ECOMax-HE Automatic Tube Cleaning System

Transcription

1 ECOMax-HE Automatic Tube Cleaning System

2 Problems affecting performance in Shell and Tube Heat Exchanger: Tube vibration Dead zone Leakage Design / Fabrication Fabrication / Maintenance FOULING Operation Cost Reduce Your Carbon Foot Print

3 Types of Fouling: 1. Scaling/Chemical fouling The cooling water contains salts of calcium& magnesium. At elevated temperature salts of calcium & magnesium tend to precipitate & deposit on the heat exchanger surfaces. The chemical changes within the fluid cause a fouling layer to be deposited onto the tube surface. Reduce Your Carbon Foot Print

4 Types of Fouling: 2. Biological fouling Organic debris that adheres to inside diameter of tube surface or blocks the intake flow at the tube sheet. This is caused by the growth of organisms within the fluid which deposit out onto the surfaces of the heat exchanger Reduce Your Carbon Foot Print

5 Types of Fouling: 3. Deposition fouling This is when particles contained within the fluid settle out onto the surface when the fluid velocity falls below a critical level, i.e., small particle dust. Although the water quality is maintained because of the dusty surrounding in the area. Reduce Your Carbon Foot Print

6 Types of Fouling: 4. Corrosion fouling Thisiswhenalayerofcorrosionproductsbuilduponthesurfacesofthetubeformingan extra layer of, usually, high thermal resistance material. Reduce Your Carbon Foot Print

7 Effectsof Fouling: Reduces the Heat Transfer Coefficient of tubes Reduces cooling or heating capacity of heat exchanger Result into increasing of specific power consumption in order to get the required heat transfer output Result in heavier working duty of relate equipment and their working life Result in additional operation cost for power consumption and maintenance

8 Effect of Fouling : Fouling decrease Heat Exchanger s overall heat transfer coefficient, thus reduce heat transfer ability of the Heat Exchanger

9 Effect of Fouling : Heat energy transfer from hot fluid to cold fluid is reduced

10 Effect of Fouling : Effect in Chiller Coeffiency of Performance (COP) Cooling Capacity (TR) COP = Power Consumption (kw) Fouling reduces cooling/heat rejection capacity Fouling increase compressor power consumption

11 Fouling Scale Thickness Vs Power Consumption 1 mm of fouling accumulation in the heat exchanger tubes increases energy consumption ~ 30%

12 Offline Cleaning Method: Drawbacks Chemical cleaning by acids or similar chemicals Chemical cleaning may damages tubes in long run & reduces tube life Standby other equipment in the system very critical during manual cleaning Acid cleaning causes environmental problem due to disposal issues Frequent mechanical cleaning deforms tubes Frequent manual / offline cleaning requires Heat exchanger disassembly, needs additional manpower & time How to eliminate these issues?

13 Offline/Shutdown Cleaning & Loss of Energy:

14 The Solution ECOMax-HE :Automatic Tube Cleaning System

15 The Solution ECOMax-HE :Automatic Tube Cleaning System Components: 1. Injection Pump 2. Collection Pump 3. Ball Collector 4. Ball Trap 5. Control valves 6. PLC based Control Panel 7. Multi Color HMI 8. Skid

16 Balls pass through each tube, How is it ensured? Works on the probability No. of balls equals 40% of the no. of tubes in the first pass of heat exchanger Probability of balls not passing into the specific tube is 0.6 No. of cycles in one hour = 3 nos. Probability of balls not passing in one hour = (0.6)*3 Probability of balls not passing in 24 hours = (0.6)*72 = 10.6 x Probability of balls passing through each tube = [1 -(10.6 x 10-16)]*100 = % Reduce Your Carbon Foot Print

17 Condenser Tubes after ECOMax-HE : After 1 Year Reduce Your Carbon Foot Print

18 Condenser Tubes after ECOMax-HE : After 20 Months Reduce Your Carbon Foot Print

19 The Solution ECOMax-HE :Automatic Tube Cleaning System Applications: All kinds of shell and tube heat exchanger Oil refinery Petro chemical process Food industry Industrial manufacturing Chiller (Condenser and Evaporator) Custom design to suit required configuration Reduce Your Carbon Foot Print

20 Key Features of ECOMax-HE : Fully automatic, no manual intervention Cleaning is done on continuous basis online Zero ball loss system, no balls can escape to cooling tower Ensures 100% clean tubes Single System for Multiple Heat Exchangers Smart System, gives an alarm for Sponge Ball Replacement Automatically operates a cleaning cycle on the running heat exchanger

21 Key Features of ECOMax-HE : User Friendly Graphical User Interface (GUI) Touch screen Multi Color HMI Indicates number of cleaning cycles on individual chiller Completes the cleaning cycle even if the chiller is stopped during the cycle No water wastage from the system No mixing of CW inlet and CW Outlet Water during operation Minimal pressure drop in the Ball Trap Negligible power consumption by the booster pumps

22 Key Features of ECOMax-HE : Highly reliable as the system has less no. of control valves Cleaning Sponge Balls would never be in contact with pump impeller Compact, smaller foot print While venting air from Ball Collector, sponge balls cannot escape from Ball Collector Sight glass on the ball collector facilitates easy counting & monitoring of sponge balls No plant shut down for system installation Reduce Your Carbon Foot Print

23 Key Features of ECOMax-HE : Simultaneous injection cycle in one heat exchanger and collection cycle in another heat exchanger is possible Results in up to 20% energy saving in HVAC chillers Increase cooling capacity of heat exchanger Improves heat exchanger tube life Improves relate equipment working life Avoids costly shutdown and downtime Eliminates offline cleaning completely Very cost effective, usually offers a payback of less than a year Green Technology

24 ECOMax-HE Installed Units Single Unit Condenser/Heat Exchanger

25 ECOMax-HE Installed Units 2 Units of Condenser / Single Control Center

26 ECOMax-HE Installed Units 5 Units of Condenser / Single Control Center

27 ECOMax-HE Installed Units

28 Reference Clients :

29 Testimonial :

30 Testimonial :

31