Heat Exchanger Tubesheet Cleaning via Submerged Impingement Jets
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Solution Overview
Problem
Conventional methods for cleaning heat exchangers and condensers require shutdown for extended periods due to fouling, and existing in-line cleaning solutions add operational complexity.
Innovation Solution
A system with spray nozzles mounted in the plenum of a heat exchanger that use submerged impingement jets to clean tubesheets, allowing for online operation and adjustable spray patterns without disassembly, utilizing a secondary conduit with a pump and filter to prevent fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cleaning methods are used to remove deposits from tubes and tubesheets, then fouling is removed, but the heat exchanger must be shutdown for three or more days
Solution Approach 1:
The system performs preliminary cleaning action continuously during operation. The sponge ball cleaner is introduced into the tube bundle before fouling becomes severe, and cleaning action is maintained continuously throughout operation, preventing deposit accumulation rather than removing established fouling during shutdown
Solution Approach 2:
The cleaning system operates continuously during heat exchanger operation. The sponge ball circulates continuously through the tube bundle, maintaining cleaning action without interruption, thereby eliminating the need for periodic shutdowns for maintenance cleaning
2Loss of time
If sponge ball cleaners are used to clean tubes in line with operation, then shutdown time is reduced, but system complexity increases
Solution Approach 1:
The sponge ball cleaner is passive and self-propelled, utilizing the flow of coolant through the tube bundle to circulate and clean the tubes. No external power source, control system, or complex mechanism is required - the cleaning system serves itself using the existing operational fluid flow
Solution Approach 2:
The sponge ball serves multiple functions simultaneously: it cleans the tube interior surfaces, traps and removes deposits, and circulates passively using the existing coolant flow. The same coolant flow that performs heat transfer also drives the cleaning mechanism
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
Enables effective and efficient cleaning of heat exchanger tubesheets during operation, reducing shutdown times and maintaining system performance while preventing impurity buildup.
Implementation Method 1
A spray nozzle or bank of nozzles is mounted in the plenum of the second fluid circuit with a spray outlet directed toward the tubesheet for cleaning the tubesheet with a submerged impingement jet issued from the spray nozzle(s)
Data Source
AI summary
A heat exchange system includes a shell having an interior with an inlet and an outlet wherein a first fluid circuit is defined from the inlet, through a heat exchange volume within the interior of the shell, to the outlet. A tubesheet is mounted within the shell dividing between the heat exchange volume and a plenum of a second fluid circuit within the interior of the shell. A set of tubes extends through the heat exchange volume, a respective interior passage of each tube being in fluid communication with the plenum through a respective opening though the tubesheet. The second fluid circuit includes the plenum and interior passages of the tubes. A spray nozzle is mounted in the plenum of the second fluid circuit with a spray outlet directed toward the tubesheet for cleaning the tubesheet with a submerged impingement jet issued from the spray nozzle.