on line tube cleaning operation

7/26/2019 On line tube cleaning operation

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Corrosion and fouling of

Condenser Tubes are majorfactors aecting theperformance of a plant.

T h e P R O B L E M



On Line Tube Cleaning Systemfacilitates continuous cleaning of theCondenser Tubes up with the Plant in

operation.IT O!"S # S#$I%& O %!#"L' ()*Lacs+#num.

Cleaning is accomplished by passingsli htl o,ersi-ed S on e "ubber alls

T h e S O L U T I O N



all Separator

all /onitoring system

/easuring and Control System

all Charger and eeder

all "ecirculating S0id

DEBRIS SEPARATOR

Major Components and AuxiliaryEquipment



"V" TYPE DEBRI EPARAT!R

The 1ebris ilter installed in theC.2. Inlet Line is an importantsecondary 3ltering e4uipment.

The design and the internalconstruction of the Debris Filter isbased on the Water ow t!"esi#e and $uantit! of the Debris

and the %ooling Water inletPressure&

The 1ebris is collected at the

inner surface of the screen.



The le,el of debris fouling on the 3lterscreen is indicated by monitoring the

1ierential Pressure across the Screen.2hen it reaches a preset limit5 thecontrol system initiates the debrisremo,al operation5 till the screen iscleared o the debris.

1ebris accumulated on the insidesurface of the screen is suc0ed by the

debris e6traction assembly whichroutes the e6tracted debris into the1ebris 1ischarge Pipe connected tothe main condenser outlet pipe or

drain



/any a times the e6traction techni4uealone is inade4uate to dislodge all the

1ebris from the screen. To eecti,elysol,e this problem a special patented"otating 7igh Pressure 2ater Injecting#rm on the rear side of the screen isincorporated . 7owe,er5 it is anoptional item.

The rotation of the lushing #ssemblyis facilitated by an !lectric &ear dri,e

mounted outside the ilter housing. The cleaning operation ceases oncethe screen is clean. The salient featureof the 3lter is that at no time is thereany signi3cant reduction of water 8owduring the screen cleaning operation.



Ball eparatorinstalled in teCondenser C#$#outlet pipe is %all&at&in' equipment(i& separates te&leanin' %alls )rom&oolin' (ater )orre&ir&ulation

Te Ball eparatoris desi'ned %asedon te Coolin'$ater *o(+ Coolin'

$ater ,elo&ityinside te C#$# line+-pstream *o(pattern+ Cleanin'%all type and si.e#



BA// EPARATI!0ARRA01EME0T all !6traction

pipes arepro,ided at theend of thescreens for thesmooth!6traction of the

balls from allseparator.

This arrangementis connected to

the all "e



Te Ball eparator is

2tted (it

sin'le3dou%le s&reensat a sele&ted an'le )orte smoot mo,emento) %alls to(ards te%all extra&tion

assem%ly Indi,idual $orm 1earand A&tuator are2tted dire&tly on tes&reen sa)t )oroperation o) tes&reens#

Te %a&4(asin' o)te s&reens areinitiated %y D3Pmeasurin' system#



1esign eatures

/anual or #utomatic Installation can be 7ori-ontal+$ertical Single screen + double screen + four

screens + eight screens depending on the

si-e of the C.2.Line Constructions in carbon steel5 carbon steel

rubber lined5 stainless steel5 Cu%i5 to suitthe application

Capability to handle 8ows ranging from)** cu.m+hr. to ::* cu.m+hr. #pplication ; Sea + "i,er < La0e 2ater.



all o,ersi-e monitoring systemis a user friendly micro ;

processor instrument to monitorthe si-e of cleaning balls whichare in circulation in the condenser

tube.



Ball Re&ir&ulatin' 4id



The all "ecirculating S0id shall ha,e aall $essel5 ball recirculating pump withmotor5 ball ,essel inlet +outlet ,al,es

installed on it. The Cleaning balls which are collected inthe all Separator are e6tracted andrecirculated into cooling water through aall $essel by non;clog impeller type

Centrifugal pump. The Cleaning alls are introduced into +

remo,ed from the system through thehand hole of the all $essel.

2hen the Cleaning alls are not incirculation they are stored in the all$essel.

!lectrically actuated all $al,es at Inlet <outlet line of the all $essel enableautomatic operation of the abo,e.



Ball Vessel =

Constructed of stainless steel >:?5

>:?L5 >:?L%5 Cu%i to suit theapplication



The 1ierential Pressure /easuringSystem



MEA-RI01 YTEM

The 1ierential Pressure /easuringSystem measures the 1ierentialPressure across the all Separator

Screen continuously and when ite6ceeds the preset limit5 initiates thebac0washing operation of the

screens5 after collecting the alls.



CO%T"OL S'ST!/



LOCAL



Control Panel &onsists6

Mimi& panel (it pilot lamps indi&atin' te

a&tual position o) ea& (or4in' element(it any e,entual de)e&t+ ele&tri&al andpro&ess )ailure#

Pressure drop indi&ation 7lo&al indi&ation8

(it& )rom automati& to manual operation Anti9&ondensation eaters Volta'e trans)ormers Internal (irin's et& All alarms3indi&ations as ne&essary are

pro,ided#



pon'e Ru%%er ; 7ardnessselected to suit ser,ice

conditions

:i' Temperature Balls ; or

application upto :@* C.

A%rasi,e Balls ; "ing+ully

coated for remo,al of harddeposits

1ranulate Coated Balls ; or



;!R EA $ATER A0D ;RE: $ATER $IT: TEMPERAT-RE-PT! <= C 7 >?@ ; 8

A "emo,al of Soft deposits

A or Copper and brasstubes

A "emo,al of 7ard ScalesCaCo>A or Copper and brasstubes



A "emo,al of Soft Scales /g

B O7 D < e So@A or welded copper andbrass tubes

A or stainless steel5

titanium tubesA " scouring balls forremo,al of bio fouled layers

A "& for remo,ing highlyadherent bio ; fouled layers



A D V A N C E M E N T I N

N D E N S E R O N L I N E T U B E C L E A N I N G S Y ST



The automatic all eeder is forcharging of new balls and remo,al of

worn out ones. One basic charge ofreplenishment sponge balls is storedin a Chamber on the all

"ecirculating S0id. The ball charge is injected into the

system automatically5 based onfeedbac0 signals of the all O,ersi-e/onitor5 as per the controlphilosophy



'ERO BA(( (OSS S)STE*



'ERO BA(( (OSS S)ESTE*



W h a t w e g a i n



Temp rise E C2 O+L Temp.; C2 I+L

Temp.

TT1 is Terminal Temperature

1ierence. TT1 E LPT !6aust Temp. F C2 O+L Temp

actors aecting TT1 and Temp. rise=

:. Tube fouling

D. #ir ingress



Month Temp rise(04-05)

TTD (04-05)

Temp rise(05-06)

TTD (05-06)

1 11.1 5.1 11.4 4.7

2 12.4 5.9 11.2 5.4

3 12.0 8.0 11.5 4.8

4 13.0 9.8 11.6 5.3

5 13.7 10.7 11.5 4.8

6 14.0 11.0 11.6 5.0



Condenser ,acuum is directly

related with LPT !6aust Temperature.

LPT !6aust Temperature

E C2 I+L T!/P. G TT1 G "ise in C2 Temp.



Before COLTS, LPT Exhaust Temperature =30+14+11

= 55C = 0.3! "a#uum After COLTS, LPT Exhaust Temperature =

30+11.$+5

= 4$.$C = 0.!4 "a#uum 0.01 %mpro"eme&t %& "a#uum #orrespo&'s to

sa"%&( of )s.340 La#s*a&um A&&ua (a%& %& "a#uum = 0.0 -S#

= 0.0 340 *.01 La#s

=!5 La#s

Condenser ,a&uum Correspondin'



Condenser ,a&uum Correspondin'to /PT Exaust Temp#

Sat.Temp.

Con.!a".

Sat.Temp.

Con.!a".

Sat.Temp. Con. !a".

De# C $s" De# C $s" De# C $s"

37.9 0.9327 46.2 0.896 54.6 Con. !a".

38 0.9324 46.3 0.8955 54.7 0.841638.1 0.932 46.4 0.8949 54.8 0.8408

38.2 0.9316 46.5 0.8944 54.9 0.8401

38.3 0.9313 46.6 0.8938 55 0.8393

38.4 0.9309 46.7 0.8933 55.1 0.8386

38.5 0.9305 46.8 0.8927 55.2 0.8378

38.6 0.9301 46.9 0.8922 55.3 0.8369

38.7 0.9298 47 0.8917 55.4 0.8362



Thanks to all of you



D. !HC!SSI$! 7!#T I% T7! P/P

%+E%, T+EISO(ATIO- .A(.ESOPE- A-D

A.AI(ABI(IT) OF

WATER I- S/%TIO-&%+E%, +A-D FREEROTATIO- OF T+ES+AFT&

%+E%, I*PE((ER%(EARA-%E&

%+E%, +EA(T+I-ESSOF BEARI-0S&

>. !HC!SSI$! 7!#T I% T7! /OTO"

%+E%, P/*P 1*OTOR A(I0-*E-T&

%+E%, BEARI-0

(/BRI%ATIO-&%+E%, +EA(T+I-ESSOF BEARI-0S&

on line tube cleaning operation

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