On-Line Condenser Tube Cleaning System (OLCTCS)

Enable your HVAC system to work permanently at peak efficiency

Water-based cooling systems inevitably suffer from fouling of the heat exchanger surfaces, leading to a reduction in efficiency that leads to increased energy use and higher operating costs. Research shows that just a 0.6mm scale layer on condenser tubes reduces chiller heat transfer efficiency by 34% and increases energy consumption by 21%. The Dyynaro Technologies make On-Line Condenser Tube Cleaning System (OLCTCS) is a unique hydro-mechanical cleaning system that operates continuously to keep heat exchanger tube internal surfaces completely free from fouling. The result of operating capacity and efficiency are constantly maintained at peak levels, reducing overall energy consumption. And there is absolutely no need for periodic shut-down of the HVAC system for costly and time consuming chemical cleaning, which saving you both time and money.

Quick and simple installation

Because systems ball strainers, ball accumulator and skid is ready with control panel, pump and motorized valves are factory skid mounted prior to delivery, and you will benefit from rapid, problem-free installation when you opt for Dyynaro Technologies make On-Line Condenser Tube Cleaning System (OLCTCS). Instead of having to spend time on site installing and testing the system controls, everything is already connected to the system and ready to go.

WHY THIS SYSTEM IS REQUIRED ?

REASONS WHICH REDUCED HEAT TRANSER EFFECTIVENESS IN CONDENSERS

FOULING :

Fouling is the resultant effect of deposition or formation undesired deposits and removal of deposits on a heat exchanger surface. Fouling is the main cause of losses in heat transfer efficiency. Micro fouling increases the energy consumption, damages cooling tubes and causes tube leakages which in turn result in unscheduled outages. Most Fouling situations are virtually unique. Fouling can be classified in to the following categories :

Particulate fouling is evolved by the accumulation of solid particles suspended in the process stream onto the heat transfer surface. Heavy particles settle on the horizontal surface due to gravity and fine particles settle on a heat transfer surface at different inclinations due to suction force. Suspended solids such as dust, mud sediments depositions on condenser tubes are example of Particulate Fouling.

Dissolved inorganic salts are normally present in fluid in heat exchanger. There is maximum amount of salt (saturated) which can be dissolved in this fluid. During heating or cooling super saturation occurs in the dissolved inorganic salts. The inverse solubility salts such as calcium and magnesium sulphate, carbonate, silicate etc. have less solubility in warm water up to certain temperature in cold water. This leads to hard scale deposits on the tubes. These are often found in heat exchanges of process industries, boilers, condensers and evaporators.

This type of fouling is reactant and it is consumed. In this case, the surface reacts with the fluid and become corroded. The corrosion products cannot foul the surface provided it is nor dissolved in the solution after formation. pH value of the solution is one of the controlling parameter. Corrosion is often more prone in the liquid side of the heat exchanger. In some cases the product of corrosion may be swept away to downstream of a process loop and cause deposition on surface there.

On the heat transfer surface the growth of biological materials results in bio fouling. In this case biological micro and macro organisms are stick to the heat transfer surface. When microorganisms (e.g., algae, bacteria, molds etc.) and their products grow there form microbial fouling. Seaweeds, waterweeds, barnacles develop microbial fouling. These fouling may occur simultaneously. The growth of attached organisms is one of the common problems in heat exchanger operation. It is the formation of organic layers. Even if hardly visible with the naked eye, bio fouling constitutes a great impediment to the heat transfer. Food processing industries, power plant condensers using seawater, etc. are experiencing bio fouling.
With the Dyynaro Technologies Condenser Tube Cleaning System which is fully automatic through you avoid such losses. You gain performance - in a technically effective, economic and ecologic way.

Effect of Fouling and Scale on Closed Circuit Cooling Tower Performance :

Fouling is the resultant effect of deposition or formation undesired deposits and removal of deposits on a heat exchanger surface. Fouling is the main cause of losses in heat transfer efficiency. Micro fouling increases the energy consumption, damages cooling tubes and causes tube leakages which in turn result in unscheduled outages. Most Fouling situations are virtually unique. Fouling can be classified in to the following categories :

The Cost Imposed Due to Fouling / Scale :

An additional cost is imposed by fouling of heat transfer equipment in industries. Few Studies have been undertaken to determine the fouling related costs in industry.

Fouling cost can generally be divided into five major categories, such as

  • Increase Capital Expenditure
  • Energy Cost
  • Maintenance Cost
  • Cost of Production Loss
  • Extra Environmental Management Cost

The heat transfer area of a heat exchanger is kept exaggerated to compensate retardation imposed by fouling. Oversized pumps and fans are selected to compensate design over-surfacing the enhanced pressure loss from reduction in the flow area.  

In some occasions standby heat exchangers are kept in process design in order to ensure uninterrupted operation while a fouled heat exchanger is taken under cleaning maintenance. In situation of cleaning in some cases are recommended while chemical cleaning is preferred for others. Altogether, cost of cleaning, cleaning equipment, chemicals all are imposing extra to the capital cost of the plant.

Muller – Stein Hagen reported that total annual costs for highly industrialized countries such as the United States and the United Kingdom are about 0.25 Percent of the country’s gross national product (GNP). Even for a relatively less industrialized country like New Zealand, the total fouling costs are around 0.15 Percent of its GNP. Muller-Stein Hagen has summarized the total fouling costs for various countries based on 1984 in above table.

Estimated fouling cost incurred in some countries

The formation of scale and fouling deposits is always not noticed by system operators due to closed circuit cooling towers with a fouled coil forces other system components for its shortcomings. In Chiller system or heat pump, the burden is placed on the compressor. With scale build-up on the condenser tubes, condensing temperature will rise, causing the compressor to work against a higher head pressure and therefore consume greater energy and reduce cooling output. This will increase system operating cost all year round, although it may not noticed until the system fails to achieve design temperatures on the hottest days or on the peak season.

Fouling in cooling tower and condenser tubes is a major cause of decrease in Chiller performance. Even fresh make-up water comprises sufficient calcium, magnesium and other contaminants to produce extensive scale and corrosion. The cooling tower acts like an air scrubber, which constantly eliminating dirt, wood elements, dust, sand and other airborne debris dumping them in sump of cooling tower. These hard particulates are problematic to avoid from developing or incoming the condenser water. Ultimately particulates end up with fouling. Condenser tubes dropping heat transfer efficiency, initiating operational failure and continuous maintenance complications. Biofilm / Bio slime formation on heat transfer surfaces is the most elusive of all fouling manners. It can coat condenser tubes within weeks and insulates four times as much as calcium scale.

Tube fouling reduces the heat transfer surface and affects the tube’s heat transfer coefficient

In process cooling application, scale on the tube will increase approach, causing the process fluid temperature to rise for a given ambient air wet bulb temperature. Increased process fluid temperature will reduce the efficiency of most industrial processes, reduces process outputs and increasing the cost of production.

SOLUTION

Consequently the Dyynaro Technologies provides utmost importance to the economy of the Chillers in HVAC Systems. Using the Dyynaro Technologies make On-Line Condenser Tube Cleaning System (OLCTCS), client can be assured that their Chiller unit works at determined performance with lowest cost as they can control its electricity consumption.

Dyynaro Technologies make On-Line Condenser Tube Cleaning System (OLCTCS)

Sponge Balls pass through Condenser Tube

Understanding of Sponge Balls passing

Condenser Tube Cleaing Spone Rubber Balls

We are sure that if you can save Power in the range of percentage with 02 digits that its worth a lot to you, isn’t it ?

Actual figures are more considerable than words. What percentage of costs you finally save by means of the Dyynaro Technologies Condenser Tube Cleaning System depends on the technical factors your Chillers units. Innumerable applications have shown, however, that the compressor consumption can usually be reduced by 10-20 % based in site condition. The diagrams show typical savings from operating systems through the fully automatic Condenser Tube Cleaning System Dyynaro Technologies has modernized further. As the condenser tubes are kept everlastingly free from deposits the stress on the compressor is reduced. The wear reduces – which is of decisive influence on the lifetime of both the compressor and the tubes. In addition to the energy saving, this advance in know-how reduces the operational cost of the plant.

PROCESS OF FULLY ONLINE CONDENSER TUBE CLEAING SYSTEM :

The efficient way to operate condenser at its highest efficiency is to be sure that tubes of condensers needs to be cleaned constantly through which maximum heat transfer can be achieved. In Dyynaro Technologies make On Line Condenser Tube Cleaning System at the initiating of each cleaning sequence, the sponge rubber balls are injected through Ball Injector in to the condensers cooling water inlet line. Each Sponge Balls are injected in one lot as we are doing batch injection. After injection sponge balls are passed through condenser water inlet area all tubes by cooling water velocity and remove soft deposits from the tube inner wall area. Then balls are passed through condenser water outlet area tubes with same water velocity and in this way all tubes are kept clean permanently. Condenser tubes inner wall kept clean as sponge balls using for cleaning purpose are slightly higher than condenser tube internal diameter. To ensure that every tube is cleaned during cleaning cycle, the specific weight of each ball is accustomed to that of cooling water. That is how a uniform distribution is reached and sponge balls passed through each tube again and again as per define sequence of operation. After completion of each cycle the sponge balls are separated from cooling water by at ball strainer which designed and proven for zero ball loss. So there is not loss of sponge balls during online sequential operation. By a ball recirculating or injector unit they are re-injected into during upcoming sequential operational cycle. The entire cycle, operation is online, smooth and due to fully automatic PLC based control panel, which does not require any operational personnel interference.

TAKE ADVANTAGE OF OUR ACQUAINTANCE :

We offer you a performance that in its complexity is as undoubted as in the facts. Expertise of system performance, which is based upon years of experience through intensive research and development in this technology. During experience more than hundreds of such systems are being operated world-wide. They are both proof and basis of our expertise in industrial and process technology. We make use of this knowledge and expertise for the development and implementation of our OLCTCS operation. Every single component of the Dyynaro Technologies make OLCTCS has been subject to long-term experiments. We take responsibility for its reliability and in this way we have reached our objective to solidify condensers units more effective, minimize their electric power consumption by minimum 10% on energy cost and guarantee lower operational cost.

KEY BENEFITS OF OLCTCS :

  • With its exceptional design, the Dyynaro Technologies make OLCTCS can easily be installed & commissioned to any existing condenser with minimum time line.
  • After Installation & Commissioning of OLCTCS condenser cleanliness is achieved without manual cleaning of the condenser tubes.
  • Ball Strainer designed with no ball loss with perforated SS Screen with negligible pressure drop across ball strainer.
  • One shot batch injection for all charged sponge balls during each cycle to get for more effective tube cleaning covering maximum tubes in outlying tubes and centre area tubes.
  • Reliable system with pump operated Injection and collection cycles and not a single sponge ball is travel through the pump, so sponge balls are safe against damaged by pump impeller.
  • Accessible to maintenance for ball strainer screen, ball accumulator and pump skid.
  • Optimal heat transfer coefficient and low electric power consumption.
  • Lower corrosion susceptibility of the condenser tubes.
  • Lower wear and tear of the Chiller condenser and compressor.
  • No additional cost of chemical for condenser tube cleaning.
  • No health hazard for workers during manual condenser cleaning.
  • Eliminate the execution of manual condenser cleaning process, which can save production time and cost.