Tube cleaning apparatus

Abstract

A tube cleaning apparatus 100 is disclosed that interfaces with a tube 115 targeted for cleaning. The tube 115 connected to the apparatus 100 via a flange 120 positioned at the open end of the tube, linked to adapter 125 integrated into tube cleaning apparatus 100. Alignment of the tube 115 with the apparatus 100 ensures their central axes are coaxial, with a system in place to address minor misalignments. Apparatus 100 features controller unit 130 responsible for managing cycle times and pertinent parameters. Operating in manual, semi-automatic, or automatic modes as configured within the controller unit 130, the apparatus 100 facilitates cleaning of the tube 115 in accordance with predefined protocols. All cleaning operations, including chemical cleaning, water washing, hot air flushing, oiling, are executed within a CIP framework, eliminating the need for disassembly or reassembly processes.

Description

[0001] “TUBE CLEANING APPARATUS”

[0002] FIELD OF THE INVENTION:

[0003] The present invention relates to tube cleaning apparatus and more particularly to a tube cleaning apparatus that performs chemical cleaning, washing, drying and lubricating of a tube.

[0004] BACKGROUND OF THE INVENTION:

[0005] In the area of tube and piping maintenance, the necessity of efficient cleaning procedures cannot be overstated. Tubes, regardless of their application, inevitably accumulate sediments and residues over time, impeding their functionality. This is particularly true for metal tubes, such as those composed of copper or brass, which develop layers of metal particles adhering to their inner surfaces. These deposits form through high-temperature processes inherent to tube operations, creating stubborn bonds that resist conventional cleaning methods.

[0006] In some instances, chemical reactions further exacerbate the issue, leading to the generation of additional sediments at elevated temperatures. These compounds lead to the challenge of maintaining optimal tube performance, as the accumulation of residues compromises heat transfer efficiency and overall operational effectiveness. Moreover, the inaccessible locations of certain tubes exacerbate the difficulty of cleaning, rendering traditional tube cleaning devices inadequate for reaching these remote areas. The importance of cleaning sediments and residue from tubes is well- recognized, as it is essential for the efficient functioning of tubes in various applications. Metal tubes, including those made of copper or brass, develop layers of metal particles on their surfaces due to high-temperature processes. These particles form strong bonds with the tube surface, necessitating thorough cleaning methods for optimal tube performance.

[0007] In certain scenarios, chemical reactions occur within tubes, generating high temperatures and resulting in sediment formation that firmly adheres to the inner tube surfaces. Additionally, external sources of high heat can exacerbate this issue. Consequently, cleaning the inside of tubes becomes a laborious task, further complicated by the challenging accessibility of some tube locations, where conventional cleaning devices may struggle to reach.

[0008] Typically, tubes, especially industrial ones, are cleaned using a single brush designed for the inside surface. These brushes often have a core made of wood or nylon and are typically 150 to 250 mm long. Various standard procedures exist for manufacturing these brushes, ensuring the bristles remain firmly upright for effective cleaning.

[0009] US Patent US10821488B2 teaches a method and device for cleaning tube bundles. This device includes a cleaning lance that is inserted to a certain depth of the tube. A lance is an extended metal pipe with round brush at the front end. The lance is positioned to rotate and enters each tube of the tube bundle. US Patent US9475071B2, teaches nozzle system for cleaning tubes. This nozzle system includes a rigid rotor, a stationary tube and a sub-medium supply source. A pressurized air source is present that rotates the rotor and sucks the sub-medium into the stationary tube passageway. US patent US10683648B2, teaches a drain cleaning apparatus. This drain cleaning apparatus includes a handle and a clogcatching member that are detachably connected to each other. The wings, barbs or hooks provide an angled projection that catches and holds a clump of debris in a drain pipe for pulling the clump out and unclogging the drain.

[0010] Therefore, there is a need for a tube cleaning apparatus that cleans metal tubes in an efficient manner using multiple brush pipes and a forward and reverse action of a piston. A tube cleaning of operators is needed that can clean industrial tubes and pipes irrespective of the size, shape, and location of the tube.

[0011] SUMMARY OF THE INVENTION:

[0012] The present invention discloses a tube cleaning apparatus that is movable and adjustable to a desirable location of a tube for cleaning the tube by chemical cleaning, washing, drying and lubrication of the tube connectable to the tube having a brake without any dis-assembly, the tube cleaning apparatus including an adapter that is selectable in accordance with geometry of the brake of the tube cleaning apparatus such that a central axis of the tube, and adapter are coaxial. The present invention includes a cylinder that is lockable for transportation and mountable on a jack including a hollow piston, an extension pipe and a fixture, the fixture clamping the extension pipe and the hollow piston. The present invention also includes a brush pipe assembly with a plurality of sets of a perforated pipe, camera and brushes. Further, there includes a plurality of liquid tanks, pumps and compressors and the tanks include chemical, water and oil, and the pumps for pumping chemical, water and oil in the tube; and heated air from the compressor. It is noted that the present invention includes a controller unit that is configured for activating compressors, pumps and valves in accordance with inputs from sensors and a Programmable Logic Control (PLC). The present invention also includes a plurality of tube cleaning cycles with a first chemical cleaning cycle, a second water cleaning cycle, a third hot air drying cycle and a fourth lubrication cycle that are performed sequentially starting from the first chemical cleaning cycle till the fourth lubrication cycle. Furthermore, the apparatus of the present invention is operable in a first semiautomatic mode and a second fully automatic mode.

[0013] The tube cleaning apparatus includes the extension pipe that is reciprocable through the hollow piston such that the extension pipe and the hollow piston are held by the fixture to clean the tube from inside due to the interference of the bristles with inner surface of the tube, the brush assembly including perforated pipes and brushes is reciprocable inside the tube. Also, the tube cleaning apparatus has the cylinder that is securely supported by a trunnion arrangement that includes a horizontally positioned rectangular frame that is normal to a central axis of the screw of the screw jack. There includes a connection of the cylinder with the tube concentrically that is defined by the hinge action of the cylinder at the centre and the trunnion arrangement by defining a clearance between the inner surfaces of U- Clamp and the outer body of the cylinder. Also, the extension pipe includes a male socket on one end for fitting to the female socket of the brush pipe. It is noted that the inclination of the tube is maintained about 5° relative to the horizontal such that the brake side is lower than the breech end to form a slope for the ease of jetting chemical, water and oil to flow out of the tube end and getting that being collected in a vessel underneath.

[0014] The adapter in the present invention includes an adapter plate, a plurality of studs that are coupled to adapter plate by nuts. Further, an adapter is connectable with the brake, that includes an annular bush which is defined by split bushes, an outside plate and an identical plate that is bolted with studs and nuts. Further, the cylinder in the present invention is securely connected to the second adapter plate such that the cylinder is perpendicular to the adapter plate and the cylinder is securely fixed by a bracket. Also, the brush assembly includes a first brush pipe with a plurality of perforations, a first brush and a bush on either sides of the brush with clearance allowing the rotational motion of the brush but restricting the transverse motion of brush.

[0015] The tube cleaning apparatus further includes the control unit that is configured to estimate the time of a cleaning cycle and the total cleaning time of the cleaning cycle in accordance with the signals being received from camera that inspects the tube surface from inside. It is noted that the adapter is a connector between the cylinder and the brake of the tube such that the first adapter plate is connected to the tube from a first side of adopter plate and the second adapter plate rom the second side includes the cylinder. Also, the adapter includes a plurality of studs with nuts that being normal to a first adapter plate. Furthermore, a dual plate fixture with a first inner plate, a second outer plate, a third cylinder adapter plate, and a plurality of studs that connect the second plate and third plate, the plate is present that is insertable in the tube. Furthermore, the second plate is of the bigger size relative to the first plate that connected with each other by the studs such that the plates are parallel to each other. Finally, the stroke length of cylinder is adjustable in accordance with the number of the brush assemblies without dis-assembly and reassembly of the tube cleaning apparatus. It is noted that the present invention is operable in a manual mode.

[0016] BRIEF DESCRIPTION OF DRAWINGS:

[0017] The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,

[0018] FIG. 1 shows a side view of a tube cleaning apparatus that is connected to a tube in accordance with a preferred embodiment of the present invention;

[0019] FIG. 2A shows a side perspective view of the tube cleaning apparatus in accordance with a preferred embodiment of the present invention;

[0020] FIG. 2B is a 5 -port manifold to divert the respective liquids and hot air and oil to the extension pipe of the of the tube cleaning apparatus of the FIG. 1;

[0021] FIG. 3 shows a cylinder of the tube cleaning apparatus of FIG. 1 that is securely coupled with an open end flange of the tube;

[0022] FIG. 4 shows a top perspective view of a brush assembly of the tube cleaning apparatus in accordance with of the present invention;

[0023] FIG. 5A shows a cross-sectional view of the brush assembly of the tube cleaning apparatus of the present invention;

[0024] FIG. 5B shows an enlarged view of male female nipples of pipes having O-ring of tube cleaning apparatus of FIG. 1; FIG. 6 shows a side perspective view of the open end of tube connected with a cylinder with hollow piston by an adapter of the tube apparatus of FIG. 1;

[0025] FIG. 6A shows a connecting cylinder with the open end of tube with a dual plate fixture;

[0026] FIG 6B show an open-end annular rings fitment for connecting the cylinder with the open end of the tube cleaning apparatus;

[0027] FIG. 7-1 to 7-8 shows preferred process of assembly and installation of the brush assembly of the tube apparatus in accordance with the present invention;

[0028] FIG. 8 shows the control unit of the tube cleaning apparatus of FIG. 1;

[0029] FIG. 8A shows the working flowchart of fully-automatic mode of the tube cleaning apparatus;

[0030] FIG. 9 shows another embodiment of the present invention wherein the tanks and compressors are positioned in a vehicle;

[0031] FIG. 10 shows another embodiment of the present invention wherein the tube apparatus is mounted on a movable trolley in accordance with the present invention; and;

[0032] FIG. 11 shows another embodiment of the present invention wherein a nipple is used to pass the liquids in the tube in accordance with the present invention.

[0033] DESCRIPTION OF THE INVENTION:

[0034] References in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0035] References in the specification to “preferred embodiment” means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.

[0036] The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching.

[0037] Referring to FIG. 1, a tube cleaning apparatus 100 in accordance with the present invention is described which is removably connected to a tube 115 in accordance with a preferred embodiment of present invention. The tube 115 is the tube that is to be cleaned with the apparatus 100 of the present invention. Accordingly, a connection of the tube 115 with the apparatus 100 is defined by a flange or opener 120 of the tube that is securely connected to adapter flanges 125 of the tube cleaning apparatus 100. The 4 studs hold / fit the flanges 125 of the adapter.

[0038] The tube cleaning apparatus 100 is connectable to the tube 115 such that a central axis of the tube 115 and adapter 125 are coaxial. The apparatus 100 includes a controller unit 130 that controls the cycle times and other relevant parameters. The apparatus 100 operates as per the configuration of the controller unit 130 to clean the tube 115 in accordance with the present invention.

[0039] The control unit 130 is configured to operate in a plurality of modes such as an automatic mode, a semi-automatic mode and a manual mode. The control unit 130 includes a plurality of input switches and displays facilitating inputs and outputs to the apparatus 100. It is noted, however, that the tube 115 is strong enough to take the clamping stress. In other embodiments weak tubes are also cleaned.

[0040] Now referring to FIGS. 2 and 3, the apparatus 100 includes a power cylinder 200 including a hollow piston 205, a brush pipe assembly 210 including perforated pipes, camera and brushes, an extension pipe 215, a fixture 220, a screw jack 225, a chassis 230, the control unit 130, and a plurality of liquid tanks 260. The power cylinder 200 is preferably a pneumatic or hydraulic cylinder or a motorized unit with gearbox and train of gears giving reciprocal action. The screw jack 225 securely supports the chassis 230 that supports the cylinder 200. The screw jack 225 is mounted on the chassis 230 that is mounted on a trolley 245 with wheels 250. The trolley 245 is movable to a desired location by pulling the trolley 245 manually for moving the tube cleaning apparatus 100. The cylinder 200 functions like a prime mover in accordance with the present invention.

[0041] The trolley 245 and thereby the apparatus 100 is movable to any desired location for performing the operation of cleaning the tube 115 (Ref. FIG. 1). In the preferred embodiment, the fixture 220 is defined by a V BLOCK clamping device that clamps the extension pipe 215 to the hollow piston 205. Referring to FIG. 2B a 5 -port manifold is described. The 5-port manifold is used to divert the respective liquids and hot air and oil to the extension pipe 215 and finally to the brush pipes 210 reciprocating inside the tube 115. The five-port manifold is used with respective solenoid valves. The solenoid valves are preferably activated in the automatic mode and semi-automatic mode of operation. And whereas in the manual mode of operation ON / OFF valves are manually operated. The 5-port manifold has four input ports while only one output port that is connected to the extension pipe 215.

[0042] In the preferred embodiment, the 5-port manifold is connected to the chemical tank, water tank preferably containing plain water or water with additives to boost cleaning of chemical residue, oil tank, compressor, air heater and the extension pipe 215. Alternatively, the 5 solenoid valves with a manifold are used instead of the 5 Port manifold. The 5 solenoid valves with a manifold perform in a similar way as that of the 5 Port manifold. Similarly, in the return path after the collection tray, a 4 Port manifold is used for diverting the used liquid received from the collection tray to the respective tanks 260 through the filter for return path of the liquids. Alternatively, 4 solenoid valves with the manifold are used instead of the four Port manifold. The combination of the 4 solenoid valves with the manifold performs in the same way as that of a single 4 ports Solenoid Vave.

[0043] Flexible rubber tubing connects the 5-port manifold and air heater. In this one preferred embodiment, the brush assembly 210 of perforated pipes and brushes advantageously reciprocate inside the tube 115, and the extension pipe 215 reciprocates through the hollow piston 205. It is to be noted that the extension pipe 215 and the hollow piston 205 are held firmly by the fixture 220 i.e. a -block fixture in this embodiment. The apparatus 100 includes a plurality of tanks 260 that are preferably chemical, water and oil tanks, respective pumps 265, compressors 270. The screw jack 225 includes a U-clamp 275, and T-pin 276. During transportation the T-pin 276 securely holds the cylinder with the body. The T-pin 2760 is removably positionable in the screw jack 225 accordance with the present invention.

[0044] The cylinder 200 is securely supported by a trunnion arrangement that includes a horizontally positioned rectangular frame that is normal to a central axis of the screw of the screw jack 225. The frame is coupled to the top of the screw of the screw jack 225. The frame includes a first set of U-shaped clamps and trunnion pin positioned approximately centrally on the frame that defines the trunnion arrangement in accordance with the present invention. The frame also includes another set of a U-shaped clamp and locking bolt that holds the cylinder 200 for the transportation of the apparatus 100. The connection of the hollow piston of cylinder 205 with the tube concentrically is advantageously achievable due to the hinge action of cylinder 200 at the center and due to the trunnion arrangement. It is noted, however, that there is a predefined clearance, for example, about 5 to 10 mm between the inner surfaces of U-Clamp 275 and the outer body of cylinder 200. The said clearance advantageously allows the slight transverse motion of the cylinder 200 to cope up with misalignment of the cylinder 200 with the tube 115. The said clearance is provided to cope up with the minor non concentricity of the tube 115, adapter 125 and piston 205 of the cylinder 200 and extension pipe 215. In the preferred embodiment, the extension pipe 215 is of about 1200 mm in length. The extension pipe 215 includes a male socket on one end for fitting to the female socket of the brush pipe. It is noted that due to the above arrangement of reciprocating all the brushes at a time, it is advantageously possible to clean the entire length of the tube 115 at a time.

[0045] It is noted, however, that in accordance with the present invention, the inclination of the tube 115 is kept at around 5° relative to the horizontal so that one side end is lower than the second end. This slope helps the chemical, water and oil to flow out of the open end by gravity and get collected in a vessel or collection tray underneath.

[0046] Now referring to FIG. 3, the adapter 125 is shown that includes an adapter plate 300, a plurality of studs 305 that are coupled to adapter plate 300 by appropriate hardware for e.g. nuts. The cylinder 200 is securely connected to the second adapter plate 310 such that the cylinder 200 is perpendicular to the adapter plate 300. The cylinder 200 is securely fixed by a trunnion bracket 315.

[0047] Referring to FIGS. 4, 5A and 5B, brush assembly 210 includes a first brush pipe 400 including a plurality of perforations 405, a first brush 410 and a bush 420. Similarly, a second brush assembly 411 includes a second brush pipe 415 including a plurality of perforations 417, second brush 420 and a second bush 425. A third bush (not shown) is present at the back of the brush. In accordance with the present invention similar bushes are tightened at the back side as well as front side of all brushes such as 410, and 420. The arrestor bushes 412, 425 restrict the axial movement of the brushes and allows only the brushes to rotate while cleaning. The time required for cleaning is to be pre-defined, accordingly the amount of brushes required could be defined and hence the stroke length is defined. The length of the brush pipe assembly 210 defines the stroke of the cylinder 200. It is to be noted that the stroke length of the cylinder 200 is adjusted by adding or removing the brush pipe assembly 210. The number of brushes required to clean the tube 115 in a particular time is decided and accordingly the length of brush pipe assembly 210 is selected. To suit this assembly of a number of brushes, the stroke length of the cylinder 200 is adjusted.

[0048] The distance between two brushes on the brush pipe assembly 210 is also adjustable. In this embodiment the first assembly includes a camera 430 is a selflighting camera; however, each of the brush assemblies may include a separate camera or cameras in another embodiment. It is to be noted that each of the brushes 410 and 420 are approximately identical. The brush 410 includes a plurality of V- shaped bristles that are fixed on a cylindrical stem of the brush. The V-shaped bristles are made of materials, for example, nylon, brass, copper, cotton or a mix of that. The cylindrical stem is fixedly mounted on a front-end portion of the respective pipe. The arrestor bush 412 connects a brush assembly 210 with another brush assembly 210 depending upon the requirement.

[0049] In the preferred embodiment, the self-lighting camera 430 is fixed at front end of a first pipe 400 of the pipe assembly 210. The camera 430 sends signals to the control unit 130. The camera 430 inspects the tube surface from inside i.e. inspecting the cleaning cycle. The control unit 130 estimates the time of a cleaning cycle and the total cleaning time of the cleaning cycle. A self-lighting camera 430 is installable at each pipe length for better information. It is understood that the cameras 430 are installed at the end of each brush pipe assembly.

[0050] The brush pipe has male socket 500 on one side of the pipe, while female socket 505 on the other side. It is noted that there is matching threading for the male socket 500 and female socket 505 for screwing and assembling. The male socket 500 and female socket 505 includes opposed identical grooves 510 for receiving the O ring 515 that fits between the male socket 500 and female socket 505. The brush pipes are tightened with each other pairing male and female sockets 500, 505 and rotating and tightening with a spanner with O-ring 515 positioned in between. The O ring 515 arrests any leakage through the joint.

[0051] Each brush has a sleeve of 520. The sleeves 520 are secured with bushes on either side and the bushes which are tightened with the bolts 525. Also, the brush pipes 210 can be assembled by screwing the male side of the brush into the female side of the brush pipe 210 using O ring 515. The O ring 515 advantageously prevents any leakage of chemical or water or oil or air when it is pumped through the perforations of the brush pipes. Brush pipes 210 are having perforation holes for jetting the liquid (Chemical or Water or Oil or air) out of the perforation inside the tube.

[0052] Referring to FIG. 6 and 6A, the adapter 125 includes a plurality of studs 620 with nuts that are normal to a first adapter plate 605. In accordance with the present invention, the first adapter plate 605 is connected to the entry 120 from a first front side. From the other side, the second adapter plate 615includes the cylinder 200 such that the adapter 125 becomes a connector between the cylinder 200 and the entry 120 of tube. In accordance with the present invention, the construction of the adapter 125 is modifiable to suit the flange 120 of the tube 115. Adapter 125 facilitates fitting of the apparatus 100 with the tube 115 maintaining the concentricity of the tube and apparatus centers.

[0053] Referring to FIG 6 A and 6B, in one embodiment of the tube cleaning apparatus 100, a triple plate adapter 601 in accordance with the present invention to connect the entry with the cylinder 200 of the tube cleaning apparatus 100. The fixture 601 includes the first adapter plate 605, the second adapter plate 610, a third cylinder adapter plate 615, and a plurality of studs 620 that connect the second plate 610 and third plate 615. The second plate 610 is of the bigger size relative to the first plate 605 that connected with each other by the studs 625 such that the plates 605, 610 are parallel to each other. Each of the inner plate and outer plates 605, 610 and 615 includes predefined through holes that match and both the plates are bolted to each other using studs 625 using bolts and nuts. The second plate 610 and the third adapter plate 615 are approximately identical and are parallel when assembled. The studs 620 and 625 are designed such that the plates 605, 610, and 615 are positioned at right angle to the central axis of the tube 115 and parallel to each other.

[0054] The first plate 605 is advantageously insertable through the entry gap. The inner plate 605 is inserted through the entry 602 so that the inner plate 605 is positioned along the center of the entry 602. The outer plate 610 is positioned from outside of the entry 602. In this embodiment, the outer plate 610 has sets of for example, four through holes at each corner. The cylinder 200 also includes an identical plate fitted to one side of the cylinder 200 i.e. the adapter plate 615. Studs 625 and nuts of length, for example, 1130 mm having threading on both the sides are kept in between plates 605, 610 and are tightened to fix the cylinder concentrically to the tube 630.

[0055] FIG. 6B, an adapter 650 i.e. another embodiment of adapter 125, and a method of connecting the cylinder 200 with the flange 675 of the tube cleaning apparatus 100 using a bush 655. The annular bush 655 is defined by split bushes 660, 660' is preferred in cases wherein an inner plate 605 is not insertable through the open end 602 of the tube to connect the tube apparatus 100 of present invention with the tube as per FIG. 6A. The annular bush 655 is semi-circular with provisions for bolting it to the entry 602. A duality of annular rings fitment 660 are bolted from outside the tube and appropriate hardware is used through the axial holes for bolting.

[0056] In such case, annular bushes 655 are fixed around the outside surface of the tube just behind the flange 120 towards a breech. Entry outside locus is shown in FIG. 6B. The holes match and both the split bush 660, 660' and the outside plate 670 facing the open end of the entry flange 675 are bolted to each other using sufficient long studs 675 and nuts. Entry Outer Plate 670 is clamped from outside the entry flange 675. Both these i.e. set of 2 Semi Circular plates 660, 660’and the outer plate 670 are bolted using the studs 675 and nuts. Each comer of the entry outer plate 670 includes four through more holes. An identical plate Cylinder Adapter Plate 680 is fitted to the one side of the cylinder 200. It is however noted that studs 675 having threading on both the sides are kept in between these two plates 655, 655’ and are tightened to fix the cylinder 200 concentric to the tube. Cylinder locking bolt is preferably provided to lock the cylinder 200 during transportation.

[0057] Now referring to FIGS. 7.1 to 7.8 a preferred process of assembly and installation of the brush assembly of the tube cleaning apparatus 100 of FIG. 1 is described. In a first step, the piston 205 is positioned at opposite direction of the flange 120. The extension pipe 215 is inserted in the hollow piston 205 V-block. A first brush pipe assembly 210 is taken. In a second step, the brush is aligned according to the extension pipe 215 and the pipe is pushed inside the tube 115 manually. In a third step, the female nipple of the first brush pipe 210 and male nipple of the piston 205 of the cylinder 200 are screwed together and assembled. In a fourth step, the first brush pipe assembly 210 is pushed inside the tube 115 using forward stroke of the cylinder 200. In a fifth step, piston 205 of the cylinder 200 is retracted. In a sixth step, a second brush assembly 212 with a second pipe is aligned between the studs 305. In a seventh step, the female nipple of the first brush pipe 210 and male nipple of the second brush pipe 212 are screwed together and assembled. Also, the female nipple of the second brush pipe 212 and male nipple of the cylinder 200 are screwed and assembled. In an eighth step, both the brush assemblies are pushed inside the tube using the pneumatic force of the cylinder 200 and the coupling are disassembled.

[0058] Referring to FIG. 8, the control unit 130 of the tube cleaning apparatus 100 is described. The control unit 130 further includes a controller for example, a PLC (Programmable Logic Control), plurality of switches for allowing and disallowing inlet air to respective various solenoid valves used for various operations including the valves for the 5 port manifold, return path for 4 port manifold and drain valves etc. all solenoid valves. It has a display showing the picture obtained by the cameras The control unit 130 also includes plurality of specialized switches for plurality of liquid pump 265, compressors 270 etc., plurality of switches for liquid proportionate valves and proportionate pneumatic valves. The controller unit 130 also include switch for heater. All the electrical switches are over-riding switches.

[0059] The control unit 130 further includes a plurality of cameras 430 and respective displays along with temperature sensors for the heated air and their displays. These individual switches are used for maintenance purpose and for semiautomatic operation. However, during full automatic operation, all the switches except the mains switch should be kept Off. The programmed PLC controls ON and OFF various solenoid valves, motors etc. automatically.

[0060] If Port A with its Solenoid valve 816 and pump 810 are selected and operated, the chemical flows to the extension pipe 215 through the flexible tubing. If port B with its Solenoid valve 820 and pump 812 are selected and operated, the water flows to the extension pipe through the flexible tubing. If port C with its Solenoid valve 824 and pump 814 is selected and operated, the Oil flows to the extension pipe through the flexible tubing. If port D with its Solenoid valve and compressor is selected and operated, the air flows to the Extension pipe through the Heater and the flexible tubing.

[0061] Similarly, the four-port manifold is used for diverting the liquid received from the collection tray to the respective tanks 260 through filter for return path of the liquids. The inflow of liquid is from the collection tray. If port 1 is selected the flow is directed to the chemical tank. If Port 2 is selected, the liquid flows to the water tank, and if port 3 is selected, the liquid flows to the valve Oil tank. It is noted that a return path of hot air is not necessary.

[0062] The modes of operation of the apparatus 100 are described. The controller 804 operates the apparatus 100 in at least 2 modes. In the first mode, the apparatus is operable in a mode termed as semi-automatic mode. In the second mode, the apparatus is operable in a mode termed as fully-automatic mode. The user has to select the mode of operation after starting the apparatus by selecting the appropriate option on the display panel.

[0063] In the first semi-automatic mode, the user decides the cycle times. The user operates the switches on the control unit 130 and manually counts the time for running the chemical cleaning, water cleaning, drying and lubricating process that is to be carried out according to the user’s discretion and experience.

[0064] Now referring to FIG. 8A, in the fully-automatic mode, after setting up and starting the apparatus 100, the user has to select the fully-automatic mode 800 option present on the display. As per the present invention, a few typical programs which are more commonly required are preloaded. These programs are written by a person skilled in the art. The operator must choose one of these or load the new program of his choice with his knowledge and experience. After this he can operate the machine as per his given parameters.

[0065] Now the operator, activates the START switch on the control panel 130. The controller 804 using the pre-loaded or new loaded timer programs 808 cleaning of the tube. The chemical pump 810 is started by the controller 804 and only the chemical valve 816 in the 5-port valve is opened. The chemical perforates forcefully in the tube 115 through the brush pipes assembly 210 and the controller 804 activates the reciprocation of the brush assembly 210 using the piston 802. During this cycle the chemical flows from Chemical Tank to pump to 5 port manifold to extension pipe to perforations of brush pipes to collection tray by gravity to filter to 4 port manifold to chemical tank. After the designated time for chemical cleaning is over, the piston 802 is stopped and the chemical inside the tube flows out into the filter and back into the chemical tank. As per the present invention, the chemical reaction with the sediment material is quick due to forceful jetting of the chemical and continuous abrasion / interface of the brush bristles with the inner surface of the tube.

[0066] The controller 804 then activates the water pump 812 releases the water valve 820 and water perforates forcefully through the brush pipes on the inside tube material. The piston 802 reciprocates again. After the designated time for water cleaning is over, reciprocation of the piston 802 stops and the water flows out of the tube. During this cycle the water flows from water tank to pump to 5 port manifold 290 to extension pipe to perforations of brush pipes to collection tray to filter to 4 port manifold to water tank. After water cleaning, the air compressor 828 is started and the air valve 832 is opened. It is noted that a separate air compressor may be designated for this purpose. Hot air is passed into tube using the perforations on the brush pipes for drying the residue of water left in the tube. After the designated drying time is over, the compressor 828 is shut off by the controller 804 and the air valve 832 is closed. Now, the oil pump 814 is activated by the controller 804 and the oil valve 824 is opened. Oil is perforated inside the tube 115. The piston is activated by the controller 130, thus activating the movement of the brushes. During this cycle the oil flows from oil tank to pump to 5 port manifold to Extension pipe to perforations of brush pipes to collection tray to filter to 4 port manifold to oil tank. After the designated lubrication time is complete, the apparatus 100 shuts off the oil pump 814 and the oil valve 824 is closed. The extra oil inside the tube 115 flows through the oil filter back into the oil tank. The controller 804 then compiles all the data and visuals received through the camera / s and this data is acquired by connecting any device such as a pen drive to the controller unit 130. After each time cycle e.g. cleaning time for chemical, water etc. some idle time is provided e.g. to drain the chemical, water etc. in the tray.

[0067] It is to be noted that the user has the option of selecting one program out of the pre-loaded programs or make his own program - new program. It is understood, however, that in the fully automatic mode and other modes as well, the user has to decide the time for chemical cleaning, water cleaning, drying i.e. drying with air flow, and lubrication at his will. This time is decided by the user based on prior experience. The user has to check the incoming voltage and rectified operational voltage with a predefined value. The user has to also check and confirm the strength of cleaning chemical or cleaning liquid, volume of both the liquids, replenishment of the liquid in the respective tanks, and the status of the compressed air from the compressor. As shown in FIG. 9, in another embodiment of the present invention, all tanks 905 and compressors 910 of the tube apparatus 900 are position able in a separate vehicle 915. In this one embodiment, there is a liberty to have bigger chemical volume and water volume tanks as compared to the preferred embodiment. It is however noted that the assembly of the tube assembly 900 of this embodiment takes lesser time to assemble the tube cleaning apparatus 100 with an entry of a tube in accordance with the present invention.

[0068] Referring to FIG. 10 in another embodiment of the present invention, the apparatus 100 is mounted on a movable trolley. The trolley allows the apparatus 1000 to be connected to various automobiles for transport and mobility purposes like trucks, tractors, lifts, etc.

[0069] In one more embodiment apparatus 100 includes a sensor, for example, optical sensor, infrared sensors, color sensors etc. to check the colour of the sedimentation in the tube during cleaning, chemical cleaning and during the washing. The sensor is positioned on the brush pipe so that the inside surface of the tube can be viewed and analyzed by the controller 804 to decide the amount of the initial sedimentation from time to time. If the tube is not sufficiently clean, then the cleaning cycles are repeated till the time the tube is properly cleaned. In this embodiment, the cleaning status of the tube is decided by comparing the present image of the sediment / tube with one or more standard images. By experience, one may possibly conclude that there can be one sensor mounted on the first brush pipe where the amount of sedimentation will be probably maximum in the entire length of the pipe or if not / altematively one sensor each can be mounted on each brush pipe in the front or at rear. Every sensor can give the feedback of the amount and the type of the sedimentation on the inside surface of the pipe. The purity of the sensors will give better idea of the sedimentation of the full pipe.

[0070] In some cases, it is necessary that the chemicals should not have any chemical reaction with the inside surface of the tube, but should be able to have chemical reaction with the sediments adhered to the inside surface of the tube. The sediments may have multiple compositions of carbon, copper, brass and other forms of many elements. Hence, it is mandatory to use such chemicals only. These chemically reacted masses of small / micro sizes can get dissolved with the water and flow out of the tube during the next water cleaning operation. The forceful jetting of the chemical and the water added with the reciprocal action of the brushes (brush bristles) with the inside tube surface hastens the cleaning process.

[0071] In certain instances, the tube must be composed of a specific grade of steel, featuring either predefined grooves or a plain surface. Additionally, it is important that the chemical cleaning operation does not impact the interior surface of the tube.

[0072] The selection of appropriate chemicals is crucial, considering factors such as system requirements, tube metal composition, sediment type, time constraints, and cost considerations. Merely ensuring efficient chemical reaction with the sediments is insufficient; residual traces of the chemicals must also be thoroughly eliminated to prevent oxidation, which could compromise the precision machining of the tube's interior surface. Therefore, complete washing out of these traces is essential. Typically, since many chemicals used are water-based, water is flushed through the tube to dissolve and remove chemical residues. However, if a chemical is insoluble in water but dissolves in another solvent, that solvent is utilized for flushing. Subsequently, after water washing, thorough drying is necessary. Hot ahis introduced into the tube to eliminate residual moisture.

[0073] To prevent oxidation of the tube's interior surface, a suitable grade of oil, potentially with additives, is flushed through. Importantly, all these processes — chemical cleaning, water cleaning, hot air flushing, and oiling — are executed using the same hardware assembly sequentially, without the need for assembly, disassembly, or re-assembly. This streamlined approach reduces manpower and time constraints significantly.

[0074] Referring to FIG. 11, in yet another embodiment of the present invention, the extension pipe 215 does not pass through the piston 205. The extension pipe 215 is clamped to the piston 205. The extension pipe 215 has a nipple 1100 which is connected to the pumps 265 and the liquids flows in the tube 115 forcefully though the perforations.

[0075] It is to be noted that the apparatus 100 is operable in a completely manual mode in another embodiment, however, such an apparatus 100 includes manually operated ball valves instead of the solenoid valves as that of the preferred embodiment. In the manual mode of operation, the PLC Controller may not be required. It is a controller 804 with manual ON / OFF Switches and not PLC or the PLC program. The user manually operates relevant switches provided on the control panel 130 and also operates ball valves physically accordingly the pumps, compressors, heater etc. are operated. The user counts the time either manually or on a stopwatch and operates the switches and the valves to complete the cycle when each time for that particular cycle is completed. All the cycles are carried out manually to end the total cleaning cycle.

[0076] Now referring to FIGS. 1 to 10, in operation, the tube 115 is firstly inspected by a user to understand the amount of the sedimentation and copper deposition on the inside of the tube 115. The user figures out the amount of cleaning required to determine various time duration of each activity to get the best results. The user also decides the duration of each cycle, strength of chemical composition and the volume required for both the liquids chemical and water. The tube to be cleaned is made inclined by approximately 5° towards the machine end.

[0077] The apparatus 100 is to be positioned as shown in the FIGS. 1 and 2 such that the adapter plate 125 of power cylinder 200 faces the flange 120 of the tube 115. The height of the apparatus 100 is adjusted by removing T Pin 276 and lifting or lowering main cylinder 200 of the apparatus 100 for the coarse adjustment and again inserting the T pin 276. It is noted, however that for fine adjustment of the height, the Jack Nut can be rotated on the threading to achieve appropriate height. By using the threads of the screw jack 225 and the nut the exact height should be adjusted so that proper fitting is possible.

[0078] Now depending on the type of the flange 120, either entry inner plate 605 or annular half plates 655 are to be used or is to be used depending on the type of the entry of the tube which is decided by the user. Now the cylinder locking bolt is loosen so that the cylinder 200 is advantageously rotatable slightly along the hinge to match the inclination of the tube 115 hinged and made in line with the tube 115 for concentric fitment. Two people are generally required for this fitment work.

[0079] In the next step, hold the flange 120 outer plate firm from outside of the tube touching the outer surface of the flange 120. Then in the next step, with the help of the studs and nuts, the holding plate is bolted firm to the entry inner plate. Then in the next step, hold the entry outer plate firm from outside of the tube touching the outer surface of the flange 120. In a next step, with the help of the studs and nuts, the holding plate is bolted firm to the annular half plates.

[0080] Now the appartuslOO adjusted for bolting the cylinder 200 so that the adapter plate 125 of cylinder 200 is bolted using the studs and nuts for holding cylinder 200. In this step all the bolts are tightened properly and to ensure that the cylinder 200 is concentric to the tube 115.

[0081] It is to be noted that the connection of the cylinder 200 with the tube 115 concentrically is advantageously achievable due to the hinge action of the cylinder 200 at the center and due to the trunnion system. Also, the gap between the inside of the C bracket of trunnion and the cylinder trunnion plates on the either sides at the trunnion shaft of the cylinder 200 can allow the slight transverse motion of the cylinder 200. This system 100 is provided to cope up with the minor non concentricity of the tube 115, Adapter 125 and the piston 205 of the cylinder 200 and the extension pipe 215.

[0082] Now, in a next step, the brush pipe 210 are inserted one after another and couple the brush pipes 210 with each other and finally with the extension pipe 215. For this purpose, the pneumatic hydraulic power of the cylinder is used. There is ON and OFF Switch for the Solenoid Valve. This is actually for forward and reverse operation of the piston 205 as selected. By pressing the Switch ON, the piston 205 is forwarded and by putting it off the piston 205 is retracted.

[0083] Now take the piston 205 to the rear side of the cylinder 200. The extension pipe 215 is to be inserted from the rear side of the piston 205 so that the nipple is located outside. Let the extension pipe 215 protrude by around (100 -150 mm) out of the piston 205. The important point is that there should be sufficient space for the brush pipe to be inserted and get screwed with the male nipple 500 of the extension pipe. It is necessary to assemble all the brushes 210 etc. to each other and finally to the extension pipe 215 passing through the hollow piston 205 using male 500 and female nipples 505 of brush pipes 210 and male nipple 500 of main cylinder 200. For this, first insert the Brush holding bush 520 on the brush pipe 210 and thereafter insert the brush on the pipe followed by another brush holding bush 520. Fix the bush at about 50 mm from the male socket end 500 of the brush pipe 210 end and tighten the bolts 525 for tightening brush holding bushes 520. There after hold the brush so that the bush face touches the brush face. Slide another bush 525 and fix that keeping about 2-3 mm space between the brush face and the bush face. Similarly assemble all the brushes to the brush pipes 210. The brush is nearer to the male socket end 500. Connect the Compressor 270. Also connect all the compressed air tubes and start it. As the compressor is ON and the compressed air is allowed to enter the system. Put ON the Solenoid valve by putting on the switch (for semiautomatic operation). Due to this action, the piston 205 is forced forward and by putting the same switch off, the piston 205 retracts to the original position i.e. caliber and length of the subject tube.

[0084] It is noted that in Semi-Automatic and in Manual mode, a cyclic Solenoid valve is used. In this valve, the compressed air is connected to the Input port of the valve. After putting it ON, the compressed air is forced out from one port of the 2 ports. There is setting knob to set the time. As this set time is over, the compressed air stops from the earlier port and it is forced out from the other port. These 2 output ports are connected to the input ports of the power cylinder to get the reciprocal movement of the Piston and the connected parts e.g. brushes, brush pipes, Extension Rod etc.

[0085] If auto mode is put on, the piston 205 is forwarded and immediately retracted automatically to get reciprocal action. The extension pipe 215 inserted through the hollow pipe and both are fixed with each other by a fixture 220. Ensure that the threaded male socket 500 is towards the tube 115 and the nipple is away from it. In Semi-Automatic and manual modes, the piston 205 travel forward with the extension pipe 215 and retracts also along with the extension pipe 215.

[0086] Now next step is to assemble the brush pipes 210 and push them in tube 115 and finally screw the last pipe to the extension pipe 215 using the V -Block fixture. Now screw the Female socket 505 of the 1st brush pipe with the male socket 500 of the extension pipe. Then Put ON the Switch and also put ON Switch to generate forward thrust to the piston 205 and hence also of the extension pipe 215. The piston 205 and the extension pipe 215 travel by 1030 mm. In operation, the forward stroke of brush pipes 210 required is limited by putting OFF ON / OFF switch. The 1st brush pipe 215 travels inside tube 115 due to the thrust of the cylinder 200.

[0087] Now, unscrew the Male Socket 500 of the extension pipe 215 from the 1 stbrush pipe female socket 505 of the brush pipe 210. Put OFF the Switch. Put ON the Switch allowing compressed air to the solenoid. The piston 205 with the extension pipe 215 is retracted back keeping the 1st brush pipe 210 inside the tube 115.

[0088] Now hold the 2nd assembled brush pipe 411 so that the male socket 500 is facing the tube 115. After that push, the male socket 500 between the two studs and nuts and bring it at the center. Now screw the male socket 500 of the 2nd pipe 210 into the female socket 505 of the 1st pipe 210. Also screw the female socket 505 of the 2nd brush pipe with the male socket 500 of the extension pipe.

[0089] Put ON the Switch. Also put ON Switch to generate forward thrust to the piston 205 and hence to the extension pipe 215. The piston 205 and the extension pipe 215 can travel by 1100 mm. During the actual operation, the forward stroke of brush pipes 210 required is limited by putting OFF the ON / OFF switch. With the above actions, the 1st brush and brush pipe 210 and the 2nd brush and brush pipe 210 both travel inside tube 115 due to the thrust of the cylinder 200.

[0090] Now, unscrew the Male Socket 500 of the Extension pipe 215 from the brush pipe female socket 505 of the 2nd brush pipe 210. Put OFF the Switch. Put ON the Switch allowing air to the solenoid. The piston 205 with the extension pipe 215 is retracted keeping the 1st and 2nd brush pipe 210 inside the tube 115. Similarly assemble the required number of brushes and brush pipes 210 screwing the male and female nipples of the brush pipes 210 and finally with the extension pipe 215 and insert required numbers of the brush pipes 210 inside the tube 115. Now the apparatus 100 is ready for operation with the following more work to be performed. Fill the Chemical tank 260 with the chemical as suggested by the user. Also test and adjust the concentration of the chemical as required. Also, fill the water tank 260 with water. Also, fill the Oil tank 260 with oil.

[0091] The Camera 430 with light has a sheathed bunch of electric wires for the camera light and communication wires from the camera 430 to camera display. These wires also should be passed through the pipe and pipe joining male and female nipples up to the V Block 220 of the extension pipe 215. The water-tight exit from the extension pipe 215 is shown. The light supply and communication cable is connected to the camera display. The camera display shows the exact position of the tube 115 for the 1st meter near the breech. Also, the breech is kept open for the light to pass through it. From the degree of cleaning of the first meter length of the tube 115, the experienced person can estimate the degree of cleaning for the full length of the tube 115. The output of each camera is displayed on the display on Controller 804. It shows the present status of the inside of the tube i.e. amount of the cleaning.

[0092] The automatic operation of tube cleaning in accordance with the preferred embodiment of the present invention is described. The users provide inputs to the apparatus 100, for example, chemical cleaning time, water cleaning time, hot air and normal lowing time for hot drying, and lubrication time. In the next step, the levels of chemical tank with required chemical concentration and water in the tank are checked to ensure that predefined levels are already there in respective tanks 260. The status of the FRL and shut off valves of both compressors 270 are opened. In this step, the compressors 270 are started with the FRLs and Shut-Off valves opened. Status of the operations is displayed on the controller display. The chemical and the water for chemical / water cleaning is are forced out of the perforations of the brush pipes 210 inside the tube 115 during its operational phase. During operation, the liquid (water, chemical or oil) is forced out of the tanks 260 to the pump to the 5- port manifold. From the 5-port manifold the liquid flows through heat resistant rubber tube to the heater and further to the extension pipe 215. For drying, the compressor provides compressed air to the 5-port manifold. From the 5-port manifold the compressed air travels to the air heater to heat the compressed air. This compressed heated air then travels to the extension pipe 215 and the heated air further travels into the tube 115 through the perforations 405 on the brush pipes. Due to the continuous flow of the hot air the residual water evaporates and escapes from the flange and breech. In another embodiment, for faster drying of the tube, the air from the compressor first passes through the air heater and the hot air is further passes though the 5 port manifold. It further passes though flexible tube to the extension pipe.

[0093] Bristles of the brushes have mechanical interface that creates forceful rubbing with the inside surface of the tube 115. During chemical cleaning process due to the interference the chemical action is enhanced. Also, during water cleaning process, the interference helps. During lubrication process, because of the perforations in the brush pipes the oil is forced in all directions and at the same time due to interference the oiling is achieved also in the upper half of the tube against gravity.

[0094] The apparatus 100 automatically performs the Tube Chemical Cleaning, Washing, Drying and Lubrication operation which uses the cylinder 200 having hollow piston 205 in the cylinder 200 and the assembly of perforated brush pipes 210. The brushes reciprocate inside the tube 115 as the entire apparatus is fixed concentrically to the flange 120 of the tube using suitable adapters performing the full operation which employs continuous availability of liquid chemical recirculated after proper filtration to remove dirt and react chemically with copper / brass particles during chemical cleaning operation; jetting the chemical through the perforations of the Brush pipes 210 inside the tube 115 and pumping of chemical and subsequently washing the residue of chemical with water while the brushing of the full length of tube using multiple brushes at a time creating interface and after water cleaning drying the full tube 115 using hot air and lubricating with oil.

[0095] The tube cleaning apparatus 100 of the present invention performs functions such as chemical cleaning, washing, drying and lubrication of the tube, results in to very effective and fast with high quality of cleaning as compared to the devices in the prior art. The manpower saving is also promising as only two persons are required for assembly and to start while one person required for operation. No additional apparatus / equipment is required for lifting or motion purpose e.g. forklift, truck etc. The apparatus 100 uses the specially designed and fabricated non- conventional pneumatic / hydraulic / electromechanical cylinder / device prime mover, which has hollow reciprocating piston 205 which is mounted on Screw Jack 225 which is mounted on a trolley 245 with wheels 250.

[0096] The apparatus 100 is fixed concentrically with the Tube of the pipe using suitable open end adapter. High degree force is required to be created to overcome the resistive forces created due to interaction (rubbing) of the brushes with the inside surface of the tube 115. Due to the fixing of the apparatus to the tube, the reactionary forces are transferred to the tube itself, allowing the apparatus 100 to not require strong foundations and become mobile. In some cases, the tube is hermetically fixed in the apparatus and not possible to take out; it is necessary to clean the tube in CIP (Cleaning in place). This invention provides the solution to such problems. The apparatus 100 is preferably mounted on a simple trolley. The trolley details are as per the transportation needs of the apparatus.

[0097] The adapter 125 is designed as per the details of the tube to have sufficient gap in between to insert the brush and brush pipe 210 one after one and get assembled with each other and also with the (front) side of the extension pipe 215. The extension pipe 215 partially passes through the hollow piston 205. The extension pipe 215 and the hollow piston 205 are held firm by fixture V-Block 220 at the tail end. Hence, when the piston 205 is forced to create reciprocal motion; the entire assembly of the brushes and brush pipes 210 and the extension pipe 215 reciprocate. The bristles of the brushes have mechanical interface (forceful rubbing) with the inside surface of the tube 115. It is noted that the tube may have grooves or may be plain inside surface. The number of required perforated brush pipes 210 and brushes inside the tube 115 depend on the length of the tube 115 to be cleaned and the force and the stroke length the particular prime mover can create and as per the capacity of the system. The reciprocal motion of the full assembly of the brushes and brush pipes 210 inside the tube 115 perform the full operation of the Tube Chemical Cleaning, Washing, Drying and Lubrication without dis-assembling and re-assembly. Continuous supply of fresh chemical and water thereafter is made available which is forced from the tail end of the extension pipe 215 end. For this purpose, tanks 260 and pumps 265 are used for circulating chemical and water and oil. The chemical and the water for chemical / water cleaning is are forced out of the perforations of the brush pipes 210 inside the tube 115 during its operational phase. Due to inclination, the liquid flows out of the open end flange 120 and it is collected in the collection tray and thereafter through coarse and fine filters in to the tank for recirculation.

[0098] The full length of tube 115 is brushed at a time using multiple brushes at a time as required. It creates the necessary interface (forceful rubbing) for cleaning. The chemical action supported by mechanical interface creates perfect cleaning of the tube and releases the carbon and other sediments and also copper / brass cladding adhered to the tube if the case may be. These are released and are flown away during the on line filtration. In order to remove the chemical residue in the tube 115, it is cleaned / washed with plain water. After water cleaning; the full tube is dried forcing hot air made available from compressor 270 and air heater through the perforations with active reciprocation of brushes and brush pipes 210. For lubrication of the tube 115, oil tank and pump forces oil through the perforations while the full assembly of brush pipes 210 reciprocates inside the tube lubricates each and every regular or irregular treads, if available. This apparatus is fully automatic PLC / microprocessor controlled. The Cycle times and other parameters are set on the controller 804 or PLC or microprocessors. The apparatus 100 operates as per the set program and cleans the tube without any dis-assembly and re-assembly or change of few parts etc. if cleaned in CIP (cleaning in place).

[0099] Initially, human effort is required to assemble the apparatus correctly and ensure an adequate supply of chemicals, fresh water, and oil, as well as to program the controller 804. In an alternative configuration, level sensors are integrated into each tank, triggering an alarm signal via the controller to alert operators when replenishment is necessary. Additionally, there may be automatic systems in place to refill the tanks and maintain optimal concentrations.

[0100] The inclusion of self-lighting cameras at the start of the respective pipes, along with a display provided in the controller, enhances the operational efficiency. This camera 430 display enables users to inspect the inside tube surface during the cleaning process, aiding in evaluating the effectiveness of the operation. It also facilitates estimating the duration of each operation and the overall cleaning time, empowering operators to make informed decisions regarding the continuation or cessation of the cleaning process.

[0101] In the embodiment of the present invention, wherein chemical tanks and compressors are positioned in a vehicle (Ref. FIG. 8), it is to be noted that the chemical tanks with higher volume for e.g. 500 liters are employed. Because of the higher volumes of the chemical tanks the potency of the chemical is within the workable limits, hence it is not required to stop the operation in between and adjusting the potency of the chemical. Also, due to the ample volume of water and oil the operation is better in quality and uninterrupted.

[0102] Referring to the embodiment of FIG. 10 wherein the tube cleaning apparatus 100 is mounted on a movable trolley, it is advantageously not necessary to assemble and disassemble the brush assemblies one by one. The entire brush assembly is inserted inside the tube by reverse motion of the vehicle or forward action of the tube. The forward motion of the vehicle takes out all the brushes from the tube 115 in assembled condition.

[0103] In another embodiment of the present invention, compressor 270 is not included in the tube cleaning apparatus 100. Instead of the hot air system using the compressor 270 and the heater to heat air. In this alternative system, a heater is used to heat the oil in the oil tank. This hot oil is then jetted through the perforations of the brush pipes the apparatus 100 into the tube 115. The hot oil evaporates the water residue in the tube 115 and the compressor 270 for heating air is not required. Some traces of water flow out of the tube 115 along with the hot oil and gets settled in the oil tank for some time and gets evaporated. Thus, the tube 115 gets dried and lubricated also.

[0104] Due to this fact the tube cleaning apparatus 100 does not require any foundation or heavy weight to get high stability to balance the reactionary force, the present invention advantageously needs only frame 230 and trolley 245 that takes the weight of the apparatus 100. It is to be noted that the reactionary force of the work done is transferred to the tube 115 through the adapter 125 and not to the structure of the apparatus 100.

[0105] The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0106] It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

Claims:

1. A tube cleaning apparatus 100 that being movable and adjustable to a desirable location of a tube for cleaning the tube 115 by chemical cleaning, washing, drying and lubrication of the tube 115 connectable to the tube 115 having a brake 120 without any disassembly, the tube cleaning apparatus 100 comprising: an adapter 125, the adapter 125 selectable in accordance with geometry of the brake 120 of the tube cleaning apparatus 100 such that a central axis of the tube 115, and adapter 125 are coaxial; a cylinder 200, the cylinder 200 being lockable for transportation and mountable on a jack including a hollow piston 205, an extension pipe 215 and a fixture 220, the fixture 220 clamping the extension pipe 215 and the hollow piston 205; a brush pipe assembly 210, the brush pipe assembly including plurality of sets of a perforated pipe, camera and brushes; a plurality of liquid tanks 260, pumps 265 and compressors 270, the tanks 260 include chemical, water and oil, and the pumps for pumping chemical, water and oil in the tube; and heated air from the compressor; a controller unit 130, the controller unit 130 configured for activating compressors 270, pumps 265 and valves in accordance with inputs from sensors and a Programmable Logic Control (PLC);a plurality of tube cleaning cycles, the cleaning cycles including a first chemical cleaning cycle, a second water cleaning cycle, a third hot air-drying cycle and a fourth lubrication cycle that are performed sequentially starting from the first chemical cleaning cycle till the fourth lubrication cycle; and the tube cleaning apparatus 100 operable in a first semiautomatic mode and a second fully automatic mode.

2. The tube cleaning apparatus 100 as claimed in Claim 1, wherein the extension pipe 215 being reciprocable through the hollow piston 205 such that the extension pipe 215 and the hollow piston 205 being held by the fixture 220 to clean the tube 115 from inside due to the interference of the bristles with inner surface of the tube, the brush assembly 210 including perforated pipes and brushes is reciprocable inside the tube 115.

3. The tube cleaning apparatus as claimed in Claim 1, wherein the cylinder 200 being securely supported by a trunnion arrangement that including a horizontally positioned rectangular frame that being normal to a central axis of the screw of the screw jack 225.

4. The tube cleaning apparatus as claimed in Claim 1, wherein the connection of the cylinder 205 with the tube concentrically is defined by the hinge action of the cylinder 200 at the centre and the trunnion arrangement by defining a clearance between the inner surfaces of U- Clamp 275 and the outer body of the cylinder 205.

5. The tube cleaning apparatus as claimed in Claim 1, wherein the extension pipe 215 including a male socket on one end for fitting to the female socket of the brush pipe.

6. The tube cleaning apparatus as claimed in Claim 1, wherein inclination of the tube being maintained about 5° relative to the horizontal such that the brake side being lower than the breech end to form a slope for the ease of jetting chemical, water and oil to flow out of the tube end and getting that being collected in a vessel underneath.

7. The tube cleaning apparatus as claimed in Claim 1, wherein the adapter 125 including an adapter plate 300, a plurality of studs 305 being coupled to adapter plate 300 by nuts.

8. The tube cleaning apparatus as claimed in Claim 1, wherein an adapter 650 being connectable with the brake 675, the adapter 650 including annular bush 655 defined by split bushes 660, 660', an outside plate 670 and an identical plate 680 being bolted with studs 675 and nuts.

9. The tube cleaning apparatus as claimed in Claim 1, wherein the cylinder 200 being securely connected to the second adapter plate 310 such that the cylinder being perpendicular to the adapter plate 300 and the cylinder 200 being securely fixed by a bracket 315.

10. The tube cleaning apparatus as claimed in Claim 1, wherein the brush assembly 210 including a first brush pipe 400 including aplurality of perforations 405, a first brush 410 and a bush 412 on either sides of the brush 410 with clearance allowing the rotational motion of the brush 410 but restricting the transverse motion of brush 410.

11. The tube cleaning apparatus as claimed in Claim 1, wherein the control unit 130 being configured to estimates the time of a cleaning cycle and the total cleaning time of the cleaning cycle in accordance with the signals being received from camera 420 that inspects the tube surface from inside.

12. The tube cleaning apparatus as claimed in Claim 1, wherein the adapter 125 being a connector between the cylinder 200 and the brake 120 of the tube such that the first adapter plate 605 being connected to the tube from a first side of adopter plate 605 and the second adapter plate 615 from the second side includes the cylinder 200.

13. The tube cleaning apparatus as claimed in Claim 1, wherein the adapter 125 including a plurality of studs 600 with nuts that being normal to a first adapter plate 605.

14. The tube cleaning apparatus as claimed in Claim 1, wherein a dual plate fixture including a first inner plate 605, a second outer plate 610, a third cylinder adapter plate 615, and a plurality of studs 620 that connect the second plate 610 and third plate 615, the plate 605 being insertable in the tube.

15. The tube cleaning apparatus as claimed in Claim 14, wherein the second plate 610 is of the bigger size relative to the first plate 605 that connected with each other by the studs 625 such that the plates 605, 610 are parallel to each other.

16. The tube cleaning apparatus as claimed in Claim 1, wherein the stroke length of cylinder 200 being adjustable in accordance with the number of the brush assemblies without dis-assembly and reassembly of the tube cleaning apparatus 100.

17. The tube cleaning apparatus as claimed in Claim 1 being operable in a manual mode.

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