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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
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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
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all Separator
all /onitoring system
/easuring and Control System
all Charger and eeder
all "ecirculating S0id
DEBRIS SEPARATOR
Major Components and AuxiliaryEquipment
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"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 $uantit! of the Debris
and the %ooling Water inletPressure&
The 1ebris is collected at the
inner surface of the screen.
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The le,el of debris fouling on the 3lterscreen is indicated by monitoring the
1ierential Pressure across the Screen.2hen it reaches a preset limit5 thecontrol system initiates the debrisremo,al operation5 till the screen iscleared o the debris.
1ebris accumulated on the insidesurface of the screen is suc0ed by the
debris e6traction assembly whichroutes the e6tracted debris into the1ebris 1ischarge Pipe connected tothe main condenser outlet pipe or
drain
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/any a times the e6traction techni4uealone is inade4uate to dislodge all the
1ebris from the screen. To eecti,elysol,e this problem a special patented"otating 7igh Pressure 2ater Injecting#rm on the rear side of the screen isincorporated . 7owe,er5 it is anoptional item.
The rotation of the lushing #ssemblyis facilitated by an !lectric &ear dri,e
mounted outside the ilter housing. The cleaning operation ceases oncethe screen is clean. The salient featureof the 3lter is that at no time is thereany signi3cant reduction of water 8owduring the screen cleaning operation.
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Ball eparatorinstalled in teCondenser C#$#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#
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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
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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 $orm 1earand A&tuator are2tted dire&tly on tes&reen sa)t )oroperation o) tes&reens#
Te %a&4(asin' o)te s&reens areinitiated %y D3Pmeasurin' system#
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1esign eatures
/anual or #utomatic Installation can be 7ori-ontal+$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.
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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.
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Ball Re&ir&ulatin' 4id
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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.
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Ball Vessel =
Constructed of stainless steel >:?5
>:?L5 >:?L%5 Cu%i to suit theapplication
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The 1ierential Pressure /easuringSystem
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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.
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CO%T"OL S'ST!/
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LOCAL
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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#
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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
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;!R EA $ATER A0D ;RE: $ATER $IT: TEMPERAT-RE-PT! <= C 7 >?@ ; 8
A "emo,al of Soft deposits
A or Copper and brasstubes
A "emo,al of 7ard ScalesCaCo>A or Copper and brasstubes
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A "emo,al of Soft Scales /g
B O7 D < e So@A or welded copper andbrass tubes
A or stainless steel5
titanium tubesA " scouring balls forremo,al of bio fouled layers
A "& for remo,ing highlyadherent bio ; fouled layers
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A D V A N C E M E N T I N
N D E N S E R O N L I N E T U B E C L E A N I N G S Y ST
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The automatic all eeder is forcharging of new balls and remo,al of
worn out ones. One basic charge ofreplenishment sponge balls is storedin a Chamber on the all
"ecirculating S0id. The ball charge is injected into the
system automatically5 based onfeedbac0 signals of the all O,ersi-e/onitor5 as per the controlphilosophy
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'ERO BA(( (OSS S)STE*
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'ERO BA(( (OSS S)ESTE*
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W h a t w e g a i n
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Temp rise E C2 O+L Temp.; C2 I+L
Temp.
TT1 is Terminal Temperature
1ierence. TT1 E LPT !6aust Temp. F C2 O+L Temp
actors aecting TT1 and Temp. rise=
:. Tube fouling
D. #ir ingress
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Month Temp rise(04-05)
TTD (04-05)
Temp rise(05-06)
TTD (05-06)
1 11.1 5.1 11.4 4.7
2 12.4 5.9 11.2 5.4
3 12.0 8.0 11.5 4.8
4 13.0 9.8 11.6 5.3
5 13.7 10.7 11.5 4.8
6 14.0 11.0 11.6 5.0
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Condenser ,acuum is directly
related with LPT !6aust Temperature.
LPT !6aust Temperature
E C2 I+L T!/P. G TT1 G "ise in C2 Temp.
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Before COLTS, LPT Exhaust Temperature =30+14+11
= 55C = 0.3! "a#uum After COLTS, LPT Exhaust Temperature =
30+11.$+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'
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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 $s"
37.9 0.9327 46.2 0.896 54.6 Con. !a".
38 0.9324 46.3 0.8955 54.7 0.841638.1 0.932 46.4 0.8949 54.8 0.8408
38.2 0.9316 46.5 0.8944 54.9 0.8401
38.3 0.9313 46.6 0.8938 55 0.8393
38.4 0.9309 46.7 0.8933 55.1 0.8386
38.5 0.9305 46.8 0.8927 55.2 0.8378
38.6 0.9301 46.9 0.8922 55.3 0.8369
38.7 0.9298 47 0.8917 55.4 0.8362
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Thanks to all of you
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D. !HC!SSI$! 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&
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