Overview of Fully Automatic Pipe Brush Online Cleaning System:

The fully automatic pipe brush online cleaning system is developed based on the automatic online rubber ball cleaning device. Compared with rubber ball cleaning, this system is equipped with a cleaning brush in the inner wall of each copper pipe, which can ensure that each copper pipe can be effectively cleaned with low friction resistance and is not prone to blockage and deposition. While cleaning the heat exchange pipe wall, the corrosion inhibition layer on the surface of the pipe wall is also protected.

The dirt inside the heat exchange tube wall can be cleaned online without shutting down or removing the cover of the chiller unit, preventing scaling of the tube wall and keeping it clean at all times, thereby improving the heat exchange efficiency of the unit, making the heat exchange equipment work more stably, efficiently, and energy-saving. The cleaning cycle can be set according to the actual working conditions, and it is recommended to clean every 4-6 hours. It is controlled by a PLC programmable control system and runs fully automatically without manual operation.

Working principle of fully automatic pipe brush online cleaning system:

Action 1

Action 2

When the system is not working, the tube brush stays in the brush basket at the outlet end of the heat exchange tube and is in a stationary state; When the system is working, the four-way valve starts to switch the water flow direction after receiving the control signal, causing the water inside the heat exchanger to flow in the opposite direction. The tube brush starts to work with the change of water flow direction, smoothly and slowly moving from one end of the heat exchanger tube to the other end, brushing the heat exchanger tube once, then resetting the four-way valve to restore the water flow in the heat exchanger to its original direction. The tube brush cleans the heat exchanger tube again and returns to the original brush basket, completing one cleaning process in only 60S-90S.

Functions of the automatic pipe brush online cleaning system:

The condenser can be cleaned online while the chiller unit is running to prevent scaling on the inner wall of the heat exchange tube, thereby improving the thermal efficiency of the unit and making the heat exchanger equipment work more stably, efficiently, and energy-saving.

Common problems with chiller units

Dirt:Dirt is a major factor in reducing the efficiency of chiller unitsDirt not only increases the energy consumption of the chiller unit, but also poses a significant threat to the operation of the chiller compressorThe service life of the condenser tube will also be shortened.

The relationship between fouling coefficient and power consumption index:

Dirt control methods:

Fully automatic pipe brush online cleaning system:

Each heat exchange tube has a dedicated tube brush, which is fixed at both ends by a brush basket,Clean every 4-6 hours for 30 seconds each time. The spiral brush head design allows the brush to rotate forward and clean the inner wall of the copper tubeEach copper pipe is guaranteed to be cleaned thoroughly.

Components of the fully automatic pipe brush online cleaning system

① A set of four-way directional valves

② A set of control panels

③ A set of tube brushes and brush baskets (one copper tube corresponds to one brush and two brush baskets)

Tube brush: The guided brush head design ensures that the brush mechanically travels back and forth inside the heat exchange tube in a rotating and forward manner, resulting in higher efficiency between the threaded tube and the inner wall of the light tube heat exchange tube.

Brush basket: Low water pressure drop design installed on both sides of the heat exchange tube. Effectively ensure that the tube brush works back and forth inside the heat exchange tube. Detachable end card design, convenient for brush maintenance and replacement.

Four way directional valve: a steel sealed structure valve with a working pressure of 150PSIG. The valve body is installed at the waterway connection to reduce installation space. The valve connection form can be flange connection or quick connector.

Control mode of fully automatic pipe brush online cleaning system:

Control system: The basic functions of the control box include: counter function, 24-hour time controller, manual reset/testing function, operation status display and working status display, alarm switch. Wireless control options.

Optional: Load monitoring of chiller unit, inlet and outlet temperature of condensate water, COP monitoring of chiller unit energy consumption, approaching temperature of condenser, inlet and outlet temperature of chilled water, daily and monthly operation data report;

Features of the fully automatic pipe brush online cleaning system:

A. Each copper tube can be cleaned

B. Threaded pipes can be cleaned thoroughly

C. 100% cleaning and recycling: Due to the one-to-one design of the tube brush system, where one heat exchange tube corresponds to one tube brush and two brush baskets, it ensures that each heat exchange tube can be thoroughly cleaned.

D. 100% tube brush recovery rate: Each tube brush is matched according to the inner diameter of the heat exchange tube, so there is no phenomenon of tube brush clogging inside the heat exchange tube during water flow switching.

E. Does not affect system operation: The automatic online circulating cleaning system can clean the heat exchange equipment without stopping the machine.

C. Improve heat exchange efficiency and save 15-30% energy.

D. The service life of the brush is 5 years, and the service life of the brush basket is 20 years. The brush and brush basket are easy to replace

E. The installation of the brush basket can protect the end of the copper tube and the tube plate from erosion by water flow

F. Low maintenance cost (quarterly inspection)

G. Low initial investment and fast recovery (usually takes 6-18 months to recover investment)

H. The tail end card design of the brush basket ensures that the brush will not enter the cold water system and is easy to replace

I. Automatic cycle cleaning, no need to stop, no chance for scale to form inside the pipe wall

J. Reduce the use of chemicals

K. Reduce the occurrence rate of chiller failures

L. Low water pressure design pressure drop can be ignored (usually less than 15KP for valves and brushes)

J. Save installation space: It hardly occupies any external machine room space, and the installation position of the four-way directional valve is flexible. It can be placed freely according to the direction of the pipeline, and the system is simple and convenient.

Energy saving analysis and comparison of fully automatic pipe brush online cleaning system:

Taking the unit running for 5000 hours a year as an example, with a load of 75% and a power consumption index of 0.6Kw/Ton

Five different colored lines represent units with different cooling capacities (250Ton-1750Ton)

Horizontal axis: Electricity fee (RMB/kWh)

Vertical axis: Total cost of electricity saved in one year

The larger the cooling capacity of the unit, the more obvious the energy-saving effect:

Electricity fee (unit: yuan/kWh)

Assuming the unit operates for 5000 hours per year and the load is at 75%, the power consumption is 0.6KW/TON

return analysis

Kunshan factory, 2 * 500TON chiller unit

Performance Comparison of Peide Fully Automatic Pipe Brush Online Cleaning System - Condenser Approaching Temperature Trend

Unit A is equipped with a Peide automatic pipe brush online cleaning system,

Unit B is not equipped with the Peide fully automatic pipe brush online cleaning system

Investment return rate:

Application of fully automatic pipe brush online cleaning system:

1. Scope of application:

Various refrigerators, condensers, and evaporators: General public facilities: hotels, hospitals, shopping malls, airports, educational institutions, buildings, office buildings, and other large public facilities

Cooling for production engineering: petrochemical, fiber, gas, semiconductor, electronics, other industries;

Refinery: Refinery, other petrochemical plants

Public utility industry: thermal power plants, thermal power plants, nuclear power plants

(1) General public facilities: hotels, hospitals, shopping malls, airports, educational institutions, buildings, office buildings, and other large public facilities.

(2) Industrial production: petrochemicals, fibers, coal gas, semiconductors, electronics, refining, chemical plants, refineries, coal chemical plants, thermal power plants, thermal power plants, nuclear power plants, etc.

2. Applicable use:

Condensers and evaporators for turbo, suction, reciprocating, and spiral chillers

Ordinary heat exchanger

Wastewater treatment, waste heat recovery, heat exchanger

Utilizing hot spring waste heat storage heat pump

Other heat exchangers

Technical parameters of fully automatic pipe brush online cleaning system

Power input: AC220V/AC380V 50/60Hz

Applicable fluid temperature: standard below 70 ℃, special customized high temperature up to 200 ℃.

Applicable pipelines: straight pipes, threaded pipes

Suitable for shell and tube heat exchangers

Tube diameter: Standard 1 '(25mm) or less, non-standard can be customized

Service life: Nylon brush has a lifespan of 5 years, brush basket has a lifespan of 20 years.

Model of fully automatic pipe brush online cleaning system

Installation diagram of fully automatic pipe brush online cleaning system

Pipe brush installation completed

Installation requirements for fully automatic pipe brush online cleaning system

Can be applied to both new and existing chillers

The new chiller unit can be installed in the factory or on-site. The existing chiller unit can be installed on-site, but it needs to be thoroughly cleaned of copper pipes to remove all scale

In the new project, the mechanical and electrical subcontractor installed a four-way directional valve and provided on-site wiring with reserved wiring ports, as well as provided terminal wiring and system debugging

The refrigeration room that has been put into use will provide installation, wiring, and commissioning of valves and fittings