Condenser Ball Cleaning Equipment

Product Details

I. Overview:

The ball cleaner is a device used to effectively clean the condenser cooling tubes of a steam turbine generator set during operation. The performance of this device directly affects the cleanliness of the condenser and its heat transfer efficiency. Its application range is quite extensive, as it is not only suitable for the condensers of steam turbines but also for the cooling tube cleaning of fixed tube sheet heat exchangers in the oil, chemical, and other industries. Under continuous operation without reducing load, this device can be put into use at any time, maintaining the cleanliness of the cooling tubes, extending their service life, reducing labor intensity, and is an indispensable device for improving the economic benefits of power plants and ensuring the safe operation of condensers.

Our factory's rubber ball device is a replacement product for other rubber ball cleaning devices currently available. The main components, the secondary filter and the ball collection net, come in two current types. It features the following characteristics:

1. Innovative and rational design structure; 2. Easy to operate; 3. High gel ball recovery rate (≥96%); 4. Strong secondary filter efficiency.

Section II: Ball Cleaning System Diagram

The rubber ball cleaning system consists of a secondary filter, ball collection net, ball loading chamber, rubber ball pump, separator, valves, pipelines, and electrical control equipment.

Section 3: Working Principle:

Select appropriate sponge rubber balls, with a wet diameter slightly larger than the cooling tube inner diameter (about 1-2mm) and a wet specific gravity similar to water. Place the balls into the ball chamber through the handhole, with a quantity approximately 10% of the condenser's water inlet copper tube count. Then, activate the ball pump and open the ball valves at both ends of the system. The balls are carried into the condenser water chamber by the water flow with a slightly higher pressure at the circulation water inlet. As the balls are a soft, elastic, porous material, under the pressure difference between the circulation water inlets and outlets, they are compressed through the cooling tubes, cleaning the inner diameter once. The dirt inside the tubes is washed away with the water flow. The balls, along with the circulating water, enter the ball collection net through the outlet pipe. Blocked by the collection net plate, the balls are separated and then extracted by the ball pump, returning to the ball chamber for reuse. This process continuously and automatically cleans the condenser cooling tubes.

Part Four: Components of the Gel Ball Cleaning System:

1. Secondary Filter: The secondary filter is one of the main equipment in the cooling water purification system. It removes all debris larger than 6mm, playing a crucial role in ensuring the smooth flow of rubber balls and the normal operation of the condenser. For detailed working parameters and other information, refer to the manual for "New Type Electrically Rotating Backflush Secondary Filter."

2. Ball Catcher: The ball catcher is a crucial component in the rubber ball cleaning system, installed on the condenser outlet pipe section. Its function is to separate rubber balls from the cooling water, ensuring it is leak-proof and ball-free. After the balls are collected, they are guided out through a pipe from the ball catcher and returned to the ball loading room. Our factory's ball catcher features the latest design, with its grate panel being rotatable. During the operation of the rubber ball unit, the grate panel is positioned for ball collection. When the cleaning unit is not in use, the grate panel can rotate to align with the water flow direction, reducing water resistance and also serving to clear debris from the grate.

The rotation and positioning of the mesh plate are executed by an electric actuator (the small ball receiver is manually controlled). Whether the mesh plate is in place is a crucial factor for ensuring the ball receiver's collection efficiency.

3. Ball Loading Room

The ball loading chamber is a device in the rubber ball cleaning system for adding, removing, storing balls, and observing the ball circulation. It is divided into Type I and II based on the storage capacity of the balls. It is categorized into electric and manual types according to user requirements. When the control valve for switching the operation status of the ball loading chamber is set to the "feed ball" position, the balls can freely and continuously circulate within the system. When the switch valve is set to the "collect ball" position, the balls are blocked inside the loading chamber, allowing cooling water to still pass through, and all balls in circulation return to the ball loading chamber.

4. Spherical ball pump

The rubber ball pump is the power source that drives the continuous circulation of rubber balls in the rubber ball cleaning system. The water flow, extracted from the ball intake net and passing through the rubber balls, increases the pressure head and is then sent into the cooling water pipes. This pump is a fixed, trouble-free centrifugal pump, featuring non-blocking, non-breaking balls, and minimal wear on the balls. Depending on different operating conditions, different parameter specifications of rubber ball pumps are selected. For small condensers and heat exchanger systems, a low-flow pump should be chosen to reduce hot water backflow; for systems with long rubber ball conveying pipelines and significant resistance loss, a high-head pump should be selected to ensure the normal circulation of the balls.

5. Operational Control Cabinet (CGK-Ⅱ)

(1) Employed with an HMI touch screen control, more advanced and rational, with a low failure rate. (HMI human-machine interface touch screen and PLC)

(2) Achieve precise location control for more accurate and targeted detection, ensuring high recovery rates for the balls. The entire process is automated. Long-distance control (operation and monitoring) via a single cable is achievable.

6. Divider

A分流器 is a three-way (pipe) valve. By switching its guide plates, it allows the ball to enter the condenser on the side that needs cleaning. It can also be used as a three-way pipe for the convergence of the ball collection net's outlet pipe and the divergence of the ball receiving pipe.

V. Installation Instructions and Precautions:

Prior to the operation of the rubber ball cleaning unit, ensure the condenser water chamber and the interior walls of the copper tubes are thoroughly cleaned of hard scale, and replace any copper tubes with cracks or internal diameter deformation to ensure smooth passage of the rubber balls.

(2) Seal off all dead corners of the condenser one by one to prevent the hiding of gel balls, which can affect the cleaning effect and the recovery rate of the gel balls.

(3) The system pipeline layout should be simple, short, and straight, with as few bends as possible.

(4) Select the ball valve pump reasonably, ensuring adequate flow rate and slightly higher outlet pressure than the circulating water pressure (about 0.02 MPa or more).

(5) Regularly check the ball room's rubber ball inventory, continuously replenish, and meet cleaning requirements.

(6) Regularly inspect the ball recovery rate; for instance, if the recovery rate is low, examine the following three aspects.

a. Is the ball intake grate in the intake position and properly seated?

b. Is there any debris in the condenser water chamber, blocking the cooling tube openings, and hindering the passage of the rubber balls?

c. Is the ball pump outlet pressure normal?