Product Details

I. Overview:

The胶球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 impacts the cleanliness of the condenser and its heat transfer efficiency. Its application range is quite extensive, suitable not only for condensers of steam turbines but also for the cooling tube cleaning of fixed tube sheet heat exchangers in the oil, chemical, and other industries. Operating continuously without reducing load, this 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 an indispensable device for improving the economic benefits of power plants and ensuring the safe operation of condensers.

Our factory's ball cleaner unit is a replacement for other existing ball cleaning units. The main components, the secondary filter and ball collection net, come in two current designs. It features the following characteristics:

1. Innovative and rational design structure; 2. Easy to operate; 3. High胶球 recovery rate (≥96%); 4. Strong secondary filter efficiency.

Section II: Spherical Ball Cleaning System Diagram

The胶球Cleaning System consists of a secondary filter, ball collection net, ball loading chamber,胶球pump, manifold, valves, pipelines, and electrical control equipment.

III. Working Principle:

Select the appropriate sponge rubber balls, with a wet-state diameter slightly larger than the cooling tube inner diameter (about 1-2mm) and a wet-state specific gravity similar to water. Insert the balls from the ball-loading room's handhole into the ball-loading room, in a quantity of approximately 10% of the condenser's 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 with a slightly higher pressure at the circulation water inlet. As the balls are a porous, soft, elastic material, under the action of the pressure difference between the circulation water inlets and outlets, they are compressed to pass through the cooling tubes, scrubbing the inner diameter of the tubes. This action removes the dirt on the tube walls, carrying it away with the water flow. The balls, along with the circulating water, enter the ball collection net via the outlet pipe. Blocked by the collection net plate, the balls are separated and then extracted by the ball pump back into the ball-loading room, thus continuously and automatically cleaning the condenser cooling tubes in a cyclic process.

IV. Components of the Gel Ball Cleaning Unit:

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 more information, refer to the manual for "New Electric Rotating Reverse Jet Secondary Filter."

2. Catching Net: The catching net is a crucial component of 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 losing or jamming balls. After the balls are recovered, they are guided out through a pipe from the catching net and returned to the ball loading room. Our factory's catching net features the latest structural design, with its grate plates being rotatable; during the operation of the rubber ball device, the grate plate is in the catching position. When the cleaning device is not in use, the grate plate can rotate to a position aligned with the water flow, reducing water resistance and also serving to clear debris from the grate plate.

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

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 is placed in the "feed ball" position, the balls can freely and continuously circulate within the system. When the switch valve is placed in the "collect ball" position, the balls are blocked within the loading room, allowing cooling water to pass through, and all balls introduced into the circulation return to the loading room.

4. Gel 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, fault-free centrifugal pump with features such as no clogging of balls, no breaking of balls, and minimal wear on 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 the normal circulation of the balls.

5. Operation Control Cabinet (CGK-Ⅱ)

(1) Employed with an HMI touch screen control, it's more advanced and rational with a lower 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. Long-distance control (operation and monitoring) via a single cable is achievable.

6. Divertor

A diverter valve is a three-way (pipe) valve. The ball can be directed into the condenser on the side requiring cleaning by switching the guide plates. It can also be used as a three-way pipe for the convergence of the ball collection net's ball extraction pipe and the分流 of the collection pipe.

V. Installation Instructions and Precautions:

Prior to the start-up of the rubber ball cleaning unit, thoroughly clean the condenser water chamber and the interior walls of the copper tubes, replacing any copper tubes with cracks or deformed inner diameters one by one to ensure unobstructed flow 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 the cleaning effect and the recovery rate of gel balls.

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

(4) Select a ball pump appropriately, ensuring 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 them to meet cleaning requirements.

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

Is the ball collection grid in the collection position and properly aligned?

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

c. Is the ball pump outlet pressure normal?