Product Details
I. Overview:
The ball cleaner is a device used for effectively cleaning the condenser cooling tubes in steam turbine generators 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 condensers of steam turbines but also for cooling tube cleaning in fixed tube plate 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, ensuring 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 for other rubber ball cleaning devices currently available, featuring a secondary filter and ball collection net as its main components. It boasts 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 2: Gel Ball Cleaning System Diagram
The胶球清洗system consists of a secondary filter, ball collection net, ball filling room, rubber ball pump, manifold, valves, piping, and electrical control equipment.
III. Working Principle:
Select the appropriate sponge rubber balls, which are slightly larger in wet state diameter than the cooling tube inner diameter (about 1-2mm) and have a wet state specific gravity similar to water. Place the rubber balls into the ball chamber through the handhole, with a quantity of about 10% of the copper tube count in the condenser water chamber. Then, start 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 slightly higher pressure at the inlet of the circulating water. As the balls are a soft, elastic, porous material, under the pressure difference between the circulating water inlets and outlets, they are compressed to pass through the cooling tubes, scrubbing the inner diameter of the tubes once. This action removes the dirt from the tube walls, carrying it away with the water flow. The balls are then carried through the outlet pipe into the ball collection net, where they are separated by the mesh of the collection net. They are then pumped out and returned to the ball chamber, repeating the cycle to continuously and automatically clean the condenser cooling tubes.
IV. Components of the Gel Ball Cleaning Device:
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 Reverse 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, ensuring it is leak-proof and ball-free. After the balls are collected, they are led out through a conduit from the ball catcher 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 mesh board are executed by an electric actuator (the small ball collector is manually controlled). Whether the mesh board is in place is a crucial factor for ensuring the ball collection efficiency of the ball collector.
3. Ball Loading Room
The ball filling room is a device in the胶球cleaning system for adding, retrieving, storing balls, and observing the ball circulation. It is divided into Type I and Type II based on the ball storage capacity, and into electric and manual types based on user requirements. When the switch valve controlling the ball filling room operation is placed in the "Add Ball" position, balls can freely and continuously circulate within the system. When the switch valve is set to the "Collect Ball" position, balls are blocked inside the ball filling room, but the cooling water can still pass through, ensuring all balls introduced into the circulation return to the ball filling room.
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 of the dense balls extracted from the ball intake net is boosted through the rubber balls and then 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. Different parameter specifications of rubber ball pumps are selected based on varying operating conditions. 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 losses, a high-head pump should be selected to ensure the normal circulation of the balls.
5. Operation Control Cabinet (CGK-Ⅱ)
(1) Utilizes advanced HMI touch screen control, more sophisticated and rational, 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 ball recovery rates. 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 rubber balls to enter the condenser side requiring cleaning. It can also be used as a three-way pipe for the convergence of the ball collection net outlet pipes and the分流 of the collection tube.
V. Installation Instructions and Precautions:
Prior to the operation of the rubber ball cleaning device, thoroughly clean the condenser water chamber and the interior walls of the copper tubes, and replace any copper tubes with cracks or deformed inner diameters one by one to ensure smooth passage of the rubber balls.
(2) Seal off all dead corners of the condenser one by one to prevent balling from hiding, which can affect cleaning efficiency and the recovery rate of the balls.
(3) The layout of the system piping should be simple, short, and straight, with as few bends as possible.
(4) Select a suitable ball pump with adequate flow rate; 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 rubber ball inventory, continuously replenish, and meet cleaning requirements.
(6) Regularly inspect the recovery rate, such as: if the recovery rate is too low, check the following three aspects.
Are the ball-catching grill panels in the receiving 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 valve pump's outlet pressure normal?
