Ultrasonic Application 1

7/25/2019 Ultrasonic Application 1

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APPLICATION 1:APPLICATION 1:

ULTRASONIC TUBE CLEANINGULTRASONIC TUBE CLEANING


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CONTENTS OF PRESENTATIONCONTENTS OF PRESENTATION

1.0 Theory of Ultrasonic Cleaning

2.0 Ultrasonic Cleaning (Scale Removal)

3.0 Applications in The Plant Operations

4.0 Dynamics Ultrasonic Cleaning System

5.0 Heat Echanger!Re"oiler T#"e Cleaning

6.0 $#estion an% Ans&er


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What is U!t"as#$i%s&

Ultrasonics is the science of sound waves above the limits of humanaudibility. Ultrasound is a sound with a pitch so high that it can not be

heard by the human ear.

+ Frequencies above 18 Kilohert ! Ultrasonic. "anging from

#$%$$$ cycles per second or &ilohert 'K() to over

1$$%$$$ K(.

+ *ommonly used frequencies between #$ K( and $K(.

,

T'EOR( OF ULTRASONIC CLEANING


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Principles

+ -f increased sound amplitude is applied to nonelastic media such

as water or other liquids%the liquid tends to fracture because of

the negative pressure% causing a phenomenon &nown as

cavitation.

+ s the wave fronts pass% the cavitation /bubbles/ oscillate and

grow to an unstable sie. Finally% the violent collapse of the

cavitation /bubbles/ results in implosions% which cause shoc&

waves to be radiated from the sites of the collapse


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ULTRASONIC CLEANING

(Scale Removal)

PRODUCT CODE : SBB UC 500

REPRESENTATIVE

SAMPLING

LABORATORY

ANALYSIS

CHEMICAL

SELECTION

DEVELOP

PROCEDURES

CAVITATION Loosing out t! s"#$! %on&ing

CHEMICAL ' Boost u( u$t)#soni" i))#&i#tion #n&

BOOSTING su%st)#t! "$!#ning*

SCRUBING B)!#+ing out t! $oosing s"#$!ULTRASONIC

PRINCIPLES

+SCALING

,IELD

APPLICATION


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Ultrasonics Spee%s Cleaning "y Dissol#tion

+ *avitation and implosion as a result of ultrasonic activity displace

and remove loosely held contaminants such as dust from surfaces.

For this to be effective% it is necessary that the coupling medium be

capable of wetting the particles to be removed.

+ 0ome contaminants are comprised of insoluble particles loosely

attached and held in place by ionic or cohesive forces. he effect of

ultrasonics is substantially the same in these cases.

+ he mechanical micro!agitation helps speed the dissolution ofsoluble contaminants and brea& the attractive forces of insoluble

particles


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'a) 2irty 0urface

Fi)*"+ 2 ,+!#- i!!*st"at+s th+ s*"a%+ # th+ /a"t ,+i$)

%!+a$+ has ,++$ "+/"+s+$t+ as a !at.

'b) *leaning 3rocess

'c) 4echanical *leaning

i.e brushing


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are needed to see this picture.Maximizing the Ulta!onic Cleaning "oce!!Maximizing the Ulta!onic Cleaning "oce!!

P"#%+ss Pa"a+t+"s

aiii$) Caitati#$

*hemical

ime

emperature cavitation intensity

emperature

viscosity of a liquid

dissolved gas


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Maximizing the Ulta!onic Cleaning "oce!!

I/#"ta$%+ # i$iii$)

iss#!+ Gas

2uring compression portion of the sound

wave% any gas which diffused into the

bubble is compressed and diffuse across

the boundary again to re!enter the liquid

s a result% cavitation bubbles formed in

liquids containing gas do not collapse all

the way to implosion


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Overall Cleaning Effect

(ighly wettedformulations

compatible with

the base metal


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So$utions Us!& -it U$t)#soni" C$!#ning O. V#)ious P#)ts /1

M#t!)i#$ o. "onst)u"tion T2(!s o. (#)ts Cont#3in#nts Suit#%$! "$!#ning #g!nt

I)on4 St!!$4 St#in$!ss st!!$ C#stings4 st#3(ing4

3#"in!& (#)ts4 &)#n

i)!4 &i!s!$ .u!$ in6!"to)s

Ci(s4 $u%)i"#nts4 $igt

o7i&!s

Hig "#usti" it

"!$#ting #g!nts

I)on4 St!!$4 St#in$!ss st!!$ Oi$'8u!n"!&4 us!&

#uto3oti9! (#)ts .in!

3!s #n& sint!)!& .i$t!)s

C#)%oni;!& oi$ g)!#s!4

"#)%on s3ut4 !#92 g)i3!

&!(osits

Hig "#usti"4 si$i"#t!&

I)on4 St!!$4 St#in$!ss st!!$ B!#)ing )ings4 (u3(

(#)ts4 +ni.! %$#&!s4 &)i$$t#(s4 9#$9!s

Ci(s g)in&ing4 $#((ing

#n& oning "o3(oun&soi$s #7!s #n& #%)#si9!s

Mo&!)#t!$2 #$+#$in!

I)on4 St!!$4 St#in$!ss st!!$ Ro$$!) %!#)ings4

!$!"t)oni" "o3(on!nts

t#t #)! #..!"t!& %2 #t!)

o) (os! &)2!) ()o%$!3s4

+ni.! %$#&!s4 sint!)!&

.i$t!)s

Bu..ing #n& (o$ising

"o3(oun&s

3is"!$$#n!ous 3#"ining4

so( #n& ot!) soi$s

C$o)in#t!&'so$9!nt

&!g)!#s!) /ini%it!&

t)i"$o)o!t2$!n!4 .o)

!7#3($!1

A$u3inu3 #n& ;in" C#stings4 o(!n'3!s #i)

.i$t!)s4 us!& #uto3oti9!

"#)%u)!to) (#)ts4 9#$9!s4

sit" "o3(on!nts4

&)#n i)!

Ci(s4 $u%)i"#nts #n&

g!n!)#$ g)i3!

Mo&!)#t!$2 #$+#$in!4

s(!"i#$$2 ini%it!& to

()!9!nt !t"ing o. 3!t#$4

o) n!ut)#$ s2nt!ti"

/usu#$$2 in $i8ui& .o)31


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So$utions Us!& -it U$t)#soni" C$!#ning O. V#)ious P#)ts /


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So$utions Us!& -it U$t)#soni" C$!#ning O. V#)ious P#)ts /=1

P$#sti"s L!ns!s4 tu%ing4 ($#t!s4

sit" "o3(on!nts

Ci(s4 .ing!)()ints4 $int4

so( &i)t

Mo&!)#t!$2 #$+#$in! o)

n!ut)#$ s2nt!ti"

V#)ious 3!t#$s4 ($#sti"s

/n2$on4 T!.$on4 !(o724 !t"*14

#n& o)g#ni" "o#tings !n

#t!) so$utions "#nnot %!

to$!)#t!&

P)!"ision g!#)s4 %!#)ings4

sit"!s4 (#int!& ousings4

()int!& "i)"uit %o#)&s4

3ini#tu)! s!)9o3oto)s4

"o3(ut!) "o3(on!nts

Lint4 ot!) (#)ti"u$#t!

3#tt!)4 #n& ot!) $igt oi$s

T)i"$o)ot)i.$uo)o!t#n!

/.$uo)o"#)%on so$9!nt14

soni"'9#(o) &!g)!#s!)


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Procedure

The cleaning liquideither aqueous orsolvent is flled in thetank

The transducer mountedat the bottom o the tankor generation oultrasonic !ave

The vibrations are

transerred into theliquid medium throughthe stainless steel tank"cavitations ormation#


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APPLICATIONS IN T'EAPPLICATIONS IN T'E

PLANT OPERATIONPLANT OPERATION

'ii) Filter *leaning

! to remove plugging materials in filter pores.

'i) ube53late *leaning 'reboiler% heat e6changer% condenser

and column pac&ing)

! to remove scale and fouling materials

+/+$i$) #$ #/+"ati#$ "+7*i"++$t8 *!t"as#$i% t+%h$i7*+

has -i+ a//!i%ati#$s /a"ti%*!a"!9 t# i/"#+ /"#%+ss

+i%i+$%98 "+t+$ti#$ ti+ a$ %#st. '#-++" #" %!+a$i$)

a$ ai$t+$a$%+ /*"/#s+s8 th+ t+%h$i7*+ is +"9 *s+*!#":


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P"#%+*"+s # U!t"as#$i% C!+a$i$)

4aterial

*ompatibility

0cale

nalysis3lanning

*hemical

0election

2esign7ayout

7ayoutpproval

2evelop3rocedure

2evelop0

9undle

"emoval

9undle

-nstallation

:quipment

-nstallation

*hemical

0oa&ing

*leaning ;

4onitoring

0cale

nalysis

9undle

7ifting

9undle

"insing

1st. 0tage

#nd 0tage


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A.A. 9$ai%s U!t"as#$i% C!+a$i$) S9st+UCS;9$ai%s U!t"as#$i% C!+a$i$) S9st+UCS;

F!#- S+7*+$%+s P


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System Specification


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S(STE CONFIGURATIONS(STE CONFIGURATION

Fi+ ai$ s+%ti#$ # UCS8 %#/"is+s #:

1; Li7*i %#$tai$+"

! U>F accumulation tan&

! =? 2iameter @ A? (eight! 4ade of 00


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2; Pi/+ itti$)s s+%ti#$

!4aBor piping and overflow piping is fabricated from 1C 00


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3; U!t"as#$i% Bath S9st+ S+%ti#$

! ' *onsist of custom made flanges% drive shaft% pipe soc&ets% rabbitclamps and fle6ible hose.

2U*0 custom made parts at

outlet flow loop were install

together with e6isting U0 bath.


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4; P*/i$) S+%ti#$' *onsist of one *entrifugal 3ump and 2iaphragm pump that used

to pump the U>F to the UCSand to recycle overflow of U>F bac& to

the accumulation tan& respectively.

*entrifugal 3ump

2iaphragm 3ump


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5; I$st"*+$tati#$ S+%ti#$!*onsist of :lectromagnetic Flowmeter% 3ressure 0ensors%

overflow level sensor and analog pressure gauges.

3*E

>utlet 3ressure

ransducer

-nlet 3ressure

ransducer

-nlet :lectromagnetic

Flowmeter

3ressure auge


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Tube Bundleafter cleaning

Tube Bundlecleaning skid

Chemicalholding tank

Cleaning Bath


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Tube Bundleduring

cleaningprocess

CleaningBath

Chemical

TubeBundleafter

cleaning


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'OTOR* C+EA* PER,OR'ACE

During the cleaning operation, parameters such as inlet and outlet pressures of

the bundle, pump flowrate and air intake for diaphragm were monitored closelyand recorded. There are three level of cleaning can be observed from theflowrate profile.

(i) Fillup period

- Accumulation of UOF in the system and

establishment of flow regime

(ii) Removal and Cleaning period

- the period where plugged catalyst is being removed

either by chemical or shear effect.

- cleaning will take place 10-20 hours dependingon the nature of bundle and UOF solution.

(iii) Stabilization and Flux Measurement Period`

- the cleaning is complete

- Measurement of average bundle permeability and flux


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E-A+UATO O, C+EAED .UD+E

:valuation is divided into three methods.

'i) 3ermeability and Flu6 4easurement

! records inlet flowrate% flu6% and pressure from the cleaning

! use 2arcy?s equation to calculate the final permeability.

! plot flu6 profile on semilog graph to verify the quality tube bundle.! compare the final flu6 and calculated permeability to original

values from manufacturer.

! updated the latest values in the process flow sheet.

,


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Evaluation of Cleaning Effectiveness

(i) Permeability and Flux Measurement

F!*3 P"#.i!+

$.$1

$.1

1

1$

$ + 1$ 1+ #$ #+

(ours

9undle


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'ii) 3ore >bservation

! his is a microscopic evaluation of cleaning effectiveness.

! 0mall specimens from tube samples of each bundle are

prepared for the analysis.

! For each tube sample% small specimens diameter

appro6imately !A mm are prepared for the 0canning:lectron 4icroscope '0:4) and :lemental 2iffraction @!"ay

':2@) nalysis.


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Figure below show photos of pores structure

before and after cleaning. he photos wereta&en at $$ times magnification.

9efore fter


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Figure below shows configuration of plugging

ta&e place in the tube.

$$6 4agnification #$$$6 4agnification


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Figure below shows the characteristic of

damaged tube bundle.

9efore *lean fter *lean


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'iii) U>F :lemental nalysis

! >bBectives of the analysis are

'i) to determine the content of copper chromite in thesolution during cleaning.

'ii) to determine the reactivity of solution with filter

materials

'iii) to identify the lifetime of U>F solution

:lemental analysis was conducted on used U>F samples after

cleaning process of every tube bundle completed.

Four elements shall be analyed

'i) copper '*u)%'ii) Jic&el 'Ji)%

'iii) *hromium '*r)

'iv) Ferrous 'Fe).


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Table : Quantitative Analysis Report of UOF Solution

Sa/!+ I C#//+")>L;

Ni%?+!)>L;

Ch"#i*)>L;

F+""#*s)>L;

>riginal U>F $.$#'927) $.$#'927) $.1'927) $.1$'927)

U>F1 9undleLF# 9undleLF= 9undleL#= #A=.#8 $.# $.H1 1=.IA

U>F 9undleL1I

#8


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BENEFITS

"educes costs of cleaning% manpower% new bundles

and maintenance.

:stimated saving "4# millions a year

0horten period of maintenance from H days to 18 hours.

"educes of ris& e6posed to to6ic and haardous chemicals.

he technique used friendly chemical i.e. U>F "emover

Used U>F "emover has moderate properties that meet

:0 specification.


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B. '+at E%ha$)+"> R+,#i!+" T*,+ Et+"$a!>I$t+"$a! C!+a$i$);

"eboiler ube

3ortable un

ransducer

Ultrasonicsenerator

7iquid 'water)

Frequency

*onverter

ransducer

'immersed)


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Sta,i!i+" R+,#i!+" T*,+ Et+"$a!>I$t+"$a! C!+a$i$);

= P+t"#$as P+$a/isa$ +!a?a; S$. Bh.'M.*ontinue)

-nlet :lectromagnetic

Flowmeter

4anager

>perator holding

3ortable ransducer

(arness. 'ood 3ractices)

"uptured bubbles

'cavitation)

*leaned

0ection


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9undle cleaned with

ultrasonic and U>F

chemical

*lose!up view

7ifting from Nater 9ath. "eady

for (ydroBet '"inse)


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7oosen 0cale

4odel Faces


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BENEFITS

"educes costs of cleaning% manpower and maintenance.

:stimated saving =$O of ordinary cleaning cost

0horten period of maintenance to 8 hours.

-ncrease heat transfer efficiency up to $O. "educesflowing pressure drop up to =$O.

"educes of ris& e6posed to to6ic and haardous chemicals.

he technique used friendly chemical i.e. >6ide5*o&e "emover

Used U>F "emover has moderate properties that meet

:0 specification.


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C. ULTRASONIC APPLICATIONS

'i) Ultrasonic *avitation '*lamping ype)

$ % & P E '

$ % & P E '


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/ii1 U$t)#soni" C#9it#tion /I33!)si%$! T2(!1

$ % & P E '


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'iii) Ultrasonic *avitation '3lug!in ype)

$ % & P E '

$ % & P E '


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Ultrasonic Application 1