ATCS Automatic Tube Cleaning System Brochure rev2 (Eng)

ECOMax-HE™Automatic Tube Cleaning System

Problems affecting performance in

Shell and Tube Heat Exchanger:

Reduce Your Carbon Foot Print

• Tube vibration

• Dead zone

• Leakage

• FOULING

� Design / Fabrication

� Fabrication / Maintenance

�� Operation Cost

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.

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

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.

Types of Fouling:


4. Corrosion fouling

This is when a layer of corrosion products build up on the surfaces of the tube forming an

extra layer of, usually, high thermal resistance material.

Effects of 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

Effect of Fouling :

• Fouling decrease Heat Exchanger’s overall

heat transfer coefficient, thus reduce heat

transfer ability of the Heat Exchanger

Effect of Fouling :

Heat energy transfer from hot fluid to cold fluid is reduced

Effect of Fouling :

Cooling Capacity (TR) COP =

Power Consumption (kW)

Effect in Chiller Coeffiency

of Performance (COP)

• Fouling reduces cooling/heat

rejection capacity

• Fouling increase compressor

power consumption

Fouling Scale Thickness Vs Power Consumption

1 mm of fouling accumulation in the heat exchanger tubes

increases energy consumption ~ 30%

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?

Offline/Shutdown Cleaning & Loss of Energy:

The Solution ECOMax-HE™: Automatic Tube Cleaning System


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

Components:


• 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

Applications:


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 10-16

• Probability of balls passing through each tube =

[1 - (10.6 x 10-16 )]*100 = 99.999999%


Condenser Tubes after ECOMax-HE™ : After 1 Year


Condenser Tubes after ECOMax-HE™ : After 20 Months


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


• 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

• 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



• 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


ECOMax-HE™ Installed Units

Single Unit Condenser/Heat Exchanger


2 Units of Condenser / Single Control Center


5 Units of Condenser / Single Control Center

Reference Clients :

Testimonial :

ATCS Automatic Tube Cleaning System Brochure rev2 (Eng)

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