Product Details

I. Overview:

The ball cleaning device is an equipment used to effectively clean the condenser cooling tubes of steam turbine generators during operation. The performance of this device directly impacts the cleanliness of the condenser and its heat transfer efficiency. The device has a wide range of applicability, not only suitable for condensers of steam turbines but also for cooling tube cleaning of fixed tube sheet heat exchangers in the oil, chemical, and other industries. Under continuous operation without reducing load, the 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 the upgraded and replaced product for 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: Gel Ball Cleaning System Diagram

The胶球 cleaning system consists of a secondary filter, ball collection net, ball loading chamber, rubber ball pump, distributor, valves, piping, and electrical control unit.

III. Working Principle:

Select appropriate sponge rubber balls, with a wet diameter slightly larger than the cooling tube inner diameter (about 1-2mm) and having a wet density close to water. Drop the rubber balls into the ball chamber through the manual access port, 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 propelled into the condenser water chamber by the water flow with slightly higher pressure at the circulation water inlet. Due to their multi-porous, soft, and elastic nature, the balls are compressed as they pass through the cooling tubes, scrubbing the inner diameter once. This action carries away the dirt from the tube walls along with the water flow. The balls then enter the collection net through the outlet pipe, where they are separated by the collection net plate. They are then extracted by the rubber ball pump and returned to the ball chamber, repeating this cycle for continuous automatic cleaning of the condenser cooling tubes.

IV. Components of the胶球Cleaning Device:

1. Secondary Filter: The secondary filter is one of the main equipment in the cooling water purification system, effectively 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 Electrically Rotating Backwash Secondary Filter" manual.

2. Ball Catcher: The ball catcher is a crucial component of 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 from the ball catcher and returned to the ball filling room. Our factory's ball catchers feature the latest design, with a rotating grill plate; during the operation of the rubber ball device, the grill plate is in the ball collection position. When the cleaning device is not in use, the grill plate can rotate to a position aligned with the water flow direction, reducing water resistance and also serving to clear debris from the grill plate.

The rotation positioning of the sieve plate is executed by an electric actuator (the small ball collector is manually controlled). Whether the sieve plate is in place is a critical factor in ensuring the ball collection efficiency of the ball collector.

3. Ball Loading Room

The ball loading chamber 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. It is categorized into electric and manual types according to user requirements. When the switch valve for controlling the operation status of the ball loading chamber is set to the "load ball" position, the balls can circulate freely and continuously within the system. When the switch valve is set to the "collect ball" position, the balls are blocked inside the ball loading chamber, and the cooling water can still pass through. All balls introduced into the 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 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 non-blocking, non-crushing, 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 normal ball circulation.

5. Operation Control Cabinet (CGK-Ⅱ)

(1) Employed with an HMI touch screen control, it is 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 thorough detection, ensuring high ball recovery rates. The entire process is automated. It allows for long-distance control (operation and monitoring) via a single cable.

6. Divider Valve

A分流器 is a three-way (pipe) valve. By switching its guide plates, the ball can enter the condenser on the 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 ball intake pipes.

V. Installation Instructions and Precautions:

Before the rubber ball cleaning unit is put into operation, first clean the hard scale inside the condenser water chamber and copper tube walls thoroughly, and replace each copper tube 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 cleaning efficiency and the recovery rate of gel balls.

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

(4) Select the ball pump reasonably; ensure it has sufficient flow rate, and the outlet pressure should be slightly higher than the circulating water pressure (about 0.02 MPa or more).

(5) Regularly check the ball room for the number of rubber balls, continuously replenish as needed to meet cleaning requirements.

(6) Regularly inspect the ball collection rate; for instance, if the collection rate is too low, investigate the following three aspects.

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 gel ball pump normal?