design and may be disposed at any appropriate position relative to the substrate <NUM> so long as it applies a temperature that may be transmitted through at least a portion of substrate <NUM> to the surface <NUM> configured to be disposed adjacent the representative fluid. The operation of the temperature modification element <NUM> may be controlled by a relay <NUM>, such as a heater relay or the like. In at least one embodiment, the temperature modification element <NUM> may be disposed to provide a modifying temperature to an opposed surface <NUM> of the substrate <NUM>, that is a surface of the substrate <NUM> opposed to the surface <NUM> in contact with the representative fluid. Referring to <FIG>, for example, the temperature modification element <NUM> may in the form of a rod <NUM> extending through at least a portion of a substrate <NUM> having a tubular structure <NUM>. In an alternative embodiment, the substrate <NUM> itself may include the temperature modification element <NUM>, as shown, for example, in <FIG>. In <FIG>, the substrate <NUM> may include a temperature modification element <NUM> that extends through or into the material of which the substrate is formed. In the illustrated embodiment, for example, surface <NUM> may be an outer surface of the rod <NUM> itself. By way of further example, a heated liquid may be pumped or otherwise circulated through the temperature modification element <NUM>.

In order to evaluate a condition of the surface <NUM> of the substrate <NUM>, heat transfer resistance through the substrate <NUM> may be determined. Those of skill in the art will appreciate that surface conditions such as corrosion and the deposit of minerals and other solids or fouling may affect the transfer of heat or coolness through the substrate and into the fluid.

In order to determine heat transfer resistance through the substrate <NUM>, at least one temperature sensor is provided. In the embodiment of <FIG>, a plurality of temperature sensors <NUM>, <NUM>, <NUM>, <NUM> are provided. In at least one embodiment, at least a surface temperature sensor <NUM> is disposed to measure a temperature near or substantially adjacent the surface <NUM> of the substrate <NUM>. While the surface temperature sensor <NUM> may be disposed at an alternative position along the substrate <NUM>, in the embodiment illustrated in <FIG>, the surface temperature sensor <NUM> is disposed proximal to an outlet end <NUM> of the substrate <NUM>, that is, at or near the outlet end <NUM> where the representative fluid flows from the system for analyzing deposit <NUM>. In this way, representative fluid that is at or near the outlet end <NUM> of the substrate <NUM> will presumably have reached a temperature that may closely approximate a temperature of the surface <NUM> of the substrate <NUM>. Utilizing data from the temperature sensors <NUM>, <NUM>, <NUM>, <NUM> as well as a temperature of the temperature modification element <NUM> and flow meter <NUM>, a representative heat transfer resistance figure may be calculated.

In at least one embodiment, the surface temperature of the substrate <NUM> may be identified by an operator. In this mode of operation, the surface temperature is kept constant by a feedback control via the surface temperature sensor <NUM>, the temperature modification element <NUM> and a control system <NUM> (discussed below), that is, algorithms associated with the control system <NUM>. The temperature of the temperature modification element <NUM> may be increased or decreased to obtain a desired temperature at the surface temperature sensor <NUM>. In this mode of operation, the overall heat transfer coefficient may be calculated, for example, based upon data from the temperature sensors <NUM>, <NUM>, <NUM>, <NUM>, the flow meter <NUM>, and the temperature modification element <NUM>. In a second mode of operation, power to the temperature modification element <NUM> may be kept constant, and the heat transfer resistance calculated based upon data from the temperature modification element <NUM> and the surface temperature sensor <NUM> as deposit conditions on the surface <NUM> change.

Additional sensors may be provided in order to provide a more precise representation of the heat transfer resistance through the substrate <NUM>. For example, an inlet fluid temperature sensor <NUM> may be disposed to measure the temperature of fluid entering the conduit <NUM>, an outlet fluid temperature sensor <NUM> may be disposed to measure the temperature of fluid exiting the conduit <NUM>, and an ambient temperature sensor <NUM> may be disposed to measure the temperature surrounding the conduit <NUM>.

In order to additionally monitor deposit that may occur on the surface <NUM> of the substrate <NUM> as a result of the flow of representative fluid from the fluid handling system <NUM>, the system for analyzing deposit <NUM> includes at least one fluorometer <NUM> and at least one camera <NUM>. In at least one embodiment, the fluorometer <NUM> and camera <NUM> are contained in a single unit, that is, the single unit is able to obtain both optical images and UV data. Such optical images may be, for example, digital images. It will be appreciated, however that the fluorometer(s) <NUM> and camera(s) <NUM> may be mounted together, or separately.

To provide the fluorometer(s) <NUM> and camera(s) <NUM> visual access to the surface <NUM> of the substrate <NUM>, the conduit <NUM> includes at least one substantially transparent section <NUM> through which the surface <NUM> of the substrate <NUM> may be observed. In an embodiment wherein the conduit <NUM> is a quartz glass tube, the conduit <NUM> itself is transparent, allowing visual access to the surface of the substrate <NUM> contained therein. In at least one embodiment, the conduit <NUM> may contain one or more transparent sections <NUM> disposed in a position or positions allowing visual access to surface <NUM>. In an embodiment wherein the conduit <NUM> itself incorporates the substrate <NUM>, the conduit <NUM> may likewise include one or more such transparent sections <NUM>. Those of skill in the art will appreciate that fluorescence and optical imaging data may be obtained through the representative fluid, while in other arrangements it may be desirable to drain the representative fluid from the conduit <NUM> before obtaining such data.

The fluorometer(s) <NUM> and camera(s) <NUM> are configured to monitor fluorescence and provide a plurality of images at locations along the surface <NUM> of the substrate <NUM>. Inasmuch as biofilm occurrence is random, that is, biofilm can start essentially anywhere along the conduit <NUM>, this multipoint imaging may enhance reliability of data acquired for biofilm detection in particular. In at least one embodiment, five such monitoring locations and images are provided. In the embodiment of <FIG>, the fluorometer <NUM> and camera <NUM> are movably mounted such that they may be advanced along the length of the substrate <NUM> to monitor fluorescence and acquire a plurality of images. The fluorometer <NUM> and camera <NUM> may be movably mounted by any appropriate arrangement. By way of example only, a mounting <NUM> of the fluorometer <NUM> and camera <NUM> may include an internally threaded section <NUM> that may be engaged with a threaded shaft <NUM> that may be rotated by a motor <NUM>, rotation of the threaded shaft <NUM> advancing the fluorometer <NUM> and camera <NUM> to a plurality of locations along the substrate <NUM> in order to monitor fluorescence and obtain the plurality of images. In at least one embodiment, the fluorometer <NUM> and camera <NUM> are configured to scan the surface <NUM> of the substrate <NUM> between position sensors <NUM>, <NUM> in an operator controlled time interval. Those of skill in the art will appreciate, however, that other arrangements may be provided to permit the fluorometer <NUM> and camera <NUM> to observe a plurality of locations.

In at least one embodiment, a fluorometer <NUM> and camera <NUM> are combined by using a UV sensitive camera, e.g., bare CCD or image intensified, to collect spatially resolved UV fluorescence with using the UV excitation light source and standard image using a white light source.

In at least one embodiment, a camera <NUM> is a hyperspectral imaging device providing wavelength dependent image analysis for improved classification of the deposit characteristics on the surface.

Alternatively or additionally, a plurality of fluorometers <NUM> and/or cameras <NUM> may be provided in order to monitor fluorescence and obtain a plurality of images of the surface <NUM> of the substrate <NUM>. In the embodiment of <FIG>, for example, three fluorometers <NUM> and three cameras <NUM> are spaced along the length of the conduit <NUM> proximal to a plurality of transparent sections <NUM>. While the fluorometers <NUM> and cameras <NUM> are stationarily mounted in this embodiment, those of skill in the art will appreciate that one or more of the fluorometers <NUM> and cameras <NUM> may likewise be movably mounted.

Those of skill in the art will appreciate that the use of monitoring relative to fluorescence, optic and heat transfer conditions on the same surface <NUM> facilitates, the diagnosing of the nature of deposits, the stage or level of the deposits, and rate at which deposits form, particularly biofilms. The analysis of this information further facilitates the construction of effective treatment protocols to reduce or eliminate such deposit formation. The use of the three technological fields reduces the possible interference that may result from the use of a single technology. Moreover, obtaining data at multiple data points may increase the reliability of detecting, identification, and treatment.

Optical camera and image analyzing technology may be utilized in the identification of deposits resulting from general deposits, scale, corrosion and microbiological changes on the surface <NUM> by contrast change, color and color changes, surface texture, and coverage monitoring and accumulation outputs, in particular, relative to initial start point values. Fluorescence monitoring at the same areas facilitates identification of biofouling, that is, a biomass/biofilm portion of the deposits. Data regarding heat transfer resistance, as discussed above facilitates further refinement of the analyses, particularly when either or both of the fluorescence and optical signal are positive. The combined analyses based upon the three different types of input may be utilized to determine the basic nature of deposits on the surface <NUM> of the substrate <NUM>, which is representative of deposits that may result in the fluid handling system <NUM>. For example, in at least one embodiment, when both an optical signal and fluorescence monitoring results are positive, it would be indicative of biofouling, or biofouling and scaling. In at least one embodiment, if the optical signal is positive, but fluorescence monitoring is negative and corrosion is not observed, it would be indicative of general deposits or a scale control issue. In at least one embodiment, if the optical signal is positive and a brownish colored deposit is observed, it may be indicative of a corrosion issue where the deposit may not be affected by a chemical treatment cycle. Heat transfer data may further refine the analyses when either or both of the optical signal and fluorescence are both positive by determining the impact of fouling on the heat transfer, and by classifying the type of fouling, e.g., mineral or biofilm; the determination of the heat transfer resistance facilitates an estimation of the thickness.

The data utilized to determine the heat transfer resistance, including readings from any or all of the sensors <NUM>, <NUM>, <NUM>, <NUM> and flow meter <NUM>, along with fluorescence data from the fluorometer(s) <NUM> and optical images from the camera(s) <NUM> may be utilized to evaluate deposits, and apply an appropriate chemical treatment from a source <NUM>, such as a tank. The information may further be utilized in the formation or adjustment of a chemical treatment protocol for the larger fluid handling system <NUM>.

Heat transfer resistance may be utilized to detect, characterize, and quantify corrosion. <CIT> discloses the use of an imaging system to monitor corrosion on a metal substrate. In the system for analyzing deposit <NUM> disclosed herein, heat transfer resistance may be utilized to detect microbial induced corrosion (MIC) and under deposit corrosion on the heated metal substrate. By way of example only, MIC corrosion on a mild steel substrate will appear as dark spots or regions on the metal substrate due to the corrosion products. Collecting a sequence of substrate images over time allows tracking the detection of a MIC feature and activity level, i.e., the rate of change in the MIC feature area. This provides an indication of the corrosion level and whether a treatment program quenching the corrosion rate. However, details on the impact of corrosion and classification, e.g., local versus general, may not be apparent because of a biofilm and/or scale coating on the substrate surface. By applying an in-situ chemical treatment procedure to the substrate surface <NUM>, e.g., acid, bleach, etc., to remove the surface deposit, a clean image of the surface <NUM> may be captured. If corrosion exists, surface defects, e.g., pits, may be detectable in the image. Classification of the corrosion as local or general is then calculated based on the area coverage, typically, corrosion features covering over <NUM>% of the substrate area being classified as general. In addition, an estimated corrosion rate may be determined based upon the time the substrate was exposed to the representative fluid prior to cleaning. While corrosion rates are generally determined by weight loss, in the disclosed system rates may be inferred from the image data.

Referring to <FIG>, data from the sensors <NUM>, <NUM>, <NUM> and flow meter <NUM>, as well as data from the fluorometer(s) <NUM> and images from the camera(s) <NUM> at a plurality of positions along the substrate <NUM> are provided to a control system <NUM>. The control system <NUM> includes at least one controller <NUM> and may include a user interface <NUM> and additional analysis software and hardware, server, or cloud system(s) <NUM>, as well as fluid handling system treatment controls <NUM>.

The control system <NUM> indicated generally by an arrow in <FIG> may operate to control certain aspects of the system for analyzing deposit <NUM>. The control system <NUM> may be a stand-alone system that may communicate with one or more systems controlling aspects of the fluid handling system <NUM> or may control aspects of the fluid handling system <NUM>.

The control system <NUM> may include components at the system for analyzing deposit <NUM> and may also include components located remotely from the system for analyzing deposit <NUM>. As a result, the functionality of control system <NUM> may be distributed so that certain functions are performed at the system for analyzing deposit <NUM> and other functions are performed remotely, such as at a remote operations center. The control system <NUM> may include a communications system including both a wireless communications system and a wired communications system for transmitting signals between components.

The control system <NUM> may include an electronic control module or controller <NUM> that may receive various input signals from components of the system for analyzing deposit <NUM> as well information from the fluid handling system <NUM> via wireless communications system, wired communications systems, control systems and sensors associated with the system for analyzing deposit <NUM>, or from any other source. The control system <NUM>, including the controller <NUM>, may control and provide input to the operation of the various aspects of the system for analyzing deposit <NUM>, including the specific tasks and operations performed by components of the system for analyzing deposit <NUM>.

The controller <NUM> may be an electronic controller that operates in a logical fashion to perform operations, execute control algorithms, store and retrieve data and other desired operations. The controller <NUM> may include or access memory, secondary storage devices, processors, and any other components for running an application. The memory and secondary storage devices may be in the form of read-only memory (ROM) or random access memory (RAM) or integrated circuitry that is accessible by the controller. Various other circuits may be associated with the controller <NUM> such as power supply circuitry, signal conditioning circuitry, driver circuitry, and other types of circuitry.

The controller <NUM> may be a single controller or may include more than one controller disposed to control various functions and/or features of the control system <NUM>. The term "controller" is meant to be used in its broadest sense to include one or more controllers and/or microprocessors that may be associated with the system for analyzing deposit <NUM> and that may cooperate in controlling various functions and operations at the fluid handling system <NUM>. The functionality of the controller <NUM> may be implemented in hardware and/or software without regard to the functionality. The controller <NUM> may rely on one or more data maps as well as characteristics and capabilities of the components of the system for analyzing deposit <NUM> and the fluid handling system <NUM> that may be stored in the memory of controller. Each of these data maps may include a collection of data in the form of tables, graphs, equations, and/or historical data.

The control system <NUM> may be configured to control the operation of the motor <NUM> to control the location of the fluorometer <NUM> and the camera <NUM> along the conduit <NUM>, as well as the operation of the fluorometer <NUM> and the camera <NUM>. The control system <NUM> may be further configured to control or adjust cleaning or chemical treatment protocols of either or both of the fluid handling system <NUM> and the system for analyzing deposit <NUM>.

The user interface <NUM> may be utilized to control and monitor a number of the aspects of the system for analyzing deposit <NUM>, as well as other functions that will be clear upon reading the further discussion below. The user interface <NUM> may be utilized to, for example, direct control the number of images obtained, and the frequency at which the fluorometer <NUM> and camera <NUM> obtain images. By way of further example, the user interface may be utilized to set UV dose ranges for the fluorometer <NUM>. In at least one embodiment, the auto fluorescence effective UV dose range for biofilm monitoring is range <NUM>-<NUM> mJ/cm<NUM> per half hour for obtaining optimized biofilm growth. The user interface <NUM> likewise may be utilized to control the flow rate of representative fluid through the system for analyzing deposit <NUM> by controlling inlet valve <NUM>.

By controlling the UV dosage and tracking the fluorescence signal over time, the method provides a means to determine the level of biofouling. For example, the method may include applying a large UV dosage outside the standard range to kill the bacteria on the surface and then applying a normal UV dosage range for biofilm detection, i.e., to avoid quenching, and tracking the signal level provides an indication of the level of biofouling.

Via user interface <NUM> or/and controller <NUM>, the control system <NUM> may be configured to apply various control algorithms in order to monitor and characterize and quantify biofouling conditions, corrosion, and deposit/scale. The configuration also can be done via independent computers or controllers via control programs. By way of example only, the control system <NUM> may be configured to characterize the nature of deposits, including biofouling conditions, send out alarms when needed, initiate or schedule system chemical treatment, adjust biocide protocols for preventative treatment as well as biofilm growth inhibition treatment. The control system <NUM> may be configured to monitor, characterize and quantify, and deposit problems, and initiate or adjust deposit control protocols. The control system <NUM> may further be configured to monitor, characterize and quantify, and alarm corrosion problems, and initiate or adjust a corrosion control protocol. The control system <NUM> may supply control operation and adjustment of the fluid handling system treatment controls <NUM> and/or, referring to <FIG>, selective application of additives to the fluid handling system <NUM>.

Prior to the initiation of and/or subsequent to completion of a monitoring cycle, a chemical treatment may be applied to surface <NUM>. In the illustrated embodiment, a pump <NUM> may be operated to selectively pump chemical treatment from a source <NUM> through a check valve <NUM> through line <NUM>. A chemical treatment is a chemical formulated to clean the deposits on the surface <NUM> of the substrate <NUM>, sensor surfaces and the system for analyzing deposit <NUM> generally. The chemical treatment may be any appropriate chemical treatment, and may be dictated by type of fluid handling system <NUM> involved. By way of example, in at least one embodiment, the chemical treatment may be Nalco DC <NUM>, a formulated chemical product for cleaning sensor and system surfaces.

Via the user interface <NUM>, a chemical treatment sequence may be initiated and continued for a set period of time as scheduled by an operator or it may be initiated and continued for a set period as set by an operator or preset by the control system <NUM>. In some embodiments, the chemical treatment sequence may be initiated by the control system <NUM> when the system for analyzing deposit <NUM> has identified the surface <NUM> to have reached predetermined deposit index level for a defined period of time; the specifics of the deposit index level and the defined period of time may be preset by an operator via the user interface <NUM>.

A chemical treatment sequence may include, for example, the controller <NUM> turning off the heater relay <NUM>, the system for analyzing deposit allowing the representative fluid to continue to run through the conduit <NUM> to allow the substrate <NUM> to cool down to the temperature of the representative fluid entering the system for analyzing deposit <NUM>, that is the temperature as measured by the inlet fluid temperature sensor <NUM>. The controller <NUM> directing the inlet valve <NUM> to close, the representative fluid may then be drained from the system for analyzing deposit <NUM> by the controller <NUM> causing the drain valve <NUM> and outlet valve <NUM> to open. The controller <NUM> then may direct the closure of drain valve <NUM> and outlet valve <NUM>. The controller <NUM> may then cause operation of pump <NUM> for a period of time, as discussed above, in order to pump chemical treatment from source <NUM> through check valve <NUM> and line <NUM> to the conduit <NUM>. The length of time for which the pump <NUM> operates may be calibrated to pump a required volume for treating the system for analyzing deposit <NUM>. The chemical treatment then remains within the system for analyzing deposit <NUM> for a set period of time as discussed above, permitting the chemical treatment to react with the deposits. The controller <NUM> then directs the inlet valve <NUM> to open, allowing the representative fluid to flush through the chemical treatment and placing the system for analyzing deposit <NUM> back in service. In at least one embodiment, the controller <NUM> opens the outlet valve <NUM> to allow the representative fluid to flush the chemical treatment through to drain <NUM>.

The fluorometer <NUM> and/or camera <NUM> may additionally be utilized during the cleaning treatment. By incorporating the fluorometer <NUM> and/or camera <NUM> during the cleaning steps, the resulting data may assist in a determination of the level of cleaning on the substrate <NUM>, i.e., "proof-of-clean. " If the level of cleaning of the substrate <NUM> is not sufficient after a cleaning cycle, then the process can be repeated. Tracking the number of cleaning cycles and length of the cleaning cycles in combination with the image analysis may serve as a target reference, and may provide an indication on the level of deposit on the substrate <NUM> as well as type. Data collected during cleaning process can be stored for comparison and/or trending over time.

Data obtained by the controller <NUM> may be provided to the user interface <NUM> or otherwise analyzed with the control system <NUM>, and may, for example, be sent to server <NUM> independently or via controller <NUM> at schedulable frequency. In addition to data from the various sensors within the system, data from the fluorometer(s) <NUM> and camera(s) <NUM> may be provided to the controller <NUM> and elsewhere in the control system <NUM>. For example, in at least one embodiment, biofilm detection is obtained via Ex280 and Em340 nm. In at least one embodiment, it has been determined that the signal from the fluorometer <NUM> is proportional to general bacterial concentration. Further, the control system <NUM> may analyze optical images provided by the camera <NUM> may be compared to optical images captured after a chemical treatment cycle to determine the extent of changes, including surface coverage percentages, per unit of time. Control algorithms within the control system <NUM> may then determine theoretic biofilm thickness in the deposit detected from bacterial concentration and coverage percentage.

Turning to <FIG>, there is shown an example of biofilm growth detection by autofluorescence and optic methods, more specifically, fluorescence and optic fouling index as a function of time. Fluorescent signal showed the dynamics of biofilm growth on the heater surface while the digital image analyses show relatively stable build ups. In this example, the digital image analysis consists of illuminating the surface with white light, capturing the image, and integrating the image to an overall intensity, thereby reducing the image to a single point. The fluorescence method detected biofilm growth about <NUM> hours earlier than the optical method in this example. The trend developed from the image analysis indicates that the deposit formation is on the substrate surface and is increasing with time. The fluorescence measurements provide classification of the deposit as a biofilm.

Turning to <FIG>, there is shown an example of biofilm growth, detected by autofluorescence, compared with surface heat transfer resistance. The fluorescent signal displayed the dynamics of biofilm growth on the heater surface, while the heat transfer resistance showed a relatively delayed response since it is depended on the types, thickness, and surface coverage of the buildups, etc. In this example, the fluorescence method detected biofilm growth reliably days before the growth affected heat transfer efficiency. The autofluorescence showed more dynamics of the biofilm growth conditions on the monitored surface.

Turning to <FIG>, there is shown an example of biofilm growth and compared with bacterial bioactivity, more specifically, fluorescence and bacterial ATP measurements as a function of time. Biofilm growth was detected by Tl fluorescence and bioactivity was determined by measuring bacterial ATP. Free ATP measurements on separated coupon surface were consistent with biofilm growth shown in this graph. The ATP levels were expressed as relative light units (RLU) by Hygiena's Ultrasnap system (Hygiena, ATP test product ASY0093 US <NUM> Ultrasnap for Surface ATP Test, <NUM>).

Turning to <FIG>, there is shown an example of biofilm growth (Tl fluorescence) and bacterial counts, more specifically, fluorescence and total bacterial counts as a function of time. Total viable bacteria (TVC) counts were determined from samples on separated coupon surface. Bacterial populations on coupon surfaces were sampled and numerated using plating technique. The <NUM> Petrifilm was used for total aerobic bacterial counts (<NUM> Petrifilm Aerobic Count Plates, distributed by Lab Media, Product No. Part # LR11001). It was found that growth of total bacteria on coupon surfaces was very well correlated with biofilm growth on heater surfaces monitored by autofluorescence, as shown in this graph.

Turning to <FIG>, there is shown an example of biofilm growth dynamics in a mixed deposit, more specifically, fluorescence and deposit fouling index as a function of time. Biofilm growth was detected by Tl fluorescence and the change in the mixed deposit was determined from Deposit Index. The Deposit Index may be an index generated by the output difference of a paired sensor output between a clean sensor and a fouled sensor over the output of the clean sensor at a given time. Biofilm growth on a surface depends on many factors. In this experiment, no treatment for scale, corrosion and microbial growth was applied in the cooling water. The fouling process is natural for both biofouling and scale under the cooling water operating conditions. The fluorescence decreased as the conditions of the surface deposits changes, as shown in the graph.

Turning to <FIG>, there is shown an example of biofilm fluorescence and turbidity changes as a result of biocide treatment, more specifically, biofilm fluorescence, biocide treatments, and water turbidity as a function of time. The autofluorescence from biofilms was used to evaluate the biocide effect. When biocide dose <NUM> was applied, biofilm fluorescence decreased dramatically, as indicated in the graph. It was confirmed that the biofilm was destroyed and released from the surface by the increase in cooling water turbidity. The fluorescence decreased further as more biocides were dosed, as shown in the graph.

Claim 1:
A system for analyzing deposit (<NUM>) within a fluid handling system (<NUM>) having a system surface, the system comprising:
a conduit (<NUM>), the conduit (<NUM>) adapted to be fluidly coupled to the fluid handling system (<NUM>) to receive a flow of representative fluid from the fluid handling system (<NUM>);
a substrate (<NUM>) disposed within the conduit(<NUM>), the substrate (<NUM>) having a surface (<NUM>) disposed to contact the flow of representative fluid, the substrate (<NUM>) being representative of the system surface within the fluid handling system (<NUM>);
a temperature modification element (<NUM>), the temperature modification element (<NUM>) being disposed to modify the temperature of the substrate (<NUM>);
at least one temperature sensor (<NUM>, <NUM>, <NUM>, <NUM>), the temperature sensor being disposed to measure a temperature transmitted through the substrate (<NUM>);
characterized in that the system further comprises:
at least one fluorometer (<NUM>), the at least one fluorometer (<NUM>) being disposable or being disposed to monitor fluorescence of the surface (<NUM>) of the substrate (<NUM>) at a plurality of fluorometer (<NUM>) locations; and
at least one camera (<NUM>), the at least one camera (<NUM>) being disposable or being disposed to provide optical images of the surface (<NUM>) of the substrate (<NUM>) at a plurality of camera locations.