Product Details

I. Overview:

The rubber ball cleaning device is an equipment used to effectively clean the condenser cooling tubes of a steam turbine generator set 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, suitable not only for the condensers of steam turbines but also for the cooling tube cleaning of fixed tube sheet 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 the updated and upgraded version of other rubber ball cleaning devices available. 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: Ball Skimming 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 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 density close to water. Drop the rubber balls into the ball chamber through the handhole in the ball chamber, with a quantity of about 10% of the copper tube number in the condenser water chamber. Then, start the rubber ball pump, open the ball valves at both ends of the system, and the rubber balls will be carried into the condenser water chamber by the water flow with slightly higher pressure at the circulating water inlet. Due to the rubber ball being a soft and elastic material with many small holes, under the action of the pressure difference between the circulating water inlets and outlets, it is compressed to pass through the cooling tubes, scrubbing the inner diameter of the cooling tubes. This action removes dirt from the tube inner walls along with the water flow. The rubber balls then enter the collection net through the outlet pipe, where they are separated by the collection net plate and pumped back into 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 Unit:

1. Secondary Filter: The secondary filter is one of the main components of 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 operational parameters and other information, refer to the "New Electric Rotating Backwash Secondary Filter" manual.

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 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 current structural design, with its grill plate being rotatable. When the rubber ball unit is in operation, the grill plate is in the ball collection position. When the cleaning unit is not in operation, the grill plate can rotate to a position aligned with the water flow direction; this not only reduces water resistance but also serves to clear debris from the grill plate.

The rotation and positioning of the mesh plate are executed by an electric actuator (for small ball collection nets, manual control is used). The correct positioning of the mesh plate is crucial for ensuring the collection efficiency of the ball collection net.

3. Ball Loading Room

The ball loading chamber is a device in the胶球 cleaning system for adding, removing, storing balls, and observing the ball circulation. It is divided into Type I and Type II based on the ball storage volume, and into electric and manual types according to the user's requirements. When the switch valve controlling the ball loading chamber's operation is set to 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 within the chamber, while the cooling water can still pass through, ensuring all balls in circulation return to the ball loading chamber.

4. 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-breaking 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 significant resistance loss, a high-head pump should be selected to ensure normal ball circulation.

5. Operation Control Cabinet (CGK-Ⅱ)

(1) Utilizes advanced and rational HMIs for touchscreen control, with lower failure rates. (HMIs, Human-Machine Interface Touchscreens, and PLC)

(2) Achieve precise location control for more accurate and thorough detection, ensuring high recovery rates for the balls. The entire process is automated. Single-cable long-distance control (operation and monitoring) is achievable.

6. Divertor

The divider valve is a three-way (pipe) valve. By switching the guide plates, it allows the rubber balls to enter the condenser side that requires 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 receiving pipes.

V. Installation Instructions and Precautions:

Prior to the operation of the rubber ball cleaning device, ensure the condenser water chamber and the interior walls of the copper tubes are thoroughly cleaned of hard scale. Replace any copper tubes with cracks or internal diameter deformation 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 the hiding of rubber balls, which may affect the cleaning efficiency and the recovery rate of rubber balls.

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

(4) Select a ball valve pump appropriately, ensuring sufficient flow rate and an outlet pressure 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, to meet cleaning requirements.

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

Is the ball receiver grid in the receiving 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?