Heat Exchanger Tube Cleaning With Pattern-Guided Water Jets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for cleaning heat exchanger tubes are labor-intensive and time-consuming, especially in plants where multiple heat exchangers need frequent cleaning, due to the difficulty in accurately directing high-pressure water jets into varying tube openings, which can lead to operator safety risks and equipment damage.
Innovation Solution
A water-jet cleaning system with a smart indexing controller that disengages heat exchangers from their use-position, moves them to a remote cleaning station, and uses a computing device to control the water jet cleaning equipment, learning and following the pattern of tube openings to ensure accurate and efficient cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water jet cleaning equipment is brought to the heat exchanger location in the plant for cleaning, then the cleaning can be performed at the use-position, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
Instead of bringing cleaning equipment to the heat exchanger location, the patent inverts the approach by moving the heat exchanger to a dedicated cleaning station. This reversal of the conventional cleaning workflow enables automated cleaning processes and significantly reduces the time required for cleaning multiple heat exchangers.
Solution Approach 2:
The cleaning station is designed to automatically clean heat exchangers using robotic water jet equipment guided by vision systems and pattern recognition algorithms. The system learns the tube opening patterns and performs cleaning operations autonomously without requiring manual setup for each heat exchanger, making the process self-service oriented.
2Adaptability or versatility
If manual water jet cleaning is performed by operators, then flexibility in handling different heat exchangers is maintained, but operator safety risks and equipment damage risks increase
Solution Approach 1:
The patent introduces vision systems, cameras, and pattern recognition algorithms as intermediaries between the operator and the heat exchanger. These intermediaries capture images of tube openings, learn the patterns automatically, and guide the water jet equipment precisely, eliminating the need for operators to manually position equipment and reducing safety risks while maintaining adaptability to different heat exchanger configurations.
Solution Approach 2:
The patent replaces manual mechanical positioning and operation with automated robotic water jet equipment controlled by computer vision systems. This substitution eliminates human exposure to high-pressure water jets and heavy equipment handling, significantly improving safety while maintaining the ability to handle various heat exchanger types through pattern learning and adaptation.
3Manufacturing precision
If water jet equipment is repeatedly set up for each heat exchanger, then accurate cleaning can be achieved, but the setup process becomes time-consuming and labor-intensive
Solution Approach 1:
The system performs preliminary actions by capturing images and learning the tube opening patterns of heat exchangers in advance. The vision system stores these patterns and uses them to automatically guide the water jet equipment during cleaning operations, eliminating the need for repeated manual setup and positioning for each heat exchanger while maintaining high cleaning accuracy.
Solution Approach 2:
The patent implements feedback mechanisms where the vision system continuously monitors the cleaning process, compares actual tube opening positions with learned patterns, and automatically adjusts the water jet equipment positioning. This closed-loop feedback system ensures high cleaning accuracy without requiring manual intervention or repeated setup procedures.
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
This method significantly reduces the time and labor required for cleaning multiple heat exchangers by automating the process, ensuring safe and efficient removal of built-up material while minimizing the risk of operator injury and equipment damage.
Implementation Method 1
direct a high pressure fluid-jet into the bore of each tube in the heat exchanger and blast away the built-up materials
Data Source
AI summary
A system, apparatus and method of cleaning tubes of a heat exchanger or a tube bundle that includes disengaging the heat exchanger or bundle from a use-position in a process or a plant; moving the heat exchanger or bundle to a cleaning station remote from the use-position; positioning the heat exchanger or tube bundle in front of a cleaning apparatus; providing water jet cleaning equipment on the cleaning apparatus; responding to programming in a computing device and controlling the water jet cleaning equipment and a cleaning operation; providing a pattern of tube openings defined in an end plate of the heat exchanger or bundle to the computing device; actuating the water jet cleaning equipment with the computing device; and manually or automatically performing a cleaning operation with the water jet cleaning equipment under control of the programming of the computing device and by following the provided pattern of tube openings.