Product Details
I. Overview:
The gel ball cleaning device is an equipment that effectively cleans the condenser cooling tubes of steam turbine generators during operation. The performance of this device directly affects 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 cooling tube cleaning in fixed tube plate 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, maintaining the cleanliness of the cooling tubes, 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 upgraded replacement for other rubber ball cleaning devices currently on the market. The main components, the secondary filter and the ball collection net, come in two current models. It boasts the following features:
1. Innovative and rational design structure; 2. Easy to operate; 3. High胶球recycling rate (≥96%); 4. Strong secondary filter efficiency.
Section II: Ball Cleaning System Diagram
The rubber ball cleaning system consists of a secondary filter, ball collection net, ball loading chamber, rubber ball pump, distributor, valves, piping, and electrical control equipment.
Section 3: Operating Principle:
Select appropriate sponge rubber spheres 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 spheres 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 spheres will be carried into the condenser water chamber by the water flow at a slightly higher pressure at the water inlet. As the spheres are 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 action removes the dirt from the tube walls, which is then carried away by the water flow. The spheres, along with the circulating water, enter the ball collection net, where they are separated by the net plates. They are then extracted by the ball pump and returned to the ball chamber, thus continuously and automatically cleaning the condenser cooling tubes in a cyclic manner.
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, 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 Type Electric Rotating Backwash 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 guided out through a 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 positioned for ball collection. 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 mesh plate are executed by an electric actuator (the small ball-catching mesh is manually controlled). Whether the mesh plate is in place is a crucial factor in ensuring the ball-catching efficiency of the ball-catching mesh.
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 volume of the balls, and into electric and manual types according to the user's requirements. When the switch valve controlling the operation 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. All balls introduced into the circulation return to the ball loading room.
4. Spherical ball pump
The rubber ball pump serves as the power source for 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 head pressure and is then sent into the cooling water pipes. This pump is a fixed, trouble-free centrifugal pump with features such as non-clogging, non-crushing of balls, and minimal wear on the balls. Different rubber ball pumps with varying parameter specifications are selected based on different 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) Utilizing advanced and rational HMIs for touch screen control, 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 rates for the balls. The entire process is automated. It allows for long-distance control via a single cable (operation and monitoring).
6. Separator
A diverter valve is a three-way (pipe) valve. By switching the guide plates, the ball can 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 divergence of the ball intake 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 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 the ball valve pump reasonably, ensuring adequate flow rate and an outlet pressure slightly higher than the circulating water pressure (approximately 0.02 MPa or more).
(5) Regularly inspect the ball room's rubber ball inventory, continuously replenish, to meet cleaning requirements.
(6) Regularly inspect the ball recovery rate, such as: if the recovery 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 ball pump outlet pressure normal?
