Product Details
I. Overview:
The胶球 cleaning device is an equipment used to effectively clean the condenser cooling tubes of a steam turbine power generation unit during operation. The performance of this device directly impacts the cleanliness of the condenser and its heat transfer efficiency. Its application range is quite extensive, covering not only the condensers of steam turbines but also the cooling tube cleaning for fixed tube plate heat exchangers in the oil, chemical, and other industries. Under continuous operation without reducing the load, this device can be put into use at any time, ensuring the cleanliness of the cooling tubes, extending their service life, reducing labor intensity, and is essential for enhancing the economic benefits of power plants and ensuring the safe operation of condensers.
Our factory's rubber ball device is the updated and upgraded product of other rubber ball cleaning devices. 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胶球清洗 system consists of a secondary filter, ball collection net, ball loading chamber, rubber ball pump, manifold, valves, piping, and electrical control unit.
III. Working Principle:
Select appropriate sponge rubber balls, with the wet diameter slightly larger than the cooling tube inner diameter (about 1-2mm) and having a wet specific gravity close to water. Insert the balls from the ball-loading manhole into the ball-loading chamber, approximately 10% of the number of copper tubes in the condenser water chamber. Then, start the ball pump and open the ball valves at both ends of the system. The balls will enter the condenser water chamber driven by the slightly higher pressure water flow at the circulating water inlet. Due to the balls being a multi-porous, soft, elastic body, under the action of the pressure difference between the circulating water in and out, they are compressed through the cooling tubes, scraping the inner diameter once, and carrying the dirt on the tube wall out with the water flow. The balls are then carried by the circulating water into the collection net, where they are separated by the collection net plate and pumped back into the ball-loading chamber by the ball pump, thereby continuously and automatically cleaning the condenser cooling tubes through this cycle.
IV. Components of the Gel Ball Cleaning Unit:
1. Secondary Filter: The secondary filter is one of the main equipment in the cooling water purification system, removing all debris larger than 6mm. It plays 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 "New Electric Rotating Reverse Jet Secondary Filter" manual.
2. Ball Collector: The ball collector is a crucial component in the rubber ball cleaning system, installed on the condenser outlet pipe section. Its function is to separate the rubber balls from the cooling water, and it must be capable of not leaking or jamming balls. After the balls are collected, they are guided out through the outlet pipe and returned to the ball filling room. Our factory's ball collector features the latest design, with its grate panels being rotatable; during the operation of the rubber ball unit, the panels are in the collection position. When the cleaning unit is not in operation, the grate panel can rotate to align with the water flow direction, reducing water resistance and also serving to clear debris from the grate panels.
The rotation and positioning of the web plate are executed by an electric actuator (for the small ball-catching net, manual control is used). Whether the grid plate is in place is crucial for ensuring the ball-catching efficiency of the net.
3. Ball Loading Room
The ball 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 comes in two types according to user requirements: electric and manual. When the switch valve is set to the "Ball In" position, the balls can freely and continuously circulate within the system. When the switch valve is set to the "Ball Out" position, the balls are blocked inside the ball chamber, allowing the cooling water to pass through. All balls introduced into the circulation return to the ball chamber.
4. 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 from the dense ball intake net is increased in pressure after passing through the rubber balls and then sent into the cooling water pipes. This pump is a fixed, trouble-free centrifugal pump, featuring non-clogging, non-breaking, 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 conveyance pipelines and high resistance losses, a high-head pump should be selected to ensure the normal circulation of the balls.
5. Operation Control Cabinet (CGK-Ⅱ)
(1) Utilizing an HMI touch screen control for operation is more advanced and reasonable, with a lower failure rate. (HMI human-machine interface touch screen and PLC)
(2) Achieve precise location control for more accurate and thorough detection, ensuring a high recovery rate of the balls. The entire process is automated. Single cable remote control (operation and monitoring) is achievable.
6. Divertor
A分流器 is a three-way (pipe) valve. By switching its guide plates, it allows the rubber balls to enter the condenser side that requires cleaning. It can also be used as a three-way pipe for converging the outlet tubes of the ball collection net and diverging the tubes for catching balls.
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. Replace any copper tubes with cracks or internal diameter deformation one by one to ensure unobstructed flow of rubber balls.
(2) Seal off all dead corners of the condenser one by one to prevent the hiding of rubber balls, which can affect cleaning efficiency and the recovery rate of rubber balls.
(3) The system piping layout should be simple, short, and straight, with the number of bends minimized as much as possible.
(4) Select the ball pump reasonably; ensure sufficient flow rate, and the outlet pressure should be slightly higher than the circulating water pressure (about 0.02 MPa or more).
(5) Regularly inspect the ball room's gel ball inventory, continuously replenish, to meet cleaning requirements.
(6) Regularly inspect the collection rate, such as: if the recovery rate is low, check the following three aspects.
a. Is the ball receiver grid in the receiving position and properly aligned?
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 outlet pressure of the gel ball pump normal?
