Heat Exchanger Cleaning Kit for Controlled Filling and Drainage
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Solution Overview
Problem
Existing cleaning processes for heat exchangers, particularly condensing heat exchangers, are tedious and often fail to completely remove fouling, leading to degraded performance and efficiency.
Innovation Solution
A cleaning assembly kit comprising a manifold assembly and a cover lid, which allows for efficient filling and drainage of cleaning fluid within the heat exchanger, utilizing a valve system to manage fluid flow and an optional auxiliary tool for thorough cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing cleaning processes are used for heat exchangers, then the cleaning process can be completed, but the process is tedious and does not completely remove fouling, leading to degraded performance
Solution Approach 1:
The cleaning system is divided into separate functional modules: a cleaning fluid delivery system with inlet valve, a drainage system with drainage valve, and a cover lid assembly. This segmentation allows each component to perform its specific function independently, making the overall process more manageable and effective while reducing operational complexity through specialized functionality.
Solution Approach 2:
The system employs dynamic valve control mechanisms that can switch between different operational modes (filling mode with inlet valve open/drainage valve closed, drainage mode with inlet valve closed/drainage valve open). This dynamic control enables the same system to perform multiple cleaning functions efficiently, improving reliability while maintaining ease of operation through automated mode switching.
2Productivity
If manual cleaning methods are used, then the cleaning process can be performed, but heat transfer efficiency degrades over time due to incomplete fouling removal
Solution Approach 1:
The cleaning system enables continuous circulation of cleaning fluid through the heat exchanger tubes via the manifold assembly and valve system. The fluid can be continuously pumped through the cleaning fluid source, through the inlet valve, through the tubes, and drained through the drainage valve, creating an uninterrupted cleaning action that maintains high productivity while reducing total cleaning time compared to manual methods.
Solution Approach 2:
The system utilizes hydraulic principles by employing fluid pressure to drive cleaning solution through the heat exchanger tubes. The pump generates pressure to force cleaning fluid through the inlet valve and along the tube bundle, while the drainage valve controls the outflow. This hydraulic approach enables more effective and faster cleaning compared to manual methods, improving both productivity and reducing time loss.
3Reliability
If cleaning fluid is introduced into the heat exchanger, then fouling can be removed, but fluid management becomes complex requiring separate filling and drainage systems
Solution Approach 1:
The cleaning fluid delivery and drainage functions are merged into a single integrated manifold assembly that houses both the inlet valve and drainage valve. The manifold assembly combines multiple fluid pathways and control mechanisms into one unified component, enabling effective fouling removal while reducing overall system complexity through functional integration.
Solution Approach 2:
The manifold assembly serves multiple functions simultaneously: it distributes cleaning fluid through the tube bundle, controls fluid flow via the inlet valve, manages drainage through the drainage valve, and interfaces with both the cleaning fluid source and the heat exchanger. This multi-functionality reduces the number of separate components needed, improving reliability while minimizing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The kit effectively cleans the inner volume of heat exchangers, improving their performance by removing fouling and enhancing heat transfer efficiency.
Implementation Method 1
valve system including, an inlet valve located inside the main conduit and disposed between the inlet opening and the coupling juncture; and a drainage valve located inside the drainage conduit, between the drainage outlet and the coupling juncture
Implementation Method 2
a main fluid conduit including (i) a fluid inlet couplable to a cleaning fluid source, and (ii) a fluid outlet couplable to the inner volume of the heat exchanger
Data Source
AI summary
Disclosed examples relate to a cleaning assembly kit for a heat exchanger and a method of using thereof. In at least one example, the cleaning kit assembly for cleaning an inner volume of a heat exchanger comprises: a cover lid couplable to an opening of a body of the heat exchanger; and a manifold assembly comprising, a main fluid conduit including (i) a fluid inlet couplable to a cleaning fluid source, and (ii) a fluid outlet couplable to the inner volume of the heat exchanger; a drainage conduit fluidically coupled to the main conduit at a coupling juncture, and comprising a drainage outlet; and valve system including, an inlet valve located inside the main conduit and disposed between the inlet opening and the coupling juncture; and a drainage valve located inside the drainage conduit, between the drainage outlet and the coupling juncture.