Cleaning of pipes using the Tornado

Transcription

1 Application Report No. A 03-4e Page 1/2 Cleaning of pipes using the Tornado Status: 12/2004 PIOMAR, Poland / SS Cleaning of an ash transportation pipe in a power plant in Poland, using the KAMAT System "Tornado" Mainly in coal-fired and oil-fired power stations there is a recurrent problem of deposits blocking up the piping used to transport the ashes (from the boiler room to the dumpsite). Hard incrustations build up which narrow the tube inner diameter and making it necessary to increase the pump performance enormously, in order to flush out the ashes. In this particular case in a Polish power station, the incrustations are about 30 mm in thickness at the beginning, but further down the line, they reach a thickness of up to 70 mm.

2 Application Report No. A 03-4e Page 2/2 Cleaning of pipes using the Tornado Status: 12/2004 PIOMAR, Poland / SS Ash transportation pipe (500 mm and 1200 m length ) before cleaning after cleaning Photo above: Propulsion unit fixed to the flange opening on the pipe For the job, we used a KAMAT High Pressure Pump Unit Type K A - DW 400 B, built on a trailer with sound-proof van body Performance: Working pressure : 1000 bar Capacity : 188 l/min. Hose connection from the machine to the Tornado : 40 m DN 20 Cleaning length in pipe : 160 m Cleaning results : m/h

3 Application Report No. A 90-4e Page 1/2 Cleaning a Conveyor Belt In The Fibre Glass Industry KAMAT Su Jeti The conveyor belts of a production line in the fibre glass industry become glued up in the course of time and have to be cleaned at given intervals. One possibility is to use a fixed installation comprising a traversing nozzle bar. However, in most cases the owners of the factories are reluctant to install such a system because of high investment costs and they prefer to assign the work to contractors. One of our Turkish customers carried out the work using a KAMAT high pressure pump type K A: Working pressure: 700 bar Gun nozzle: 1.5 mm Jetting angle: 15 or 30 Photo above: Conveyor belt before cleaning Photo on the right: The belt is cleaned with a gun and fan jet nozzle

4 Application Report No. A 90-4e Page 2/2 Cleaning a Conveyor Belt In The Fibre Glass Industry KAMAT Su Jeti Photo above: The photo above shows the separate elements of the conveyor belt after cleaning. The same type of incrustations and deposits which have to be removed from the conveyor belt are also to be found in all production processes in the fibre glass industry. All production piping as well as air ducts also require cleaning.

5 Application Report No. A 04-5e Page 1/2 Cleaning Parts of an Extruder in the Status: 04/2007 Polypropylene-Production Process S.Smets In the course of the manufacturing process of polypropylene after a number of months there is a steady accumulation of deposits. One of our customers in Hungary carried out the job of cleaning an extruder, using a working pressure of 2500 bar. The equipment which was used for the job: A high pressure unit model KAMJET (performance 23 l/min at 2500 bar) plus a KAMAT gun type Roto-Lance. Pictures above and on the right: The incrustations are difficult to remove and a working pressure of above 2000 bar is essential.

6 Application Report No. A 04-5e Page 2/2 Cleaning Parts of an Extruder in the Status: 04/2007 Polypropylene-Production Process S.Smets Areas after cleaning Areas before cleaning

7 Application Report No. A 04-4e Page 1/2 Pipe Line Cleaning KAMAT Su Jeti In all industrial processes the same problem arises: The necessity to clean pipe lines where, in the course of time, the internal pipe diameter has become narrower, due to deposits gradually building up. In the past, many companies used chemical methods to remove the incrustations. Nowadays, where environmental protection has become a serious subject, these old methods are hardly applicable any more. If chemical products are used today it is expensive to have them disposed of adequately, or to have them incinerated. Other companies saw no other possibility than to dispose of the blocked pipes at special dump sites and to replace them with new pipe lines. Using the KAMAT High Pressure Technology with a wide selection of special nozzles, the problems can be solved economically and without environmental pollution. Various cleaning methods can be employed, either manually or automatically (refer to our Application Report No. A 03-4). Photo above: The photo shows a pipe ID 100 in use in a plastics factory, blocked with plastic incrustations - prior to cleaning.

8 Application Report No. A 04-4e Page 2/2 Pipe Line Cleaning KAMAT Su Jeti Photo above: The photo shows the same pipe ID after cleaning. The flange of the pipe has also been cleaned. Photo on the right: The work was carried out using a pump model K A ( 900 bar at 83 l/min.), a foot valve and a rotating pipe cleaning nozzle type RTKH with 2 nozzle inserts on the rotor at 40 and 2 nozzle inserts at 80.

9 Application Report No. A 04-2e Page 1/2 Automatic Heat Exchanger Cleaning Status: 03/2005 (Tube Bundle Cleaning) PTC, Italy In large refineries, every year hundreds of heat exchangers (tube bundles) have to be cleaned of deposits. The external and internal cleaning is done by automatic cleaning systems, as shown below. Photo on the left: Our partner in Italy is able to supply automatic cleaning systems, for both inner and outer cleaning. This system is driven by a high pressure unit with a power rating of 400 kw. Photo on the right : Shows a drawn-out tube bundle before cleaning. The extremely heavy deposits on the heat exchanger are clearly visible.

10 Application Report No. A 04-2e Page 2/2 Automatic Heat Exchanger Cleaning Status: 03/2005 (Tube Bundle Cleaning) PTC, Italy Photo on the left and below: Automatic tube bundle cleaner in operation (external cleaning) Driven roller bearings Guide track Nozzle bar The cleaning systems can be equipped with either 3, 4, 5 or 6 lances, to work simultaneously. The length of the lances can be designed to match existing requirements. The cleaning rate of an automatic system compared to manual cleaning can be increased to more than five times. Scissor-type lifting table with lance unit for internal cleaning On all of the jobs shown above a KAMAT High Pressure Unit type K A - DW 350 B was used (900 bar l/min.).

11 Application Report No. A 04-1e Page 1/2 Heat Exchanger Cleaning - Manual PTC, Italy In refineries and in petrochemical plants hundreds of heat exchangers (tube bundles) have to be cleaned every year. During the shut-down period where the time available is limited, very often fully-automatic cleaning systems are used (refer to our report A 04-2e). Whenever cleaning is required during the rest of the year, the work is carried out by contracting companies and is done manually. For instance, in a refinery in Turkey our customer is carrying out the work using a KAMAT pump model K A (1000 bar at 68 l/min). Photos on the right and below: The photos on this page show various types of tube bundles prior to cleaning. The deposits on the shell side (external) and the incrustations on the tube side (internal) are clearly visible.

12 Application Report No. A 04-1e Page 2/2 Heat Exchanger Cleaning - Manual PTC, Italy Photos above and on the left: The tubes were cleaned internally using a steel hose (flexible lance) and a KAMAT foot valve.

13 Application Report No. A 03-6e Page 1/2 Cleaning of Boiler Tubes Status: 04/2007 S.Smets One of our customers in Hungary approached us and asked us to find a solution as to how to clean the inside of boiler tubes, which were heavily incrustated with hard deposits. Previous attempts to clean the tubes using conventional methods had failed. We carried out some tests and succeeded in cleaning the tubes using a Roto-Lance and a special nozzle. Using a working pressure of 2500 bar and a capacity of 23 l/min it was easy to remove the incrustations. The photo below shows our KAMJET machine, which was used for this job. Pictures above and to the right: The photo shows the heavily incrusted tube

14 Application Report No. A 03-6e Page 2/2 Cleaning of Boiler Tubes Status: 04/2007 S.Smets Pictures above and below: The tube after cleaning

15 Application Report No. A 03-5e Page 1/2 Cleaning of Boilers Flame-exposed Side KAMAT Su Jeti Cleaning boilers in power plants is a job which has to be carried out regularly. If the walls and the pipe bundles of the boilers are polluted, their efficiency will be reduced. To keep the costs of heating up the boilers as low as possible, these deposits have to be removed regularly. Worldwide, most of the power plants engage service companies to carry out the work. Such service companies make use of high pressure water to do the job. There are two possible methods of solving the problem: Either manually, using high pressure guns or semiautomatically using tank cleaning heads with guiding devices. Photos above: The pictures show a soiled boiler which has been turned off, before the cleaning work has been started.

16 Application Report No. No. A A 03-5e Page 1/2 2/2 Cleaning of Boilers Flame-exposed Side KAMAT Su Jeti Photos on the left: All pictures show the boiler on the flameexposed side after the cleaning with high pressure water has taken place. On this particular boiler, the work was carried out with high pressure guns, at a working pressure of 600 bar. The insert nozzles used were size 2 mm.

17 Application Report No. A 03-1e Page 1/2 Cleaning of Condensers in Power Plants KAMAT Su Jeti Condensers in power plants need to be cleaned whenever the exchange of heat is no longer fully efficient. Previous methods used (drilling, brushes and chemicals) have meanwhile been replaced by high pressure water jetting. Using brushes or drilling caused damage or roughening of the surface of the tubes. Once the surface was roughened the build-up of deposits was encouraged, as they could adhere even better to the roughened surface. The use of chemicals is no longer economically justifiable, due to the costs and problems of disposal. The picture above shows the use of high pressure water on this application. Accessories being used - KAMAT Foot valve - Rigid hose DN 6 - Pipe cleaning nozzle ¼"

18 Application Report No. A 03-1e Page 2/2 Cleaning of Condensers in Power Plants KAMAT Su Jeti The picture shows the high pressure nozzle as it leaves the condenser tube. These are the parameter normally required for the job: Pump type : K 9000, K oder K Working pressure : bar Capacity per nozzle : l/min.

19 Application Report No. A 01-2e Page 1/2 Evaporator Cleaning in the Food Industry PIOMAR, Poland During the production of fruit syrup the fluid has to be thickened. This process is carried out in so-called "evaporators". The tubes of the evaporators become blocked in the course of some months. When they are fully blocked, the production comes to a standstill. Photo above: View of a factory in Poland, showing a large number of storage tanks Photo on the right: View of a work platform with five evaporators in an open position

20 Application Report No. A 01-2e Page 2/2 Evaporator Cleaning in the Food Industry PIOMAR, Poland Photo on the left: Cleaning an evaporator. The opened-up evaporator on the right clearly shows the external contamination. Photo on the right: Tubes which are completely blocked. Photo on the left: The cleaning is carried out at a pressure of approx. 800 bar, using a hose, a foot valve and a rotating nozzle with 4 nozzle inserts on the rotor, at an angle of 85 rearwards. Right: Evaporator after cleaning Left: Cleaned tubes of the evaporator

21 Application Report No. A 01-1e Page 1/2 Heat Exchanger Cleaning in a Sugar Factory KAMAT Su Jeti In the food industry, cleaning of heat exchangers is part of the daily business. Blocked bundles reduce the exchange of heat and the resulting efficiency. The pictures in this report show a job being carried out by a customer in Turkey. Photo below: New-type KAMAT Rotating Nozzle for streakless cleaning The work was carried out with a KAMAT electric foot switch, a steel-coated hose DN 8 and a new-type KAMAT Rotating Nozzle. This special nozzle has two rotors, one of which rotates clockwise and the other one anti-clockwise. This method of rotation ensures that a streakless cleaning is achieved.

22 Application Report No. A 01-1e Page 2/2 Heat Exchanger Cleaning in a Sugar Factory KAMAT Su Jeti Normally, a pressure of between 1000 and 1200 bar is required for cleaning heat exchangers in the food industry, in order to achieve an effective work performance (good cleaning results in an acceptable time limit), to meet the requirements of the customer. KAMAT foot switch High pressure hose DN 8