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 impacts 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 cooling tubes of fixed tube sheet heat exchangers in the oil, chemical, and other industries. Operating continuously without reducing load, this unit can be deployed at any time, ensuring the cleanliness of 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胶球 recovery rate (≥96%); 4. Strong secondary filter efficiency.
Section II: Spherical Ball Cleaning System Diagram
The胶球Cleaning System consists of a secondary filter, ball collection net, ball loading chamber,胶球pump, manifold, valves, pipelines, 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 density close to water when wet. Place the rubber balls into the ball chamber through the handhole, with a quantity equal to about 10% of the condenser's incoming water chamber copper tube count. Next, activate the rubber ball pump and open the ball valves at both ends of the system. The rubber balls are then propelled into the condenser water chamber by the slightly higher pressure water flow at the inlet. As the rubber balls are a soft, elastic, porous material, they are compressed under the pressure difference between the inlet and outlet of the circulating water, scraping the inner diameter of the cooling tubes. This action removes the tube's inner wall dirt, which is then carried away with the water flow. The rubber balls are recirculated through the outlet pipe into the ball collection net, where they are separated by the net's plate and removed by the rubber ball pump, returning them to the ball chamber for reuse. This process is continuously repeated to achieve a continuous and automatic cleaning of the condenser's cooling tubes.
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, 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 manual for "New Electric Rotating Jet 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, and it must be capable of not leaking or jamming balls. After the balls are recovered, they are guided out through the outlet pipe and returned to the ball loading room. Our factory's ball catcher features the latest design, with its grate plate being rotatable; during the operation of the rubber ball unit, the grate plate is positioned for ball collection. When the cleaning unit is not in use, the grate plate can rotate to align with the water flow direction, reducing water resistance and also serving to clear debris from the grate plate.
The rotation and positioning of the sieve plate are executed by an electric actuator (the small ball-catching sieve is manually controlled). Whether the sieve plate is in place is crucial for ensuring the efficiency of the ball-catching sieve.
3. Ball Loading Room
The ball chamber is a device in the胶球cleaning system used for adding, retrieving, storing balls, and observing the ball circulation. It is divided into Type I and Type II based on the storage capacity of the balls and into electric and manual categories based on the user's requirements. When the switch valve controlling the operation of the ball 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 within the ball chamber, allowing cooling water to still pass through, with all balls introduced into the circulation returning to the ball 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 from the ball intake 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, featuring non-blocking, non-crushing of 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 high resistance losses, a high-head pump should be selected to ensure the normal circulation of the balls.
5. Operational Control Cabinet (CGK-Ⅱ)
(1) Utilizes advanced HMI touch screen control for better and more rational operation, with a low failure rate. (HMI Human-Machine Interface touch screen and PLC)
(2) Achieve precise location control for more accurate and thorough detection, ensuring high recovery rate of the balls. The entire process is automated. Long-distance control (operation and monitoring) via a single cable is achievable.
6. Divertor
A分流器 is a three-way (pipe) valve. By switching its guide plates, it allows the ball to enter the condenser side that needs cleaning. It can also be used as a three-way pipe for the convergence of the ball collection net's ball outlet pipe and the分流 of the ball collection pipe.
V. Installation Instructions and Precautions:
Prior to the operation of the rubber ball cleaning device, ensure the condenser water chamber and the inner walls of the copper tubes are thoroughly cleaned of hard scale. Replace any copper tubes with cracks or deformed inner diameters 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 may affect the cleaning effect and the recovery rate of rubber balls.
(3) The system pipeline layout should be simple, short, and have as few bends as possible.
(4) Select the ball valve pump reasonably; ensure it has sufficient flow rate, and the outlet pressure should be slightly higher than the circulating water pressure (approximately 0.02 MPa or more).
(5) Regularly check the ball room's胶球quantity, continuously replenish, to meet cleaning requirements.
(6) Regularly inspect the recovery rate; for instance, if the recovery rate is too low, check the following three aspects.
a. Is the ball collection grid panel in the collection position and properly in place?
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 ball pump normal?
