Product Details

I. Overview:

The胶球cleaning device is a device used to effectively clean the condenser cooling tubes during the operation of a steam turbine generator set. The performance of this device directly impacts the cleanliness of the condenser and its heat transfer efficiency. The application range of this device is quite extensive, as it is not only suitable for condensers of steam turbines but also for the cooling tube cleaning of 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, maintaining the cleanliness of the cooling tubes and extending their service life, reducing labor intensity, and is essential for improving 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 reasonable design structure; 2. Easy to operate; 3. High gel ball recovery rate (≥96%); 4. Strong secondary filter mesh filtration capacity.

Section II: Schematic of Gel Ball Cleaning System

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

Section 3: 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 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 ball pump and open the ball valves at both ends of the system. The 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 balls being a soft, elastic, and porous material, under the pressure difference between the water inlets and outlets, they are compressed through the cooling tubes, scrubbing the inner diameter once. This removes the dirt from the tube walls, carrying it away with the water flow. The balls then enter the collection net through the outlet pipe, where they are separated by the collection net plate and pumped back to the ball chamber by the ball pump, thus continuously and automatically cleaning the condenser cooling tubes in a cyclic manner.

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. It removes all debris larger than 6mm, playing 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 instruction 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 no ball leakage or jamming. After the balls are collected, they are led out through an outlet pipe from the ball catcher and returned to the ball loading room. Our factory's ball catcher features the latest design, with its grate panel being rotatable. During the operation of the rubber ball device, the grate panel is in the ball collection position. When the cleaning device is not in use, the grate panel can rotate to align with the water flow direction, reducing water resistance and also serving to clear debris from the grate.

The rotation and positioning of the web plate are executed by an electric actuator (small ball-catching net is manually controlled). The presence or absence of the grid plate at the correct position is crucial for 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 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 "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 loading room, while the cooling water can still pass through, ensuring that all balls introduced into the circulation return to the ball loading room.

4. Gel Ball 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 intake net, after passing through the rubber balls, increases the head pressure 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 loss, 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's 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. Long-distance control (operation and monitoring) via a single cable is achievable.

6. Divertor

A diverter valve is a three-way (pipe) valve. By switching the guide plates, it allows the ball to enter the condenser on the side that needs cleaning. It can also be used as a three-way pipe for the convergence of the ball collection net outlet pipe and the分流 of the ball intake pipe.

V. Installation Instructions and Precautions:

Before the rubber ball cleaning unit is commissioned, the condenser water chamber and the interior walls of the copper tubes must be thoroughly cleaned of hard scale, and any copper tubes with cracks or deformed inner diameters must be replaced one by one to ensure the smooth passage 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 pipeline layout should be simple, short, and have as few bends as possible.

(4) Select a 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 rubber ball inventory, continuously replenish, to meet cleaning requirements.

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

Is the ball receiving grate in the receiving position and properly in place?

b. Is there any debris in the condenser water chamber, blocking the cooling pipe openings, and obstructing the passage of the rubber balls?

c. Is the outlet pressure of the ball pump normal?