+65 6863 3231 ekjcheng@acmvtech.com

Automatic Tube Brush (ATB) Cleaning System

For The Commercial and Industrial Buildings of Today, The Highest Consumption of Energy Is From Operation of Air-Conditioning. Water Cooled Chillers is Predominantly use in such Buildings. The Efficient Operation of Water-Cooled Chillers Should Be The Major Concern of All Building Owners and Users.

ACMV Automatic Tube Brush System Plays An Important Role In Keeping The Heat Exchangers of Water Cooled Chillers Clean and Efficient and Contribute Towards the a Major Savings in Energy Use.

ACMV – Automatic Tube Brush Is a System That Cleans Internal Tube Surfaces Of Heat Exchangers At the Water Side. Assured And Automatic Operation Ensure the Heat Transfer Efficiency All The Time.

– ATB is a Singapore Green Mark Product

Benefits
  • 365-days Automatic Cleaning of Heat Exchanger Tubes
  • Reduce Manual Cleaning Time And Frequency by 90%.
  • Maintain High Efficiency Or Keep Low kW/TR For Old or New Chillers.
  • Reduce The Cost Of Water Treatment.
  • Prolong the Life of  Heat Exchanger Tubes.
Design Features
  • Assured Cleaning of Heat Exchanger Tubes By Dedication of Every Tube With a Cleaning Brush. Cleaning is Assured and not  Random or by Probability in order to Achieve the Highest possible heat exchanger efficiency.
  • Reliable and Consistence Performance.
  • Lowest Cost of Service and Maintenance.
  • Long Life Span of Brush (5 Years)
Applications

ATB system is suitable for all chillers in location such as

  • High or Low Rise Office Buildings
  • Hospitals
  • Hotels
  • Data centers
  • Churches
  • Cold Storages with Central Chillers
  • Factory Buildings
  • Laboratories
  • Storage Warehouses
Product Range and Customization Features

Sizes – Condenser Water Inlet And Outlet Connection
4″ to 20″

Operating Pressure
10 Bar to 25 Bar

Actuator Type (Note: Pneumatic is Possible Only In The Presence of Air Compressor On Site.)
Electric or Pneumatic

Input supply
Available For All Standards

Piping connection type
Grooved Coupling or Flanged

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ATB (Automatic Tube Brushing System)

Application

  • HVAC-CHILLER Automatic cleaning to ensure constant efficiency throughout the life of the equipment.

Benefits

  • Saving in Energy
  • Saving in Maintenance
  • Reduction in Chemicals
  • Reduction in Downtime

Heat exchanger tubes begin to foul-up the moment it starts to operate. Fouling in heat exchanger tubes not only reduces cooling capacity, energy usage would be higher than the intended design condition. With the automatic tube brushing system, energy consumption can be reduced by up to 30 percent.

Chillers operating in high ambient temperature particularly face compromise in cooling capacity with increase heat exchanger fouling.

Saving In Energy

Heat exchanger tubes begin to foul-up the moment it starts to operate. Fouling in heat exchanger tubes not only reduces cooling capacity, energy usage would be higher than the intended design condition. With the automatic tube brushing system, energy consumption can be reduced by up to 30 percent.

Chillers operating in high ambient temperature particularly face compromise in cooling capacity with increase heat exchanger fouling.

Saving in Maintenance

The automatic tube brushing system brushes the heat exchanger tubes 3 to 4 time daily. Regular manual brushing or high-pressure cleaning and chemical cleaning of heat exchanger tubes becomes unnecessary or is eliminated entirely.

Reduction in Chemicals

When heat exchanger tubes are badly fouled, normal chemical water treatment needs the most aggressive introduction of chemicals which often leads to greater heat exchanger corrosion. When heat exchanger tubes are kept clean daily by the automatic tube brushing system, expensive chemical cleaning can be avoided and chemicals used in the normal program of water treatment reduced.

Reduction in Downtime

Downtime due to scheduled or unscheduled cleaning of heat exchanger tubes are often an expensive exercise for the manufacturing plants. Plants forced to carry out maintenance on the heat exchanger tubes need also to shut down the rest of the production processes leading to lost in production time. The automatic tube brushing system maintains the fouling of the heat exchanger at an acceptable level reducing the downtime needed for heat exchanger maintenance.

How The Tube Automatic Brushing Systems Works

Baskets are installed at both ends of every available heat exchanger tube. A brush is assigned to each tube and resides in the basket which holds and captures the brush as it moves in a spinning motion from one end of the tube to the other.

By tuning from Normal Position to Reverse Position and back again, the 4-way diverter valves installed in the pipeline changes the water flow in the heat exchanger which causes the brush to move back and forth and clean the tube in the process.

The movement of brush from one end of the tube and back again is a complete brushing cycle. The 4-way diverter valve changes position 3 to 4 times daily in every interval of 6 to 8 hours to activate 3 to 4 brush cycles in a 24 hour day. The 4-way diverter valve is kept in a reverse position only 30 seconds in every brush cycle.

A control panel provided activates the brushing cycles automatically by turning the 4-way diverter valve while the chiller is online –  brushing the tube clean without the need to shutdown the chiller.

Condenser Automatic Tube Cleaning System

 

 

 

 

Ball System

Disadvantages of Ball System
Random Movement and Probability Cleaning of Balls Result in Many Heat Exchanger Tubes Being Not Clean and Getting Dirty and Result in Balls Being Stuck in Tubes.
There is no assigned ball for each individual tubes to ensure all tubes are cleaned. Tubes closest to condenser inlet and outlet receive many ball entries while tubes in peripheral area receive least amount of ball entries. When tubes are not cleaned regularly, fouling forms in these tubes that cause balls to clogged in these tubes.
Balls clean tubes by gathering dirt onto its own body. The dirty balls increase in size and are also unable to squeeze pass through the entire length of the tube.

Condenser with 2 Different Sizes of Tubes

When condenser heat exchange have 2 different sizes of tubes, 2 different ball sizes can be use to match the different tube sizes.
Small balls match for small tubes when they enter the bigger tubes will result in no cleaning of the bigger tubes.
Bigger balls will eventually wear out and become small enough to enter small tubes but still not small enough to entirely pass through the length of the small tubes. This will result in in balls stuck in smaller tubes. The smaller tubes can be about 10% or more of the total tube population. When 10% or more of the tubes are obstructed and received no water flow, the heat exchanger will be severely compromised.
Condenser Cover Divider Plate Partially Covering Part of Condenser Tubes in the Center Rows of Condenser Heat Exchanger resulting in Ball Being Jam at the Mouth of Tube Opening and Prevent Water from Flow Through These Tube
Balls will attempt to enter the partially obstructed tubes by the condenser cover divider plate at the centre of the condenser. This balls that are jammed at the mouth of these tubes will cause water not to flow. The tubes population at the centre row of the condenser heat exchanger is often at least 10% of the total tube population. When water is not flowing through these tubes the heat exchanger will be severely  compromise.
Peripheral Tubes of Heat Exchanger will Receive Much Fewer Balls Resulting on Dirtier Tubes in Peripheral Area
Balls enter and leave Heat Exchanger through the Condenser Water Inlet and Outlet. Tubes that are closest to the opening of condenser water inlet and outlet receive the most amount of entering balls as water nearest the condenser water inlet and outlet is the fastest moving. The peripheral tubes with slower moving water experience fewer and less frequent ball entry resulting in dirtier peripheral tubes.
Balls Entering Tubes that are dirty will result in balls being clog along the length of the tubes and block condenser water from being able to flow in these tubes.
Peripheral Tube quantity can be as much as 50% of the total tube population. When these tube are dirty not only will the heat exchanger effectiveness be compromised, it will result in balls not being able to fully pass through these tubes and obstruct the  water flow of the tubes.
The random movement of the balls and not being able to target cleaning of all tubes results not only in unreliable cleaning but also results in affecting the proper heat exchanger function of the chiller and eventual increase in energy cost to operate the chiller failing the ball system original intended objective to reduce the energy use or at least keep energy increase at bay.
Balls Clog at Ball Catcher Outlet and Rest of Balls Block the Rest of Opening of Strainer. Worn Out Balls Escaping Pass the Ball Strainer.
Balls leave the Ball Catcher through a opening usually about 2 to 3 inch. Typically ball sizes are about 5/8 inch in diameter. As many balls rush out through this opening, it takes only a hand full of balls to clog an area of 2 to 2.5 inch. When the strainer outlet opening is obstructed the rest of balls will plug the opening of the strainer and result in reduce flow through the strainer and eventually reduction in water flow leaving the condenser heat exchanger.
The Ball Catcher is inline to condenser water outlet pipe. The Ball Catcher not only catches the balls but also catch large amount of dirt, cooling tower infill, rust bits etc that will reduce the condense water flow.
The Inline Ball Catcher will eventually need to be removed for cleaning.

ATB 4-Way Diverter Valve Typical Mounting Positions

"H" Style Horizontal Mounting

"H" Style Horizontal Mounting

"H" Style Vertical Mounting

"H" Style Vertical Mounting

"LA"

"LA" Style

"LD" style

"LD" Style

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Address

ACMV Pte Ltd
9,Tuas South Avenue 10
#02-16 T99
Singapore 637014

ACMV Technology Sdn Bhd
Setia Business Park
8, Jalan Laman Setia 7/3
Taman Laman Setia
81550, Johor Bahru

Phone

+65 6863 3231
+60 75950893

 

Email

ekjcheng@acmvtech.com
hariharan@acmvtech.com