Heat Exchanger Cleaning

Cleaning Marine Diesel Heat Exchanger

2011-10-05T00:35:00.000-07:00

This video shows a hands on example of how to clean a marine diesel heat exchanger on a westerbeke. It's quite simple and easy to follow. Check it out.

Cleaning Heat Exchangers, Vents & Ducts with Dry Ice Blasting

2011-09-05T00:32:00.000-07:00

Cleaning the heat exchanger, vents and ducts on the USN Pecos can actually be done using ice blasting technology as well. So, if you find it difficult to clean heat exchanger using water, you now know how to do it fast and efficient.

Heat Exchanger Shellside Cleaning System (NBL Corp.)

2011-08-05T00:28:00.000-07:00

This is a video that shows a huge machine that is used to clean a shell and tube heat exchanger. A trailer mounted bundle cleaner with a single hydraulically operated crane to easily position the cleaning head over the bundles. The arm also permits easy loading and unloading of the included hydraulically actuated rollers, which turn the bundles during the cleaning process. NLB Model SSC9200A {Pressure:10,000 PSI (690 bar)}, NLB Model SSC8900A {Pressure:20,000 psi (1380 bar)}.

Refinery Heat Exchanger Tubes Cleaning

2011-07-04T23:51:00.000-07:00

Have you seen how a shell and tube heat exchanger is cleaned? Then the video above can best illustrate the process. If you have the jet pressure facility with a pressure up to 200 psi, then you can use it to clear the tubes. However, if you don't have the equipment nor the expertise, then you have to outsource for the service. It might be a wet activity but the reward will be a smoother heat transfer and less pressure drop across the

Alfa Laval Spiral Heat Exchanger for Liquid-Liquid Heating-Cooling

2011-06-05T00:09:00.000-07:00

Video shows the conceptual flow paths for an Alfa Laval Spiral Heat Exchanger for Liquid-Liquid Heating-Cooling duty.

Thermal Cleaning of Heat Exchangers, nearly new made possible

2011-05-05T07:29:00.000-07:00

Cleaning of heat exchangers polluted with (partly) organic contaminations like cokes, plastic, oil, paint, rubber, food etc. still is a major problem for many companies. The need of parts’ cleaning is found in each and every industrial branch. Some take it as a daily necessity; others consider it an incidental procedure in times of calamity, turnaround or shutdown. Apparently it is just part of the game, but nevertheless it should be done as quickly as possible and as best one can. In most cases this is very often related to the available knowledge of the known cleaning techniques.

Photo 1: Heat exchanger soiled with plastics

As a result of the ever increasing quality of final products, the search for longer running times, the need for better cleaning results and cutting down costs or due to more stringent environmental laws and procedures, most of the traditional methods of cleaning, like chemical or high-pressure cleaning, are sometimes no longer adequate. Maybe the thermal cleaning method can offer the desired solution for your cleaning problem?

Thermal cleaning methods

1. Advantages of thermal cleaning

Vaporizing organic elements only yields some 5 to 10% of the original pollution, which can be easily removed. Moreover, thermal cleaning very intensively removes the broadest range of pollutants in a relatively short period of time, without causing damage to the substrate.

2. Brief introduction to the technique

2.1. The process

Pyrolysis is the thermal conversion of organic materials in an oxygen-poor environment. At a temperature below 400°C (750°F) the organic materials are converted into a homogeneous residue, ready for further controlled processing.

At such high temperatures higher hydrocarbons are decomposed into components with a much lower molecular mass, resulting in pyrolysis gases (ethane, ethene, propane, propylene), pyrolysis oil which contains aromatic components and a carbon-rich residue.

The pyrolysis gas as well as the oil is transformed into carbon dioxide and vapour, because of partial oxidation. This phase is exothermic, at which 40% of the released energy is re-used to decompose the organic material.

A very important factor in the process, together with a steady heating and cooling, is maintaining a constant temperature, in order to prevent damage to the parts that are to be cleaned. This is also important in order to avoid unwanted (waste) gaseous fractions.

3. Pyrolysis ovens

As stated before, this is the only correct thermal cleaning technique for the treatment of soiled heat exchangers. To give you of proper idea, I will describe the general functioning of this type of installation, after which the conditions necessary to guarantee a safe and perfect heat exchanger cleaning will be further examined.

General functioning

The pyrolysis ovens consist of an operating room of 1 to 75 m³, depending on the type. The common maximum dimensions currently are 8m x 3m x 2,5m, but note that even bigger dimensions are also possible.

The objects to be processed are put on a loading cart, which is pulled into the furnace chamber. After closing the door, this chamber is made inert by lowering the oxygen level to 8%. Then the temperature is slowly increased to 420°C (788°F), depending on the character of the objects and the kind and amount of pollution.

The oxygen content of the cheapest oven systems is even not controlled. It is taken for granted that the oxygen will leave the chamber automatically during the gasification. If the temperature increases after all, a lot of water is injected so that the temperature has to fall. These are of course the real paint stripping ovens which are note suitable for the “real” job.

When the temperature required for vaporizing is reached, a slight overpressure leads the released gases towards the afterburner chamber. Here they are processed at high temperature, after which they are removed. Occasionally this air current is used for heat recycling in order to recover a part of the energy.

As a result of the fact that all organic components are gasified because of the heat, only a residue consisting of pigments and inorganic fillers remains after cooling. This is in general 5% of the original pollution volume and can be easily removed by various techniques.

Because the heat is able to reach every spot – also in the middle of tube heat exchangers or between the tubes and the shell of a heat exchanger with fixed shell - thermal cleaning is extremely suitable for heat exchangers. This is impossible with for example only high-pressure cleaning.

Special conditions for the thermal cleaning of heat exchangers

To be sure that the heat exchanger gets the best possible thermal treatment, a number of essential matters have to be respected. Besides a proper oxygen control, there exists a method to monitor the exchanger itself by means of thermocouples at various with the owner agreed spots. It is important to utilize object temperatures instead of chamber temperatures in order to be able to follow the process in the oven correctly.

Another important technical aspect is the presence of an excellent internal circulation unit which takes care of a proper circulation in the oven chamber. Due to this there is a homogeneous temperature on all sides which is essential to avoid temperature differences inside the object to clean.

The newest systems dispose of an internal heat exchanger to cool down with air instead of water. Through this, temperature control has increased considerably; it is almost made possible to steer accurate to a degree. Moreover not having to inject water in the chamber involves less trouble with volatile rust on the parts to clean.

To draw up a proper temperature protocol, it is important to know the exact composition of the material as well as the pollution. In case of doubt, a reliable laboratory analysis can give a decisive answer. The weight of the exchanger, the type of material, the geometry and the type of pollution determine the heating up and cooling down curve and can largely give an indication of the total necessary time in the oven.

Photo 12: After thermal cleaning, note that also the paint will be gone afterwards

Also the pollution itself strongly influences the temperature program to follow. Does the pollution liquefies before it gasifies - like some plastics - or does it remains solid until complete gasification? A laboratory analysis or practical research can also give a decisive answer on this matter, which enables a more correct assessment of the program.

If the pollution liquefies during the heating up, there will be a foreseen phase in the program around the melting point of the pollution. This phase enables the pollution to melt in large measure out of the object to clean. Subsequently the gasification of the remainders can more easily take place and the total cleaning time will be reduced. In case of extreme pollutions of thousands of kilos, even a two-phase treatment can be chosen. A great part of the pollution will than be melted during a first thermal treatment at low temperature. Afterwards the remaining part will be gasified completely during a second treatment to remove the pollution entirely.

Also the type of material used for the construction of the heat exchanger is very important; after all the material determines the maximum temperature for the thermal treatment. Although there are differing opinions concerning the possible thermal cleaning of duplex steel bundles, various tests have revealed that this type of heat exchangers can be properly cleaned using this method. Only the maximum delta T between the different thermocouples is much lower than with exchangers made out of regular steel types, due to the expansion differences between the metals used in duplex steel.

Besides all conditions concerning the correct installation technique, a proper knowledge of the used material and an analysis of the pollution, also the know-how of the oven operator is very important. The operator has to know exactly which program to follow in order to have the correct heating up and cooling down process. During the thermal cleaning of a heat exchanger, it is imminent that the material is heated up and cooled down simultaneously to avoid internal tensions. The operator has to make sure that the temperature is steered in such a way that it increases or decreases at the same time on the inside as well as on the outside. This can be done in large measure automatically by means of thermocouple steering in the newest installations, although supervision is still necessary.

Advantages of thermal cleaning for the different types of heat exchangers
The traditional methods for the cleaning of heat exchangers are often very effective and therefore used for many years. Nevertheless there are a number of very specific problems which everyone recognizes. The problem with high-pressure cleaning is the deterioration of the surface as well as the accessibility of the pollution. Remainders involve that your exchanger has to be taken out of production sooner to be cleaned again.

Using chemical cleaning can sometimes take a long time to dissolve the pollution. The availability of the bundle will be postponed. Thermal cleaning on the other hand is very effective and reaches every spot. The results proof that a degree of cleanliness of almost 100% can be reached which results in longer operating times and consequently cost savings.

To be quoted as a good example are the heat exchangers from a naphta cracker which were cleaned with high-pressure every two months. After the first thermal cleaning, they could be used without problems during 2 years; a huge improvement. And there are more.
Hereunder you will find a definitely not complete overview of the different types of heat exchangers, together with the typical advantages and disadvantages of thermal cleaning for each.

Pipe bundles

With this type of heat exchanger, the contamination can be in or/and around the tubes. High-pressure cleaning has the problem that the water jet can barely reach the very inside of the exchanger to remove the pollution around the tubes. This means that some bits are left behind so the contamination happens more quickly during the production, resulting in a shorter operating time.
Thermal cleaning destroys the pollution everywhere and therefore gives a much better level of cleanliness which results in a longer operating time. For extreme contamination, often a high-pressure cleaning is used for the first rough cleaning of the bundle, after which thermal cleaning can take place.
In case of hairpin bundles, thermal cleaning can remove the pollution inside the corners of the tubes easily, where most of the times the problems occur.

Bundles with a fixed shell

The problem with classic high-pressure cleaning is that there is practically no access to do a cleaning around the tubes. Often chemical cleaning by flushing is used to clean the soiled inside, but the effectiveness is often very poor. Very good results were seen using the thermal cleaning method to remove the pollution around the tubes.
To get a good temperature control on the inside of the heat exchanger often a blow through system is used to allow a good air ventilation on the inside of the shell. Besides of the heat, you will need a bit of oxygen to get a good oxidation of the pollution. Otherwise you will be confronted with carbonized material after the thermal treatment which is very difficult to remove.
Like always all organic parts are reduced to ashes, but in this case it is better to use air to remove already a great part of this dust. Using water will leave the remaining ashes very sticky and therefore difficult to remove all of it. After the cleaning by air, a rinsing with water is done, but there still can be the possibility that during the first running hours, dust particles coming from remaining ashes can disturb your process. This normally goes away after a short time. In some cases an endoscopy is done to verify the result of the cleaning on the inside.

Bundles with static mixers (fix or non-fix)

High-pressure water cleaning has no use here, the penetration degree is zero. Chemical treatment can give results depending on the possibility of a flow on the inside of the used chemical to dilute the pollution enabling it to be removed. In most cases however both traditional methods gave a very poor result, which immediately shows the necessity of the thermal cleaning method.
First the thermal treatment will be executed to destroy the organic pollution on the inside of the static mixers. Then a combination of water and air is used to remove the dust particles from the inside of the mixers. This is done until the water is clear again, which indicates that most of the ashes are gone.
No guarantee can be given after the treatment that it is 100% clean, because in case of the use of fix static mixers, no control method can be used to inspect the inside of the tubes. The only control you will have is to see that the water flows trough normally, so the tube is not blocked.
After the cleaning procedure is done, there also might be the possibility of dust particles in your flow during the first running hours. This is not the case with removable static mixers, because they are removed after the thermal treatment and worked on separately to get them 100% clean.

Spiral or plate heat exchanger

High-pressure does not give an optimal result here either, and chemical cleaning generates an awful lot of waste. With the classic methods, there are always deposits left on the walls, which means the exchangers become dirty more quickly during production; that's why thermal cleaning is also the most feasible solution here.

Compablocs

Traditional water cleaning is, depending on the pollution, in some cases very difficult even impossible.

Like with all other heat exchangers, thermal cleaning offers a good possibility to make your Compabloc almost new again using controlled heat and a good rinsing afterwards.

Twisted tube heat exchangers

Because of the twist in the tubes, the accessibility needed for a good cleaning by water is very poor. You only can clean the outside like this.
Thermal cleaning offers very good results because of its technical characteristics. All dirt will be removed also from the very inside of this kind of heat exchangers.

Plate heat exchangers

In most of the cases a chemical treatment is used and has been proven to be very effective to clean the soiled plates of this kind of heat exchangers. High-pressure cleaning is sometimes done, but the risk of damaging is very high.
Thermal cleaning can be used to remove all kinds of pollution on the plates, like glue, and a polymerized or carbonized pollution, which are difficult to remove with chemicals.
Thermal cleaning however can not remove scale, while this is inorganic!

Certainly more types of products can be cleaned with the thermal cleaning method like big vessels, pumps, extruder parts, filters, pipelines, reaction vessels and many more. Also all kinds of organic pollution like PP, PE, PS, PC, SAN, PET, PA (also reinforced), PBT, PU, carbonized material, cokes etc. can be removed, which shows that the thermal cleaning method has a very high potential as a substitute or even an improvement for today’s cleaning techniques. In fact in a lot of cases, the thermal cleaning technique offers you the possibility to make your soiled heat exchangers or other parts like new again. This surely is an advantage which can not be ignored. Therefore I hope the information given to you in this article helps you to make the right decision next time a cleaning problem occurs.

For more information, please contact Robert Mol (robert.mol@thermoclean.com), General Manager Thermo-Clean Group or visit: www.thermoclean.com/www.heatexchangercleaning.eu.

Cleaning Shell and Tube Crude Oil Heat Exchangers

2011-05-05T00:04:00.000-07:00

As shown previous month about the shell and tube heat exchanger cleaning, here is a company that is an expert in the business. Tube Tech International proved that previous industry standards for cleaning such equipment with U bends were inadequate and, for the first time on this unit, Tube Tech gave not only the straight legs, but also the U sections a complete internal clean. It is actually a little tricky to clean a U tube bend.

Plate Heat Exchanger Cleaning Using Dry Ice

2011-04-05T00:15:00.000-07:00

Check this out. It is a faster method of cleaning the plates of the plate and frame heat exchanger. Typical method of cleaning the plates are by soaking it into a tank containing certain concentration of heated acid (maybe using agitated steam). After that, what is normally done is to bring out the plates and jet clean using normal tap water. However, this company used dry ice to clean the plate easily and fast. Such an amazing outcome!!! For more information, visit www.renetech.com.my and
www.cleantech.com.my.

Crude Heat Exchanger Cleaning - Tube Tech International

2011-03-04T23:17:00.000-08:00

The video above presents a crude heat exchanger cleaning technique which was developed by Tube Tech International. It basically shows innovative solutions for removing crude fouling within blocked crude heat exchangers on the outer surface of the shell and tube heat exchanger. This method is applicable for cleaning crude heat exchangers in refineries world wide.

To learn more and also to review crude heat exchanger cleaning case studies, visit www.tubetech.com or call +44 (0)1268 786999.

Air Fin Cleaner Heat Exchanger Cleaning

2011-03-04T22:54:00.000-08:00

Do you know how an air fin heat exchanger can be cleaned? Well, check this out. MB Technical Innovations (MBTI) from Terneuzen, a companybased in the Netherlands have developed this innovative cleaning equipment. Whilst the "Air Fin Cleaner" has principally been designed for the cleaning of heat exchanger air fins, this machine can be adapted to suit many applications requiring precise, controlled, high pressure hydro cleaning. The MBTI Air Fin Cleaner can either be electric or air powered, dependent on the client's requirements. In principle, the "Air Fin Cleaner" system applies controlled volumes of water or other cleaning media at high pressure through a specially constructed spray head, over the surfaces to be cleaned. Whilst the technique is very suited to delicate alloy air fins of a heat exchanger cooling bank, this air or electric powered cleaning device has many more capabilities in the industrial world. For further details, visit: http://airfincleaner.com

Better Heat Exchanger Cleaning Through Technology

2010-08-10T05:21:00.000-07:00

The old methods are becoming more outmoded due to advancements in technology. It is inefficient to bypass the unit. Just as it would be less efficient to run your car with 2 cylinders not firing. This inefficiency, of course, also increases operational costs. It is time consuming and costly to cut the U-bends and re-weld them. Sometimes it can be difficult or impossible to get access to reattach them.

Some of these new methods include the ability to clean areas with limited access, and clear deposits from U-bends without ever removing them. This can sometimes be done without even taking the unit offline, and usually takes less time and results in a higher degree of defouling. In fact, many units can be restored to near-factory efficiency. For big refineries, petro-chemical plants, or power plants, this can amount to six figure savings.

The U-bends themselves also retain many deposits, and continue to be a bottleneck to the system. Full replacement carries the cost of completely replacing equipment that, other than the heat exchanger tube fouling, is still in working order. This method also requires the unit be taken offline for the full duration of replacement. obviously this carries a heavy expense and serious loss of production.

Traditional heat exchanger cleaning methods and heat exchanger cleaning equipment have changed very little over the last few decades. Pressure jetting is still the primary means used by many companies, but it is slow, inefficient, and ultimately very costly. Additionally, many companies are skeptical of newer methods, falling back on the "that's the way it's always been done," chain of logic. They are also weary of trying new techniques that are not as "proven" to be effective. Finally, many have long term tube cleaning contracts that do not allow for a change in heat exchanger cleaning technique, unless the contractor were to adopt the new methods.

Newer heat exchanger cleaning equipment and techniques are more technologically advanced, and by extension, require a higher skilled laborer than old style pressure jetting. These new developments include the ability to clean tight radius bends, clean units while keeping them in place, and even while keeping them online. It has also resulted in faster, more efficient cleaning. Many tube bundles can now be cleaned more effectively than with pressure jetting, and jobs that used to take days may now take only a few hours. Difficult to access units are now accessible with these new technologies.

Some of the technology that has been developed includes special nozzles that can be used on tight bends, laser cleaning, and new "smart" metals that respond to changes in density and pressure to prevent damage to the tubes. With these methods, jobs can be finished with less downtime, because cleaning and descaling can be done more quickly. Equipment is also less likely to be damaged in the process. Many of these new processes are safer, create less waste, use no chemicals, and have a significantly reduced environmental impact.

Photo credited to http://www.linde-gas.com.cn/International/Web/LG/CN/likelgcn.nsf/repositorybyalias/ind_other_dry_clean2/$file/ind_other_dry_Cryoclean2.jpg

Heat exchanger tubes before cleaning using a video inspection pipe camera

2010-07-18T08:42:00.000-07:00

Very interesting technology of evaluating the condition of heat exchanger tubing. Check out the video below:

These random tubes was part of an internal inspection to determine the condition prior to mechanical cleaning to remove the hard deposits of the exchanger tubes and later re-inspected after the cleaning to verify removal of the hard deposits. Maverick Inspection Ltd in Sherwood Park, Alberta, Canada has been in the oil and gas industry working for over 16 years.

Refinery Heat Exchanger Tubes Cleaning

2010-07-18T08:41:00.000-07:00

Heat Exchanger Tube Bundles Inspection

2010-04-26T04:07:00.000-07:00

Heat exchangers are used by many industries, especially in oil refineries and chemical plants. Their purpose is to exchange heat from one place to another, usually from one liquid to another liquid. The continued efficiency of this device demands regular heat exchanger inspection to determine whether or not the integrity of the equipment.

Where are Heat Exchangers Found?

Most homes also have a heat exchanger of some kind. The most common household heat exchanger can be found in a refrigerator. In hot countries air conditioners are common; another kind of heat exchanger. Cars contain them too - the radiator removes the excess heat from the radiator fluid by making use of the natural airflow caused by the car's forward progress.

A similar principle applies in large industry where heat needs to be transferred from one place to another. The most common type of heat exchanger found in oil refineries and other large plants is the "shell and tube heat exchanger".

This design employs a large shell, usually a very large diameter tube that can withstand high pressures. It contains a bundle of tubes inside. The heat exchanged is from two different fluids. One fluid flows through the shell of the exchanger while the other flows through the tube bundle. The two fluids do not make direct contact with each other, but the difference in their respective heat values is changed through the indirect contact that is made.

A shell and tube heat exchanger is a complex design. The internal tubes are often of differing types and design in order to achieve different results. Some tubes may be plain while others may be finned horizontally or longitudinally. The tubes may also be composed of different materials and different thermal conductivity. They may be made from stainless steel, carbon steel, brass, copper or cupronickel, for example.

Because of their complex nature it is necessary to have a regular the equipment regularly inspected. This can determine the wall thickness of the tubes, which are subject to pitting and corrosion as well as erosion over time. The condition of the entire tube bundle can be charted and evaluated through a highly detailed inspection using a device called an Internal Rotary Inspection System.

The Internal Rotary Inspection System works through ultrasonic testing and it is non-destructive in nature. The Internal Rotary Inspection System probe has to be inserted into a tube which is then filled with water.

The Internal Rotary Inspection System probe has a small mirror that rotates and focuses an ultrasonic beam onto the wall of the tube. The mirror rotation is driven by a small turbine, which in turn is driven by water pressure as it is pumped into the tube. The Internal Rotary Inspection System probe is slowly pulled out of the tube at a rate of about one inch or 25 millimetres per second, recording the condition of the internal wall of the tube as it progresses.

The results gained from a heat exchanger inspection using an Internal Rotary Inspection System probe is generally extremely accurate. Its accuracy can be as good as to within .005 inches, or .13 millimetres. Of course, in order to gain this level of accuracy it is necessary for the heat exchanger tubes to be thoroughly cleaned down to bare metal prior to the inspection.

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Photo credited to http://picture617.bloguez.com/picture617/page190/

C. J. Rose writes on the subject of tube bundle and heat exchanger cleaning and onshore/offshore environmental safety for Sureclean, global industrial waste management experts. Topics include HP & UHP water jetting, tank/vessel cleaning, vacuum transfer/pumping, industrial painting, asbestos management/removal, HVAC/duct management, NORM management. For videos see http://www.sureclean.com/video.

Do You Really Need Fireplace Heat Exchanger Cleaning Equipment?

2010-02-07T09:14:00.000-08:00

Before deciding whether heat exchanger cleaning equipment is something you need, it's best to take a step back and make sure you know exactly what a fireplace heat exchanger is. Simply put, it's a device used to make sure no cool air from outside of your home is brought inside when the fireplace returns air it's using from inside your home. So what happens when your heat exchanger breaks or gets built up with gunk and dirt? The fireplace becomes quite ineffective and starts actually cooling your house rather than heating it, the opposite of your intent.

This is where the cleaning equipment comes in to play! The tools are used to clean the exchanger making it possible for your fireplace to function properly at all times, keeping your house as warm as you'd like it to be. Unfortunately, finding the right cleaning gear can be kind of intimidating when it comes time to determine whether it's what you need, or whether there's another problem with the fireplace. Before investing in heat exchanger cleaning equipment make sure you're experiencing the right signs for the need, instead of signs of some other kind of trouble.

These signs include suddenly feeling much colder in the room than usual, especially when the difference seems to have taken place literally overnight. Also make sure that everything else seems to be working right on the unit. Finally, you may want to consult a professional so they can tell you whether you need such cleaning equipment or not. There's a chance the professional can simply take care of the problem for you right then and there, or even rent you the proper heat exchanger cleaning equipment.

If the tools are something you end up having to purchase, don't do so without comparison shopping first. Make sure you find the best deal possible for the highest quality. You'll also want to verify what the return policies are (in case the equipment is something you don't really end up needing or it doesn't work) and whether or not parts on the equipment can be easily replaced.

Sanno Zaye covers more about heat exchanger cleaning equipment at Heat Exchanger Equipment.

Refinery Heat Exchanger Tubes Cleaning

2010-02-07T09:12:00.000-08:00

This video presents how a typical high pressure tubes cleaning process seems like. Check it out.

Better Heat Exchanger Cleaning Through Technology

2010-02-07T09:09:00.000-08:00

Maintenance of a platform's Waste Heat Recovery Unit (WHRU) and similar shell and tube heat exchangers can be an extremely dangerous process. It needs to be disconnected, taken off line, and moved to shore for repair. Shell and tube heat exchangers are made of coiled tubes and can become fouled with carbon deposits. The traditional methods for clearing the blockage include bypassing the fouled unit, cutting off bends and cleaning the tubes, then re-welding the U-bends, and complete unit replacement.

The old methods are becoming more outmoded due to advancements in technology. It is inefficient to bypass the unit. Just as it would be less efficient to run your car with 2 cylinders not firing. This inefficiency, of course, also increases operational costs. It is time consuming and costly to cut the U-bends and re-weld them. Sometimes it can be difficult or impossible to get access to reattach them.

Some of these new methods include the ability to clean areas with limited access, and clear deposits from U-bends without ever removing them. This can sometimes be done without even taking the unit offline, and usually takes less time and results in a higher degree of defouling. In fact, many units can be restored to near-factory efficiency. For big refineries, petro-chemical plants, or power plants, this can amount to six figure savings.

The U-bends themselves also retain many deposits, and continue to be a bottleneck to the system. Full replacement carries the cost of completely replacing equipment that, other than the heat exchanger tube fouling, is still in working order. This method also requires the unit be taken offline for the full duration of replacement. obviously this carries a heavy expense and serious loss of production.

Traditional heat exchanger cleaning methods and heat exchanger cleaning equipment have changed very little over the last few decades. Pressure jetting is still the primary means used by many companies, but it is slow, inefficient, and ultimately very costly. Additionally, many companies are skeptical of newer methods, falling back on the "that's the way it's always been done," chain of logic. They are also weary of trying new techniques that are not as "proven" to be effective. Finally, many have long term tube cleaning contracts that do not allow for a change in heat exchanger cleaning technique, unless the contractor were to adopt the new methods.

Newer heat exchanger cleaning equipment and techniques are more technologically advanced, and by extension, require a higher skilled laborer than old style pressure jetting. These new developments include the ability to clean tight radius bends, clean units while keeping them in place, and even while keeping them online. It has also resulted in faster, more efficient cleaning. Many tube bundles can now be cleaned more effectively than with pressure jetting, and jobs that used to take days may now take only a few hours. Difficult to access units are now accessible with these new technologies.

Some of the technology that has been developed includes special nozzles that can be used on tight bends, laser cleaning, and new "smart" metals that respond to changes in density and pressure to prevent damage to the tubes. With these methods, jobs can be finished with less downtime, because cleaning and descaling can be done more quickly. Equipment is also less likely to be damaged in the process. Many of these new processes are safer, create less waste, use no chemicals, and have a significantly reduced environmental impact.

Alex Parry writes about heat exchanger safety at his heat exchanger cleaning equipment site

Cleaning Shell and Tube Crude Oil Heat Exchangers

2010-02-07T09:07:00.000-08:00

Tube Tech International proved that previous industry standards for cleaning such equipment with U bends were inadequate and, for the first time on this unit, Tube Tech gave not only the straight legs, but also the U sections a complete internal clean.

Heat Exchanger Tubes Cleaning Basics

2009-08-08T19:26:00.000-07:00

Clean your heat exchanger tube is a job everyone can do if they know how to do it. If you are a handy type of person, then you should have no problems with this task.
There are several methods for cleaning the heat exchanger tubes. Here are some of them; one of them is the use of chemicals for cleaning. Another is the use of water with high pressure in the system. The final method is to use mechanical cleaning with brushes of balls scrapers and abrasives. These are the best ways to clean the tubes.

Regular cleaning of the heat exchanger tubes should be the life of the whole unit. It helps to work at the heat exchanger maximum efficiency.

Many people use heat exchangers for heating swimming pools in nowadays. With the ability to clean by its own, heat exchanger tubes would be a good way to save money and your operating system.

It would be helpful to the clean the tubes of the heat exchanger every few months. At least check to see if they need to be cleaned. If they do not need to be cleaned, make sure that they are thoroughly cleaned twice a year.

To properly clean the heat exchanger tubes, they must be removed from the system. Remove all in bulk, near the ends of the pipes and inside of them. Use a brush and press down to the tubes as cleaning begins. The brush should be good strong nylon bristles. This help to resolve and remove all the material such as scale and debris in the tubes.

During the brushing process you will find material adhered to the wall of the heat exchanger tube. A plastic of metal scraper, will help eliminate, those unwanted thing stuck to the tube wall. Be careful not to damage the tube. Don’t use anything that is harder than the tube.

Try not to scratch the wall of the heat exchanger tubes in which the tube could not work. This will scratch the tube internally. This means, a plastic scraper is a good tool to be used.

As a final step, of cleaning the heat exchanger tubes, you can use jets to force out all loosen particles, which have been missed with the previous methods. If you have deposits of calcium in the tubes then you need chemicals to eliminate them.
Now you have the basics for cleaning your exchanger tubes. Collect as much information as possible before you do this work.

Chemical Cleaning - Methods and Applications

2009-06-24T06:33:00.000-07:00

Chemical cleaning is a method relevant in freeing walls and surfaces of various equipment, heat exchangers, pipelines, vessels and kettles from unwanted residues and bacterial contaminants. It is also essential in water purification, treatment, disinfection and conditioning. With varying methods to its name, several industries benefit from the procedure.

The most important facets of chemical cleaning gear on providing environment-friendly alternatives to consumers. No matter where it is applied, the aim is to primarily free the surface from contaminants. Below are the different methods listed under this cleaning process.

Chlorine dioxide method

Biofilms and legionella are two of the most common microbes that reside in water. Biofilms are residences or havens for organisms that contaminate products in water solutions. Legionnaires disease is caused by legionella or a Gram negative bacterium.

With the aid of chlorine dioxide, the biofilm or legionella may be removed from the water system. It is a favored technique because it has the capacity to prevent future formation of contaminants plus it can also be used in both hot and cold water systems. Chlorine is proven to have a safer solubility in water and has the capability to destroy THM precursors. It also increases coagulation while it destroys phenols. It is not hazardous to health and does not have any distinct smell.

Ultraviolet radiation

Another proven chemical cleaning process for water disinfection is the ultraviolet or UV radiation. Aside from water, it may also disinfect air and solid surfaces contaminated by microbes. Its capacity to disinfect was reported since biology and light waves were introduced in the fields of science research.

Ultraviolet radiation has several advantages. It is considered safe because there is no need to monitor any dangerous chemicals thus the results of disinfection are quickly attained. Any household or business establishment does not need to spend a lot since the initial system and operating costs are very minimal. It does not change the taste and smell of water as well plus they are easily installed and maintained.

Ozone purification

Ozone is one molecule that contains three atoms of oxygen and is naturally produced by a series of chemical reactions. It may come from the ultraviolet rays of the sun as well as from waterfalls and thunderstorms. It is also a chemical cleaning process used in wide areas of water treatment and purification. It is used in potable water treatments and in the broader municipal wastewater sites. It is also being widely recognized in several industries.

Visit the US-European Industrial Directory and Portal (ForeignTRADEX.com) to find and compare Europe's leading manufacturers, exporters and suppliers of Industrial Machinery, equipment and other products for the industrial marketplace such as chemical cleaning as well as other goods and services.

Positive Effects of Air Duct Cleaning

2009-06-04T08:26:00.000-07:00

As air indoor pollution becomes more of a hazard, the state of our indoor air quality is becoming more of a health concern. According to the American Lung Association, "Indoor Air Pollution is wide spread. You are more likely to get sick from pollution in your home and office than from pollution in the air outside. Poor indoor air quality can lead to a number of health problems such as respiratory illnesses. As well, microorganisms such as mold and bacteria can be harmful to one's health. One way of improving indoor air quality is to have your air ducts cleaned.

Duct cleaning consists of cleaning various heating and cooling system components of forced air systems such as air ducts and registers, grills and diffusers, heat exchangers, heating and cooling coils, drip pans, fan motor, and the air handling unit.

When you have yur ducts cleaned, you will experience the following effects:
Improved Heating and Cooling Systems: Your heating and cooling systems will run better and less often thereby improving energy efficiency. You will save money, conserve energy, and have a longer lasting system.

Dry Ducts: Moisture in ducts is a breeding ground for bacteria and fungi which can cause respiratory illnesses when inhaled. When your ducts are cleaned, organisms will be removed and the ducts will be clean and dry preventing further growth.

Eliminate Rodent Waste: If there are mice or rats running through the ducts, they will leave their waste in the ducts. Air blowing the droppings through the system can contaminate indoor air. This can lead to health problems if inhaled. Cleaning your air ducts will get rid of any rodent waste.

Eliminate Accumulated Debris: By having your ducts cleaned, you will eliminate the debris such as plaster and drywall particles, wood, dust, and insulation particles that may have accumulated in the ducts over many years. Dust mites and ants feed on debris found in air duct so you will remove the mites along with the debris. You and your family will breathe easier and feel less ill.

Better Health: Air circulation will be improved because you will have eliminated contaminants that have built up in the ducts. Symptoms of indoor air pollution include: allergies, illnesses, eye irritation, sinus congestion, headache, sore throat, nausea, cold and flu symptoms, asthma and increased asthma symptoms, diseases, fatigue, cough, congestion, tightness in chest, wheezing and hypersensitivity, and eye, nose, and throat irritation. Removing dirt, dust, and contaminants will improve your overall health. The home will be cleaner and less dusty because there will no longer be any dust blowing into rooms. You will see a reduction in allergy symptoms such as sneezing, coughing, watery eyes, and wheezing when you breathe. You will also be able to sleep better, concentrate better, and feel more awake and alert.

Improved Odor: When ducts accumulate material over a period of time, one may often start to detect an unpleasant odor. Clean ducts will help keep air fresh.

According to the Environmental Protection Agency EPA, -6 out of 10 homes are 'sick.' This means that -they are too hazardous to your health to occupy as a result of airborne contaminants. Because people spend the majority of their life indoors (60-90%), the air you breathe should be of the highest quality. There are many positive effects that clean indoor air provides. Duct cleaning technicians have the knowledge and experience to thoroughly clean ducts for both homes and businesses. Enlisting the services of a certified professional duct cleaning once or twice a year will greatly improve the health of families, pets, employees, clients, and customers.

Duct Cleaning Toronto Company servicing residential, commercial and industrial customers. Visit one of our locations at : duct cleaning Pickering

Cutting Edge Cleaning

2009-04-27T05:49:00.000-07:00

A five day shut down had been planned at an oil refinery to accommodate traditional pressure jetting and chemical cleaning methods to clean four crude train heat exchangers. Tube Tech challenged this route using an alternative innovative method to overcome the main disadvantages: Difficult to clean with lengthy downtime leading to expensive lost production.

The company was able to clean each bundle in a few hours without chemicals or high pressure water jetting, while the other three exchangers were kept running to maintain continuity of production, effectively ‘flat lining’ the production output. The cleaning procedure delivered a substantial Kj/C-hr improvement on just one bundle compared to all four bundles previously cleaned with either of the traditional procedures.
Cleaning technology

There has been little change over the decades in the methods and equipment used to clean and de-scale heat exchangers and pipelines. The low-tech approach of high pressure water jetting has kept it as a low skilled job with largely unimpressive and variable results.

Despite being armed with demonstrable evidence of being able to achieve better results than traditional methods, the company has faced an up hill struggle to get its innovative techniques widely accepted. It has not been easy persuading potential clients to consider trialling new techniques designed to improve substantially on traditional water jetting methods.

There has even been outright skepticism that Tube Tech’s claims can be substantiated. Persistence and determination were needed to change the industry mind set regarding the effectiveness of current cleaning methods. Long-term maintenance contracts can also act as a barrier to an investigation of the company’s advances.

The historical reliance on low tech, low skill water jetting for pipe cleaning has meant that clients have accepted that this is the best that can be achieved. This meant that there was often no quantifiable data against which Tube Tech’s improved results could be measured.

Setting out to devise a more scientific approach to the whole cleaning and de-scaling process,

The company has created more than 40 innovative techniques. This has led to several ‘firsts’ in heat exchanger and pipeline cleaning processes. These developments include:

• The ability to clean exchangers in-situ where previously they were pulled.

• The ability to clean and unblock hairpin bends.

• Speed cleaning difficult bundles in hours instead of days.

• Online cleaning of difficult heat exchangers.

The introduction of more sophisticated technology enables the cleaning and de-scaling to be carried out faster so there is considerably less downtime, and potential mechanical damage to equipment is eliminated. Less waste, dry processes and the elimination of chemicals provides a safer and more environmentally acceptable process.

The company has also taken traditional pigging methods and tailored them to achieve much better results. Operating in a tube and pipe environment from 2mm to upwards of 1m, equipment is modified to suit the consistency of deposit and pipe configuration. A wider variety of deposits can be removed by an innovative drift system loaded into large diameter pipes through a very small aperture which then expands to suit the diameter. It also has the ability to return back down the same line without creating an expensive loop system.

Aluminum tubes

The scale which builds up in aluminum furfural exchangers is notorious for being highly tenacious. The accepted wisdom has been that due to their delicate nature, aluminum hairpin heat exchangers can only be cleaned using 200bar (3625 psi) bar water pressure.

This low-pressure approach only removes 20% of blockages and scale with the additional problem that it tends to compact coke deposits on the U bends rather than remove them. Working with clients sample tubes, Tube Tech’s research and development team devised a combined mechanical and water jet system which used 2500 bar ( 40,000psi) to remove coke deposits and improve overall cleanliness to 90%.

The three-stage process included a sensitive mechanical hairpin-cleaning device coupled with exceptionally low volumes of water. First, each tube was cleaned using the Softdrill™ lance made from ‘intelligent’ metals to prevent damage to the tube wall. These soften on entering the U-tube and stiffen on extraction, while an oscillating motion drills the blockage using a mixture of water and an occasional infusion of food grade media at 12 * the pressure and four times the speed of the conventional approach. Finally, a micro turbine rotating under controlled hydraulic pressure was guided through each tube.

Not only were the results substantially improved but also cleaning was carried out in-situ, reducing downtime by 200% and avoiding possible handling damage, the cost of cranage and bundle pulling equipment.

A U-bend first

The inability of traditional water jetting to remove hard coke and oily sludge in the U bends in heat exchangers in crude oil distillation complex has produced a 70% cleaning standard.

After analyzing the nature and composition of the deposit and its dimensions, the Tube Tech approach was used. The result was:

• 99% of contamination removed.

• Hairpins cleaned for the first time ever.

• Heat exchangers returned to virtually as new condition.

• Cleaning operation completed in three times faster than the standard pressure jetting times, down from six to two days.

• Greatly improved throughput.
In-situ cleaning

Solving problems related to specific equipment often enables the company to further improve on its initial performance. The cleaning process for an important tube bundle In a catalytic cracker was initially reduced from nine days to six but this first experience subsequently lowered the barriers further. A smaller sister unit was subsequently cleaning in three hours instead of three days.

For the first time the operation was carried out in-situ, using a new turbine method, incorporating a low-pressure water jetting system avoiding the cost and effort of removing 10t of exchanger gaskets, scaffolding or cranes. In-situ cleaning lengthens the life of the bundles, which deteriorate through damage caused when they are removed for cleaning.

Mike Watson, Managing and Technical Director

Run by its founder and inventive visionary Mike Watson the company is supported by a wealth of hand selected department managers. With many years experience in developing engineered solutions to complex problems in industry, Mike’s belief is that convention should always be challenged in order to find a better way to achieve improved results. This “never say never” approach, led to him founding Tube Tech in the 1980s. Today, the company cleans the toughest cleaning projects the world can throw at it. Mike often says “If people say it can’t be done, its like a red rag to a bull to me. I will always find a solution”. Mike continues to invest in new technology development, leading the world in new cleaning methodology.

Article Source: http://EzineArticles.com/?expert=Mike_Watson

How Often You Should Clean Your Ducts

2009-04-03T08:11:00.000-07:00

Researchers are learning more about the quality of indoor air. They are discovering that air in our homes can often be filled with dust and pollutants. As more people learn that indoor air pollution is a health issue of growing concern, they are looking for ways to keep their air clean. One method of improving air quality is cleaning air ducts.

Air ducts are susceptible to the following hazards:

- Ducts can be infested with vermin such as rodents and insects. Contaminants from their droppings can be blown through the ducts into a home where they may be inhaled.
- When there is moisture, bacteria and fungi can grow in air ducts where microorganisms and spors can blow through the home.
- Dust, dirt, and oil particles can build up in the ducts and be sent through the home.

You should have your ducts cleaned for the following situations:

- If you have a problem with moisture in your ducts. If the conditions causing the mold growth in the first place are not corrected, mold growth will recur.
- If you are moving into a newly constructed house. There may be construction debris in the ducts such as drywall dust, fiberglass pieces, and sawdust.
- If you are having trouble with furnace airflow.
- If there is an accumulation of debris in the air registers. Pet dander can often build up in the registers.
- If you or a family member are sneezing a lot or you see particles blowing though your vents, it is time to get your ducts cleaned.
- If you place your hand over a duct vent and the air flow is not very strong. Cleaning the ducts may restore proper airflow.
- If you detect an odour coming from the vents when the air is turned on

By having your ducts cleaned, you will improve air quality and reduce the amount of pollen, allergens, mold, and fungi from infecting the air. Not only will air quality be improved, but family member who suffer from asthma will breathe better. People with asthma are extremely sensitive to dust and allergens in the air. Clean air ducts will reduce the chances of family members developing allergies. It will be a much healthier environment for children and pets. Duct cleaning will also reduce energy costs and make it easier to keep the house clean.

It is recommended that you have your ducts cleaned every two years. The best time to get your ducts cleaned is in the late summer or early fall. If you have family members that are afflicted with breathing problems, you may want to have your ducts cleaned every year. The Environmental Protection Agency recommends that people have their air ducts cleaned.

If you decide to have your ducts cleaned, it important to make sure you have a qualified service provider who cleans all of the components. If your ducts are not properly cleaned, there is an increased chance of recontamination. Service providers will use specialized tools to remove dirt and debris in ducts. They will then vacuum the ducts with a high-powered vacuum cleaner. Many companies are promoting their products and services as a means to improving the quality of your indoor air.

Preventing moisture, debris, and dirt from accumulating in your ducts is the best way to reduce the number of indoor air pollutants. By maintaining good quality air, you, your family, and pets will be healthier and breathe much easier.

Keeping your air ducts clean allows for a cleaner, healthier environment in residential and commercial structures. For quality air duct equipment and insulation blowing equipment, consider Heat Seal Equipment Ltd.

Keeping Cooling Towers and Heat Exchangers Clean

2009-03-25T07:16:00.001-07:00

Filtration Systems Can Reduce Maintenance and Downtime.

To strike an interesting analogy, your cooling tower and heat exchanger is what the lungs and heart are to the human body; when either aren't working properly, it effects other parts of the body and your health suffers. Similarly, when your cooling tower and heat exchanger isn't clean, the heat exchange process doesn't work efficiently and the health of your production and process cooling system suffers.

Process cooling systems that rely on cooling towers to dissipate heat from process cooling water accomplish this by drawing massive volumes of air into the cooling tower as the water travels through the fill material on its way back to the basin. Through the natural evaporative process, heat is dissipated from the water before it reaches the water basin from which it is re-circulated through the chiller then through the heat exchanger and back again (kind of like when you sweat while working and letting the air evaporate the perspiration to cool you down). It is important to realize that cooling towers are gigantic air scrubbers that capture all airborne debris that happen to be floating nearby, and if your system doesn't have effective filtration, the debris can clog the fill and get circulated and trapped in the heat exchanger where it can build-up, restrict water flow and cause your process equipment to malfunction due to overheating.

An example of this is illustrated by a major automotive assembly facility that had faced periodic downtime due to their robotic welding systems not holding tolerances and causing quality problems. After the robotic technicians spent several days trying to initially solve the problem, one of the maintenance workers opened the heat exchanger and discovered that it was impacted with cottonwood seed, insects and other debris - flow had been reduced and the robotic equipment was running hot. Now you might be asking yourself, whey didn't they have some sort of filtration equipment? The answer is simple; at the time the facility was built, the ambient conditions in that area didn't require a filtration system. However, as the years went by and the area became more developed and cottonwood tree populations grew, the need eventually surfaced.

The interesting thing to note about this situation is that even though cleaning the heat exchanger got the robotic welding system back on-line and running at peak performance, it didn't solve the problem. In fact, cleaning heat exchangers is like taking a cold capsule to relieve the symptoms of a cold. Unless you treat the root cause of the problem, the cooling system will suffer time and again. The root cause in this case and in most heat exchanger fouling situations is the cooling tower - stop the debris from getting into the cooling tower and it will protect the entire process cooling system including fill, cooling water, chiller and heat exchanger. With the proper filtration technology, your process cooling system will stay clean and running efficiently all season long.

Selecting The Right Filtration System

It is important to realize that optimizing the ecology and operational efficiency of your evaporative cooling system is best accomplished by combining a chemical treatment regimen with some type of filtration. The reason is that chemical treatment specifically targets suspended solids and particulates of 40 microns and below, while filtration systems are designed to stop larger debris, especially the kind that causes system clogging and fouling.

For cooling tower filtration, there are two general technologies: Water Based Systems for which there are a few different variations and Air Intake Filtration Systems. With water-based systems, the choices include basic water strainers that remove debris by simply passing water through a mesh strainer; sand filtration systems that remove debris by passing the water through sand and centrifugal separators that spin the water and remove the debris through centrifugal action. In contrast, Air Intake Filter Systems remove the debris by filtering the air as it is being drawn into the cooling tower, keeping the debris out of the system in the first place. When considering your filtration options, the following questions should be asked.

What is the cost associated with downtime due to heat exchanger or cooling tower fouling or clogging? (Knowing this will help you justify your filtration system cost)
What type of debris is most problematic (can you see it or is it microscopic)?
Specifically what part of the system does the filter protect?
Which system provides the greatest filtration surface area (this can directly impact frequency of cleaning - the smaller the filter the more frequently it needs cleaning)
Can the system be installed without shutting down the cooling tower? (If the cooling tower must be shut down for installation, you need to factor lost productivity into the cost of your filtration system if it's not being installed during shutdown periods.)
What is the cost associated with both the filter and installation?
How easy is the system to install and maintain?

Answering the above questions will help you to fully understand your options and to make the best choice for your operation.

In the case of the automotive manufacturer, the solution they selected was the Air Intake Filter system. The reason was that they needed a system that would protect their entire process cooling system including fill material, cooling water, chiller and heat exchanger. When they evaluated water-based systems, they discovered that the options provided varying degrees of protection for the chiller and heat exchanger but didn't protect the cooling tower where the root of their problem was. If they had selected a water-based system, their cooling tower would have still drawn airborne debris into both the fill and water where the water filter would have captured the debris before it circulated throughout the system. From a maintenance standpoint, that would have solved the heat exchanger problem but it would have done little to reduce maintenance on the cooling tower. Further, when they compared the cost of water based filtration versus air intake filtration technologies, Air Intake Filtration was found to be the more cost effective approach for their operation.

If you are not currently using a filtration system as part of your process cooling system, then any filtration technology will give you more protection than you have now, however, selecting a solution best suited to your operation requires that you know what kind of debris is the problem and where it is getting into the system. As a rule of thumb, " don't select a small debris solution to solve a large debris problem". Conversely, "don't select a large debris solution to solve a small debris problem". There is clearly a place for both water based filtration and air intake filtration - be sure you're selecting the right filtration for your specific need.

If you are looking to protect only your chiller and heat exchanger from airborne debris, then one of the water-based filtration technologies in combination with a good water treatment program can help you manage the debris that gets into the cooling water. If on the other hand, you're looking for full process cooling system protection, then you should look at Air Intake Filtration - It will stop the debris from getting into your system in the first place.

Air Solution Company developed and patented the first Air Intake Filter specifically engineered to mount to the outside of cooling towers and other HVAC equipment for purposes of stopping the debris before it entered into the system. Since that time, Air Solution Company has been manufacturing and has introduced a variety of other innovative filter systems including its new Fine Mesh Filter which is engineered for use on small and medium size refrigeration coils and machine fan intake housing units. Air Solution Company Randy Simmons is with Air Solution Company, author of articles can be reached at http://www.airsolutioncompany.com

Turbine Condenser Tube Cleaning

2009-02-20T14:33:00.000-08:00

Keeping operating costs low is a vital factor in electricity generation. Turbine condensers need to be working at maximum efficiency to benefit not only the electricity producer but also the consumer. This was the case at the EON UK's Connah's Quay Power Station in Flintshire, Wales where optimum performance needed to be maintained. That's why they regularly cleaned their turbine tubes to ensure optimum process.

The Basics of Exchanger Tube Cleaning

2009-01-31T22:21:00.000-08:00

Tube cleaning is not a particularly popular subject. However, there are people who are looking for this type of specific information. Let us begin with some basics of this process. In order for heat exchangers to function, properly all of the tubes must be clean and free of any debris. This is why it is very important to keep the tubes clean at all times.

If any formation of debris or algae growth forms then the flow of any coolant and heat exchange through the tubes will be reduced. If tube cleaning is not done on a regular basis then it could lead to over heating and failure in the engines or in the plant itself. Simply put, it would be costly!

Now what causes the tubes to become dirty? One of the leading causes is dirty water and algae growth. You just cannot ignore your heat exchanger tubes. In order to avoid any issues with the tubes, it is essential that qualified individuals perform regular inspection of your heat exchangers. Preventive maintenance is better than un-planned shutdowns.

One particular type of cleaning unit follows these basic steps. The heat exchanger tubing cleaning consists of flushing water through the shaft to help remove any deposits inside the tube. A forward direction foot switch allows the operator to focus on the cleaning. It features large wheels for easy mobility. The amount of water used in the process can be controlled as well.

An electric tube cleaning device is environmentally friendly. In addition, they are compact and are easily movable. They have the ability to clean either a straight or a curved tube. A cleaning tool is attached to a flexible shaft and then inserted into the tube to be cleaned. This cleaning tool uses a rotary motion to clean the insides of the tube. Water is also passed through the shaft to help with the cleaning and flushing out of debris.

For more information on tube cleaning please, visit my website today!

Your guide to everything you have ever wanted to know about exchanger tube cleaning and water chillers. We also provide information on various types and brands of heat exchangers. Visit our site today! http://www.theheatexchangers.com
ByM. Applebaum

Dirty Furnace Filters Can Be Deadly

2009-01-06T05:36:00.000-08:00

What do you assume is the result if you neglect to keep your furnace filter clean? Do you think that your furnace will be able to run forever without problems using the same dirty filter year after year? What do you think will happen when your filter becomes over saturated by dirt, pet hair, allergens and dust? You are looking at more than the fan simply refusing to run properly. A dirty filter in your furnace can be deadly, make you sick or worse, causing your home to go up in flames.

When either your furnace or air conditioning unit are not being maintained properly every six months or every year, dirt, dust and other debris can build up inside causing serious problems in the long run. Not only will you be paying more for heating if your heating unit has to struggle harder to heat the same amount of space but also run the risk of some pretty serious dangers are also involved with not properly responding to a dirty furnace filter. When your furnace and the motor in your air conditioner become clogged by dirt and debris, that air is what will be circulating through your home, rather than the clean, fresh air that you once enjoyed. Your family will be breathing in all these toxins that otherwise would have been sucked out of the air by a clean or new filter. If you continue to breathe this bad air, there is the possibility you will become sick. So if your family is sick and the cause cannot be found, it might be time to replace your filters and to restore the clear air in your home.

After a few years worth of neglecting your furnace serious things can possibly happen. Your furnace may simply break down and you will be lucky if you could find a cheap replacement part. If your heat exchanger becomes warped or cracked from the unbearable heat build up within your furnace, noxious carbon monoxide fumes may leak into your home, not only making you sick but also potentially killing you and your entire family. Can you imagine all of this, simply because you could not be bothered to maintain your furnace filter?

Faulty furnaces have also been known to cause fires, all because the filter wasn't clean, and air couldn't circulate properly through the furnace and throughout your home. Clean up after a fire is incredibly expensive, and there is no telling what damage you may in the process. What if your entire house goes up in flames? What is a pet, or a family member is trapped inside when it happens? Hopefully now changing out your furnace filters or buying filters that are permanent and only need to be cleaned seems like less of a trivial matter. You can save yourself a lot of stress, a lot of health problems and a whole lot of financial burden simply by keeping your filters clean, or replacing them often. If there is any doubt, you can always contact a contractor who can check your furnace and clean your filters if need be.

With so many reasons to keep up on your furnace maintenance, and no known reasons for why not to, you should take the next few moments to check out the state of your furnace filter to make sure that air is circulating properly through your home, that your heat exchanger is still in one healthy, solid piece, and that there is no risk or danger present that you could easily have avoided.

Bill Whitworth writes air quality articles for Web Products, Inc., the Internet's premier supplier of furnace filters, air filters, replacement filters, and custom filters.

Annual Furnace Maintenance - A Homeowner's Guide

2008-12-05T05:27:00.000-08:00

Most heating contractors, and furnace manufacturers will recommend that you have your furnace checked by a qualified HVAC technician every year, prior to needing to turn on the heat for the season. A reputable and qualified HVAC technician will have the experience and knowledge to know the operating specs or your heating equipment. He/she will also know the check the things that you will not know.

However, there are things you can do yourself, to catch problems before they become more dangerous or costly. This article contains some things that an average homeowner can do to help properly maintain a heating system. If you have a propane or natural gas furnace, you must exercise extreme caution.

Shut off the gas and power supplies before proceeding! Do not do anything to your furnace with the gas or power on. Only qualified HVAC technicians should ever test your heating system while it is running.

The most obvious thing that a homeowner can do to maintain a heating system is to replace the furnace filter. It recommended that you use a high quality pleated style filter. In some cases, you will need to find a compatible equivalent to your existing furnace filter. Furnace filters should be checked monthly. Depending on your local air quality, and the type of filter, some higher end furnace filters may last significantly longer.

One of the most common reasons people will call a technician complaining of having no heat is that they have a blockage in the drain system. All high efficiency furnaces have a drain hose and drain trap of some sort. Bacteria can grow into a slimy formation that restricts condensation flow through the drain system. You can pour household bleach into the drain lines to kill this bacteria.

Outside the house, check the furnace intake pipes and exhaust pipes to be certain that trees and shrubs are not growing into them. Remove the intake and exhaust pipe and check to see if there are any leaves or other obstructions in them. This is another major problem people have with their heating systems.

Check if any wire connections are loose or shorted. Test the plug harness connections to make sure that they are not loose. The blower compartments and burners can be vacuumed to prevent contamination of the blower motor and burners. If your blower motor requires oiling, you may need to call a qualified service technician. The blower assembly will most likely need to be removed in order to oil it on both sides.

It's recommended to have a service technician clean the burners and inspect the heat exchanger. The technician should also clean the flame sensor. People will often break the igniter thinking that it is the flame sensor. Have the technician check pressure switches, limit controls, and other safeties.

Although these steps may not seem like there is that much you can really do yourself, you should ask the service technician as many questions about your system as you can. Being informed about your heating system can be very helpful in diagnosing or even preventing a problem. Down the line, it will save you money.

Find out more about heat exchanger maintenance at my heat exchanger cleaning equipment site.

Heat Exchanger Safety - A Maintained Furnace is a Safe Furnace

2008-11-02T07:03:00.000-08:00

Heat exchangers are pieces of equipment that are used for the transfer of heat from one fluid to another. When a heat exchanger goes bad, chances are, important things stop working. When your automobile engine is overheating, it's likely that the heat exchanger is the problem. You probably call it a radiator, but it's one type of heat exchanger. In your radiator, antifreeze cools air that flows past it. This air is then blown by a fan onto the engine to keep it cool. If the radiator doesn't work properly, you won't be driving very far until the situation is fixed.

Your home heating system also has a heat exchanger. In fact, nearly every piece of mechanical equipment that has a need to intentionally heat or cool part of a system does. Inside your furnace there is a combustion chamber. There is a metal wall that separates the internal combustion from the air that flows past the heat exchanger and on through the ductwork to heat your home. You need this separation because you don't want the toxic gases inside mixing with the air that is distributed throughout your home. In the previous example, a faulty heat exchanger could lead to a broken down automobile, but in your home you could be gambling with your life.

Carbon Monoxide can be present in the combustion gases. It's supposed to be contained inside, but as time goes on, it becomes possible for the heat exchanger in your furnace to crack or warp. Each time your furnace turns on, the metal wall heats up and expands. During the off cycles, the metal of the heat exchanger cools and contracts. Over time this repeated process of expansion and contraction of the metal takes it's toll. The metal can become fatigued, and eventually warp out of shape, or just plain break.

As I noted before, these metal walls were designed to keep the toxic combustion gases inside the heat exchanger chamber. Guess what happens if there is a crack? That's right, the toxic gases inside can mix with the forced air that is being blown through the ductwork and into your home. Having a reliable Carbon Monoxide detector is an inexpensive measure to protect yourself and your family from the danger of Carbon Monoxide poisoning, but you can also take some proactive measures to protect against any potential danger.

Give your furnace an annual checkup, just before the heating season, to check the condition of the burners, the heat exchanger, the furnace filter, and other components that can affect the performance of your furnace. I recommend have a certified HVAC specialist do this. Only a certified specialist will have the knowledge and experience needed to know exactly what to look for, and where to look for it, as well as knowing what the operating specifications for your unit should be.

If your furnace is over 10 years old, it is even more important to keep that annual checkup. This is the time period where the years of wear and tear on your heat exchanger make a failure of the heat exchanger wall significantly more likely. Keeping your furnace in good health can also help keep you and your family in good health.

Find out more about heat exchanger safety at my heat exchanger cleaning equipment site.

How to Clean Your Pellet Stove

2008-10-17T09:09:00.001-07:00

Most of the time wood pellet stoves will run better and more efficient when they are clean. The air inside can move around better and this will allow the appropriate combustion in the firebox. You can clean your pellet stove yourself and it will not take much time or work at all. You will have to have a few simple tools in order to get a better clean and have an easier time as well.

A few things that you will need to clean your pellet stove are a paintbrush, paper towels, cloths, shop vac and the scraping rod that usually comes along with your stove. When you place a new bag of pellets into the hopper of the stove, it is a good idea to clean the heat exchanger. When you are cleaning this it will allow the heat to move from the firebox to your area a lot easier. It is best to use a good quality pellet to avoid cleaning more often.

When you shut your pellet stove off, you can then use the paintbrush to clean the dust that the stove produces. You can use any other type of duster or brush for this job too. The brush will have the ability to get into the small cracks and spaces that the dust can fall into. You will then be able to vacuum the ash out of the collection pan easily.

Doing simple cleaning each month will make it easier to do a thorough cleaning every few months or so. You can use your brush or shop vac to clean the tough to see areas that are going to need cleaned. Each year you should get a professional furnace cleaner check your gaskets and motors to make sure that they are running freely. They will be able to get into the tough areas and see if there is anything that looks like it needs replaced or fixed. Also have the firepot cleaned well wand test your battery back up system if you have one equipped on your pellet stove.

When it is time to shut your pellet stove off for the summer, you should take out all of the pellets from the hopper. Pellets that are left inside over the summer may accumulate moisture and not need feed properly when you turn your stove back on in the fall. You will have to unplug your stove to protect in if there are any lightning strikes or even a power surge can harm your stove.

You should also check your owner’s manual to see if there are any other recommended cleaning and safety tips to follow. It is always smart to use caution and common sense when you are using a pellet stove. When you follow the rules and the instructions, you will see that this is a great way to heat your home.

Copyright 2006 - Ivar Rudi. Ivar suggests you find great market for less by shopping online today. For more information and resources about this subject check out: http://www.pellet-stoves.org/ and also http://www.wood-pellet-stoves.com/ and http://www.woodburning-stoves.org/

Keeping Cooling Towers and Heat Exchangers Clean

2008-10-07T19:29:00.000-07:00

Filtration Systems Can Reduce Maintenance and Downtime.

Selecting The Right Filtration System

What is the cost associated with downtime due to heat exchanger or cooling tower fouling or clogging? (Knowing this will help you justify your filtration system cost)
What type of debris is most problematic (can you see it or is it microscopic)?
Specifically what part of the system does the filter protect?
Which system provides the greatest filtration surface area (this can directly impact frequency of cleaning - the smaller the filter the more frequently it needs cleaning)
Can the system be installed without shutting down the cooling tower? (If the cooling tower must be shut down for installation, you need to factor lost productivity into the cost of your filtration system if it's not being installed during shutdown periods.)
What is the cost associated with both the filter and installation?
How easy is the system to install and maintain?

Answering the above questions will help you to fully understand your options and to make the best choice for your operation.

Heat Exchanger Safety - A Maintained Furnace is a Safe Furnace

2008-09-26T13:49:00.000-07:00

Find out more about heat exchanger safety at my heat exchanger cleaning equipment site.

Filtration Systems Can Reduce Maintenance and Downtime.

2008-09-06T10:15:00.000-07:00

Selecting The Right Filtration System

What is the cost associated with downtime due to heat exchanger or cooling tower fouling or clogging? (Knowing this will help you justify your filtration system cost)
What type of debris is most problematic (can you see it or is it microscopic)?
Specifically what part of the system does the filter protect?
Which system provides the greatest filtration surface area (this can directly impact frequency of cleaning - the smaller the filter the more frequently it needs cleaning)
Can the system be installed without shutting down the cooling tower? (If the cooling tower must be shut down for installation, you need to factor lost productivity into the cost of your filtration system if it's not being installed during shutdown periods.)
What is the cost associated with both the filter and installation?
How easy is the system to install and maintain?

Answering the above questions will help you to fully understand your options and to make the best choice for your operation.

Plate Heat Exchanger Cleaning In Place (CIP)

2008-06-06T04:30:00.000-07:00

Frequency of CIP is once a year per plate heat exchanger. However, when any of the plate heat exchanger performance has deteriorated, the CIP need to be carried out immediately.

Drain out the remnant oil from the plate heat exchanger that is scheduled for cleaning.

Dismantle the flanges that are connected to the plate heat exchanger for fixing flexible hose of CIP line.

Fill in fresh water into the CIP tank until the marked level and heat the water to 70 to 90°C.

Circulate the hot water from CIP tank to plate heat exchanger and back to CIP tank for 4 to 6 hours.

After 4 to 6 hours drain out the water from the Plate Heat Exchanger, CIP line and CIP tank.

Prepare 8 % of caustic solution by pouring 6 bags X 25 kgs of caustic soda pearls and fill water into CIP tank.

Note: Wear personal protective equipment (PPE) like goggles, rubber glove and dust mask when preparing lye solution.

Heat the caustic solution to 70 to 80°C.

Circulate the caustic solution from CIP tank to plate heat exchanger and back to CIP tank for 4 to 5 days.

Record the flow rate of the initial caustic flow and take a sample of the circulated water (for reference).

After 1 day of caustic circulation, stop the CIP pump for 10-15 minutes. Then run it again. Repeat this step in a space of every six hours. This is to aggressively loosen any stubborn scale sticking on the plate surface.

After 2 or 3 days of caustic circulation, stop the CIP pump and reverse the flow. The flexible hose connection needs to be changed.

Repeat the steps.

After circulating for 4 to 5 days take the flow rate reading and water sample of the circulated caustic solution.

Drain out the used caustic solution from the plate heat exchanger, CIP line and CIP tank and clean the CIP tank.

Drained Lye solution will be pumped to Effluent Plant for further treatment.

Fill in water into the CIP tank and heat the water to 70 to 80°C.

Circulate the hot water from CIP tank to Plate Heat Exchanger and back to CIP tank for 4 to 6 hours.

Repeat this exercise for 3 times.

After 3 times of washing with hot water check the PH of hot water.

If the PH is 7 which is neutral, drain out the water from the plate heat exchanger, CIP line and CIP tank.

Record down the CIP of plate heat exchanger in weekly cleaning checklist.

Plate Heat Exchanger Cleaning

2008-06-05T05:57:00.000-07:00

Cleaning Plate Heat Exchanger - Oil/Oil with high temperature

This method can be used for plate heat exchanger cleaning using the "cleaning in place" (CIP) method. This is the cheapest way to clean a plate heat exchanger and it is better then dismantling, washing and re-gasketing the plates. We need to use caustic solution at a temperature between 60-70oC.

Cleaning Plate Heat Exchanger - Oil/Water with high temperature

This method can be used for plate heat exchanger cleaning using the "cleaning in place" (CIP) method. This is the cheapest way to clean a plate heat exchanger and it is better then dismantling, washing and re-gasketing the plates. We need to use phosphoric or sulfuric acid at a temperature between 60-70oC.