Product Details
I. Overview:
The胶球 cleaning unit is a device that effectively cleans the condenser cooling tubes during the operation of a steam turbine generator set. The performance of this unit directly affects the cleanliness of the condenser and its heat transfer efficiency. Its application range is quite extensive, covering not only condensers of steam turbines but also the cooling tube cleaning of fixed tube plate heat exchangers in the oil, chemical, and other industries. Operating continuously without reducing load, this unit can be put into use at any time, maintaining 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, with the main components being the secondary filter and ball collection net, which are the two current types. It features the following characteristics:
1. Innovative and rational design structure 2. Easy to operate 3. High gel ball collection rate (≥96%) 4. Strong secondary filter screen filtration capability
Section II: Gel Ball Cleaning System Diagram
The rubber ball cleaning system consists of a secondary filter, ball collection net, ball loading room, rubber ball pump, diverter, valves, pipelines, and electrical control equipment.
III. 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 rubber balls into the ball chamber through the handhole, with a quantity of approximately 10% of the condenser water chamber copper tube count. Then, start the rubber ball pump and open the ball valves at both ends of the system. The rubber balls are then driven into the condenser water chamber by the water flow at a slightly higher pressure at the water inlet. Due to the rubber balls being a multi-porous, soft, elastic body, under the action of the pressure difference between the water inlet and outlet of the circulating water, they are compressed through the cooling tubes, once cleaning the inner diameter. This removes the dirt inside the tubes along with the water flow. The rubber balls are then carried by the circulating water into the collection net, where they are separated by the collection net plate and pumped back to the ball chamber by the rubber ball pump, thus continuously and automatically cleaning the condenser cooling tubes in a cyclic manner.
IV. 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, which removes 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 Electrically Operated Rotating Backwash Secondary Filter" manual.
2. Ball Collector: The ball collector is a crucial component of the rubber ball cleaning system, installed on the condensate outlet section of the cooler. Its function is to separate the rubber balls from the cooling water, ensuring it does not leak or jam balls. After the balls are collected, they are guided out of the collector through an outlet pipe and returned to the ball loading room. Our factory's ball collector features the current design, with its grate plates being rotatable; during operation of the rubber ball device, the grate plates are positioned to collect balls. When the cleaning device is not in use, the grate plates can rotate to align with the water flow direction, reducing water resistance and also serving to clear debris from the grate plates.
The rotation and positioning of the mesh board are executed by an electric actuator (for the small ball-catching net, manual control is used). Whether the mesh board is in place is a crucial factor in ensuring the ball-catching efficiency of the net.
3. Ball Loading Room
The ball loading room is a device in the rubber ball cleaning system used 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 and into electric and manual types according to the user's requirements. When the switch valve for controlling the operation status of the ball loading room is set to the "load 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 ball loading room, but the cooling water can still pass through, and all the balls that have been circulated are returned to the ball loading room.
4. Sphering Pump
The rubber ball pump is the power source that continuously circulates rubber balls in the rubber ball cleaning system. The water flow from the ball collection net, after passing through the rubber balls, increases the pressure head and is sent into the cooling water pipes. This pump is a fixed, trouble-free centrifugal pump with features such as no ball clogging, no ball breaking, and minimal ball wear. 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 pipes and significant resistance loss, a high-head pump should be selected to ensure normal ball circulation.
5. Operation Control Cabinet (CGK-Ⅱ)
(1) Employed HMIs for touchscreen control, more advanced and rational, with a lower failure rate. (HMIs, Human-Machine Interface Touchscreens and PLC)
(2) Achieve precise location control for more accurate and thorough detection, ensuring high ball recovery rates. The entire process is automated. Single cable long-distance control (operation and monitoring) is achievable.
6. Divider
The diverter valve is a three-way valve (pipe). Switching the guide plates allows the ball to enter the condenser side that requires cleaning. It can also be used as a three-way pipe for converging the outlet pipes of the ball collection net and diverging the intake pipes.
V. Installation Instructions and Precautions:
Prior to the operation of the rubber ball cleaning device, ensure that the condenser water chamber and the interior walls of the copper tubes are thoroughly cleaned of hard scale. Additionally, replace any copper tubes with cracks or internal diameter deformities one by one to ensure unobstructed flow of the rubber balls.
(2) Seal off all dead corners of the condenser one by one to prevent the hiding of ball sealants, which can affect the cleaning efficiency and the recovery rate of ball sealants.
(3) The layout of the system piping should be simple, short, and straight, with as few elbows as possible.
(4) Select ball valves pumps reasonably, ensuring sufficient flow rate and slightly higher outlet pressure than the circulating water pressure (approximately 0.02 MPa or more).
(5) Regularly inspect the ball chamber for sufficient rubber ball quantity, continuously replenish, to meet cleaning requirements.
(6) Regularly inspect the ball recovery rate; for instance, if the recovery rate is low, check the following three aspects.
Is the ball catch grid in the ball collection 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 rubber ball pump normal?
