Heat Exchanger Tube Indexer With Sensor Mapping for Remote Jet Cleaning
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Solution Overview
Problem
Existing water-jet cleaning systems for heat exchanger tubes face challenges in accurately aiming high-pressure water jets due to varying tube bundle patterns and spacings, requiring time-consuming manual adjustments and posing safety risks for operators.
Innovation Solution
An indexer system with orthogonally arranged arms, a trolley, and sensors allows for remote operation using a communication device to map the pattern of tube openings, enabling precise movement of nozzles and efficient cleaning without manual intervention, including a retrofit kit for existing indexers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment is used to aim water jets at tube openings, then the cleaning can be performed, but the setup time is excessive and operator safety is compromised
Solution Approach 1:
The system uses sensors to automatically detect tube opening locations and the indexer to autonomously position nozzles, eliminating the need for manual adjustment by operators. The system serves itself by mapping the tube bundle pattern and using this information to automatically navigate to each tube opening for cleaning.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated indexer system that uses sensors to detect tube positions and mechanically positions the nozzle array automatically. This substitution eliminates operator exposure to high-pressure water jets while maintaining precise positioning accuracy.
2Adaptability or versatility
If manual adjustment is used to accommodate varying tube bundle patterns, then different heat exchangers can be cleaned, but the setup process becomes time-consuming
Solution Approach 1:
The system performs preliminary mapping of the tube bundle pattern using sensors before the actual cleaning operation. This preliminary action captures the spatial coordinates of all tube openings, creating a digital map that the indexer uses to automatically navigate to each tube during cleaning, eliminating the need for repeated manual adjustments when moving between different heat exchangers.
Solution Approach 2:
The indexer system is designed with universal adaptability to handle different tube bundle patterns and configurations. By using sensor-based detection and programmable positioning, the same system can accommodate various heat exchanger designs without requiring dedicated setup procedures for each configuration.
3Productivity
If high pressure water jets are directed at tube openings, then cleaning effectiveness is achieved, but operator safety is compromised due to water deflection
Solution Approach 1:
The indexer system acts as an intermediary between the operator and the high-pressure water jet. It automatically positions the nozzle array precisely at each tube opening, ensuring the water jet is directed exactly where needed without operator proximity. This intermediary function maintains cleaning effectiveness while eliminating operator exposure to deflected water jets.
Solution Approach 2:
The system replaces manual mechanical aiming with automated indexer positioning controlled by sensor data. This substitution allows precise nozzle positioning for effective cleaning while keeping operators at a safe distance from the high-pressure water jet, eliminating the safety hazard of water deflection.
Data Source
AI summary
A system and method for cleaning of heat exchanger tubes including an assembly, an indexer and a communication device provided with specialized software and programming. The indexer includes orthogonally arranged first and second arms. A trolley and sensors are provided on the indexer arms. One or more lances are provided on the trolley to deliver water jets into the openings. Sensors measure displacement as the trolley is moved relative to the heat exchanger's face plate. An operator controls the system from a distance away using the communication device. During setup, the pattern of the face plate is learned and mapped utilizing information from the sensors as one of the inputs. This information is utilized to help navigate the face plate during a subsequent cleaning operation. A kit for retrofitting existing X-Y indexers is also disclosed.