Product Details

I. Overview:

The Turbine Generator Set's Ball Cleaning Device is an equipment used to effectively clean the condenser cooling tubes during operation. The performance of this device directly impacts the cleanliness of the condenser and its heat transfer efficiency. The application range is quite extensive, as it is not only suitable for turbine condensers but also for cooling tube cleaning in 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, 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 a 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 designs. It features the following characteristics:

1. Innovative and rational design structure 2. Easy to operate 3. High ball recovery rate (≥96%) 4. Strong secondary filter screen filtration capability

Section II: Spherical Ball 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 appropriate sponge rubber balls, with a wet diameter slightly larger than the cooling tube inner diameter (about 1-2mm) and having a wet density similar to water. Insert the rubber balls into the ball chamber through the handhole, with a quantity of approximately 10% of the condenser inlet 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 carried into the condenser water chamber by the water flow with a slightly higher pressure at the water intake. Due to their porous and soft elastic nature, the rubber balls are compressed through the cooling tubes under the pressure difference between the water flow in and out. This action cleans the inner wall of the tubes by removing scale with the water flow. The rubber balls are then carried through the outlet pipe to the ball collection net, where they are separated by the mesh of the collection net. They are then pumped back to 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胶球Cleaning Device:

1. Secondary Filter: The secondary filter is one of the main equipment components of the cooling water purification system. It removes all debris larger than 6mm, playing a crucial role in ensuring the unobstructed flow of rubber balls and the normal operation of the condenser. For detailed working parameters and other information, refer to the "New Type Electrically Rotating Reverse Jet Secondary Filter" manual.

2. Ball Collector: The ball collector 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 collection, the balls are guided out through an outlet pipe and returned to the ball loading room. Our factory's ball collector features the latest design, with its grate plates being rotatable. During operation of the rubber ball unit, the grate plates are positioned for ball collection. When the cleaning unit is not in use, the grate plates can rotate to align with the water flow direction, reducing water resistance and also serving to clear debris from the grate plates.

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

3. Ball Charging Room

The ball loading room is a device in the rubber ball cleaning system for loading, retrieving, 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 "load 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 loading room, allowing cooling water to pass through, and all balls introduced into the circulation return to the loading room.

4. Spherical ball pump

The rubber ball pump is the power source that continuously circulates rubber balls in the rubber ball cleaning system. Water flow from the dense 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, faultless centrifugal pump with features such as non-blocking, non-breaking, and minimal wear on the balls. Different rubber ball pumps with varying 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 normal ball circulation.

5. Operation Control Cabinet (CGK-Ⅱ)

(1) Utilizing HMI touch screen control, it's more advanced and reasonable 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. Divider

The分流器 is a three-way (pipe) valve. By switching its guide plates, the ball can be directed into the condenser side that requires cleaning. It can also be used as a three-way pipe for the convergence of the ball collection net's outlet pipes and the divergence of the receiving 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 balling from hiding, which can affect the cleaning efficiency and recovery rate of the balls.

(3) The system piping layout should be simple, short, and have as few elbows as possible.

(4) Select the ball valve pump reasonably, ensuring sufficient flow rate and an outlet pressure slightly higher than the circulating water pressure (approximately 0.02 MPa or more).

(5) Regularly check the ball room's胶球 inventory and continuously replenish to meet cleaning requirements.

(6) Regularly inspect the collection rate, such as: if the recovery rate is low, check the following three aspects.

Are the ball receiving net grids in the receiving position and properly aligned?

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

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