Method and device for cleaning tube bundles

Abstract

A method and a cleaning device for cleaning tubes of tube bundles, wherein at least one rotating cleaning lance is used. During the insertion of the cleaning lance, the insertion depth E of the cleaning lance is measured and is stored and documented in a storage and documentation device. The cleaning device has an XY displacement device, on which a support rail is arranged, which supports a cleaning apparatus.

Claims

1. A method for cleaning tubes of a tube bundle, wherein each tube of the tube bundle comprises an open end at an end face of the tube bundle, and wherein the method comprises the steps of: positioning at least one cleaning apparatus adjacent to the open ends of the tubes of the tube bundle, wherein the cleaning apparatus comprises a cleaning device with a cleaning lance, arranging the cleaning lance along a travel path successively aligned with each tube of the tube bundle, placing the cleaning lance in rotation and inserting the cleaning lance into each tube and also supplying the cleaning lance with liquid under a pressure of between 25 bar and 3000 bar, measuring and monitoring a depth of insertion E of the rotating cleaning lance for each tube of the tube bundle during the inserting of the cleaning lance into each tube of the tube bundle, and saving, processing, and documenting the depths of insertion E in a storage and documentation device such that a three-dimensional cleaning profile of the tube bundle is produced, wherein the three-dimensional cleaning profile comprises depths of insertion information for the tubes of the tube bundle, and wherein the measuring of the depth of insertion E is done by a driving device of a propelling device of the cleaning lance.

2. The method as claimed in claim 1, wherein the cleaning method is carried out in a semiautomatic or fully automatic way.

3. The method as claimed in claim 1, wherein the cleaning apparatus comprises a plurality of cleaning devices, wherein the plurality of cleaning devices comprises a plurality of cleaning lances that are inserted at the same time into neighboring tubes, and wherein depth of insertion data of each cleaning lance is measured and stored individually.

4. The method as claimed in claim 1, wherein torque values D of the driving device are measured continuously or discontinuously during the inserting of the cleaning lance into the tubes of the tube bundle, wherein the measured torque values D are saved with depths of insertion data, and wherein the measured torque values D are coordinated with depths of insertion data in the storage and documentation device.

5. The method as claimed in claim 4, wherein upon rise in the torque value beyond a given value D.sub.v the driving device is switched off, placed in reverse, switched to a free rinse mode or to a shaking mode.

6. The method as claimed in claim 1, wherein before inserting the cleaning lance into the tubes, the orientation of the cleaning apparatus relative to the tube bundle is determined and orientation data is saved and used for correcting the travel path of the cleaning device.

7. The method as claimed in claim 1, wherein at least the first tube being cleaned for the tube bundle is approached manually.

8. The method as claimed in claim 1, wherein the cleaning lance is shoved with a constant speed of advancement into the tubes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Sample embodiments of the invention shall be explained more closely in the following. There are shown:

(2) FIG. 1 a side view of the cleaning apparatus with cleaning lance not extended.

(3) FIG. 2 the side view of FIG. 1 with cleaning lance extended into a tube of the tube bundle,

(4) FIG. 3 a top view of the cleaning apparatus represented in FIGS. 1 and 2,

(5) FIG. 4 a block diagram to explain the relationship of the different driving devices to the control device and the storage and documentation device,

(6) FIG. 5 a vertical cross section along line A-A in FIG. 1,

(7) FIG. 6 a detail view of the propelling device,

(8) FIG. 7 a top view of the end-face side of the tube bundle with a displacement device according to one embodiment,

(9) FIG. 8 another embodiment of the cleaning apparatus in side view for an upright tube bundle,

(10) FIG. 9 a top view of the cleaning apparatus shown in FIG. 8,

(11) FIGS. 10+11 two different incrustation situations in a tube with corresponding torque diagrams of a servomotor.

DETAILED DESCRIPTION OF THE INVENTION

(12) FIG. 1 shows a horizontally arranged tube bundle 1 partly in cross section, so that the individual tubes 4 of the tube bundle 1 can be seen. This might be, for example, a tube bundle of a heat exchanger, an air cooler, or a condenser. The tube bundle 1 has an open end 5, so that the interior of the parallel arranged tubes 4 are accessible for cleaning from there.

(13) In front of the open end 5 of the tube bundle 1 is arranged a cleaning apparatus 10, comprising at least one cleaning device 12, an XY-displacement device 30, a support rail 40, a supply hose 70, which is connected to a high-pressure device (not shown) for providing a cleaning fluid, and a supporting device 80.

(14) The cleaning device 12 comprises a cleaning lance 14, a propelling device 50 and a rotation device 60.

(15) The XY-displacement device 30 is directly attached to a flange 2 of the tube bundle 1. Such a flange 2 is provided at the end face of the tube bundle 1, in order to secure a cover there (not shown). After removing the cover, this flange 2 can be used for attaching the XY-displacement device 30.

(16) The XY-displacement device 30 comprises two first guide rails 32 extending horizontally, i.e., in the X-direction, and one second guide rail 34, extending vertically, i.e., in the Y-direction. The first guide rail 32 is arranged on the flange 2 of the tube bundle 1 by fastening means 39.

(17) With the help of two first driving devices 36, which also comprise a trolley, the second guide rail 34 can travel in the X-direction on the first guide rail 32 (also see FIG. 3 for this). The support rail 40 is arranged on the second guide rail 34, extending in the Z-direction and oriented perpendicular to the second guide rail 34. This support rail 40 can travel by means of a second driving device, likewise comprising a trolley, along the second guide rail Y.

(18) On the support rail 40 there is arranged a cleaning device 12, comprising the cleaning lance 14, which has a lance tube 17, at whose front end there is arranged a lance tip 15. The lance tip 15 comprises an exit nozzle 16 (see FIGS. 10 and 11) and a cleaning implement, not shown. The lance tip 15 is shown in front of a tube 4.

(19) At the end of the cleaning lance 14 opposite the lance tip 15 there is provided a connection end 18, by which the cleaning lance 14 is connected to a rotation device 60. With the aid of this rotation device 60, which has a fourth driving device 66, the cleaning lance 14 is placed in rotation. At the opposite side of the rotation device 60 there is a rotary feedthrough 62, to which the supply hose 70 is connected for supplying cleaning fluid to the cleaning lance 14.

(20) The rotation device 60 is adapted to travel on the support rail 40. The rotation device is driven by a propelling device 50, having a third driving device 52 at the rear end 42 of the support rail 40. The third driving device 52 drives a driving wheel 53, which drives a driving belt 56, especially a toothed belt. At the front end 41 of the support rail 40 there is provided a deflection roller 54. The driving belt 56 runs inside the support rail 40, designed as a hollow profile, and on top of the support rail 40.

(21) The rotation device 60 is fastened to the driving belt 56 and can thus travel along the support rail 40 in the Z-direction, so that the cleaning lance 14 can be extended into the tube 4, as shown in FIG. 2.

(22) For the supporting of the cleaning lance 14 lance guide elements 46 are provided on the support rail 40. The lance guide element 46 at the front end 41 of the support rail 41 is stationary, while the other two lance guide elements 46 represented are movable on the support rail 40. The lance guide elements 46 are joined together by a flexible connection element 47, such as a cable. When the cleaning lance 14 is introduced (FIG. 2), the lance guide elements 46 are pushed together, and when it is retracted the lance guide elements 46 are again moved apart and positioned at a distance from each other.

(23) The rear end 42 of the support rail 40 engages with a supporting device 80. This supporting device 80 in the embodiment shown here is designed as a suspension 82. This suspension 82 comprises two support frames 83, which are joined together by a crosspiece 88, designed as a running rail. Each support frame 83 has two telescopically extensible support braces 84, which are joined together by a likewise telescopically extensible support frame crosspiece 86.

(24) As can be seen from FIG. 3, a traveling crab 90 can travel freely on the crosspiece 88 or the running rail 88, having a cable winch 92 with a fifth driving device 94. On this cable winch 92 is arranged a hanger means 96 in the form of a cable, at whose lower end a holder 98 is fastened, engaging with the rear end 42 of the support rail 40.

(25) When a horizontal displacement of the cleaning device 12 is carried out by means of the XY-displacement device 30, the traveling crab 90 is pulled into the corresponding position by the cable 96 and by the corresponding movement of the rear end 42 of the support rail 40. When a Y-displacement is carried out on the XY-displacement device 30, the fifth driving device 94 is actuated so that the cable 96 is pulled up or let down appropriately.

(26) Furthermore, one can see in FIG. 3 a top view of the cleaning apparatus 10 represented in FIG. 1. The lower first guide rail 32 is shown by broken line, since this is only used optionally. When the cleaning lance has only a slight length, so that the support rail 40 can also be designed shorter, the lower first guide rail 32 is not required. With long cleaning lances and correspondingly long support rails 40 this second first guide rail 32 should be provided for stability reasons and this should likewise be fastened by fastening means 39 to fastening openings 3, which are provided for the fastening of the cover, on the flange 2 of the tube bundle 1.

(27) The support rail 40 is connected by means of a connection element 48 to the trolley of the second driving device 38. The rotation device 60 has a fourth driving device 66, for example in the form of a pneumatic motor. The rotary feedthrough is designated as 62.

(28) Besides the rotation device 60, another rotation device 60 is shown by broken line. The support rail 40 is likewise shown by broken line, since two cleaning devices 12 may also be arranged next to each other on the connection element 48.

(29) FIG. 4 shows a block diagram representing how the individual driving devices are interconnected with a control device 100 and a storage and documentation device 102. The control device 100 is connected to all five driving devices 36, 38, 52, 60 and 94 and can be activated by means of a remote control 104.

(30) The storage and documentation device 102 may be a self-standing device, but it may also be an integrated component of the control device 100. The third driving device 52 of the propelling device 50 can be connected to a torque measuring device 120. This torque device 120 is likewise connected to the storage and documentation device 102.

(31) A measurement device 110 for measuring the depth of insertion is likewise connected to the storage and documentation device 102. This measurement device according to the embodiment shown in FIG. 1 may comprise measurement markings 118 on the cleaning lance 14, which can be optically detected, for example, by a measurement sensor 112 fastened to the front lance guide element 46. By counting the measurement markings 118 upon inserting the cleaning lance 14 at the tube 4, the depth of insertion E is measured. FIG. 6 shows another embodiment of the measurement device 110.

(32) FIG. 5 shows a cross section along line A-A through the cleaning apparatus 10 represented in FIG. 1, in order to explain the profiled rail guidance of the rotation device 60 and the support rail 40. The support rail 40 is designed as a hollow profile, with the driving belt 56 running inside the hollow profile and being led upward by the deflection roller 54, where it is led on top of the leg 43 of the hollow profile. The rotation device 60 has rail elements 64, which engage with grooves 44 of the hollow profile. The rotation device 60 has a fastening plate 65, which is connected to the driving belt 56, so that the rotation device 60 can travel together with the cleaning lance 14 along the support rail 40.

(33) FIG. 6 shows another embodiment of the measurement device 110. The driving wheel 53 of the third driving device 52 of the propelling device 50 has measurement markings 118 in the form of openings 119, which are detected by a measurement sensor 112. The measurement sensor 112 is fastened to a sensor holder 114 and connected to the storage and documentation device 102. By counting the measurement markings 118, the depth of insertion E is determined.

(34) The driving device 52 is connected to a torque measuring device 120, which is likewise connected to the storage and documentation device 102.

(35) In FIG. 7, two first guide rails 32 are fastened to the flange 2 by way of the fastening means 39. Before the cleaning process is carried out, the orientation of the XY-displacement device 30 to the tube arrangement must be checked. As a rule, the first guide rail 32 may not be arranged parallel to the tube rows 152 on the flange 2, so that an angle offset a occurs. This angle offset a between the parallel line 150 to the first guide rail 32 and the tube row 152 is determined and saved in the control device 100, so that when moving the cleaning device 12 this angle offset a can be considered and factored into the position coordinates X and Y of the tubes 4.

(36) For this purpose, the tube 4a for example is approached manually with the cleaning device 12 and the position is saved. After this, the cleaning device 12 is driven by means of the XY-displacement device 30 in front of the tube 4b and this position is likewise saved, from which the angle of the tube row 152 can then be determined.

(37) FIG. 8 shows another embodiment showing a cleaning apparatus 10 which is mounted on an upright tube bundle 1.

(38) The XY-displacement device 30 corresponds to the XY-displacement device of FIG. 1. A support rail 40 is likewise arranged on the XY-displacement device 30, carrying the cleaning device 12 with lance 14 and rotation device 60. This arrangement likewise corresponds to the embodiment shown in FIG. 1. This also holds for the propelling device 50, which is not represented in FIG. 8.

(39) The supporting device 180 is designed as a stiffening device 182 and comprises two stiffening elements 184, which are connected by a stiffening plate 186 to the support rail 40. The trolley of the second driving device 38 is designed distinctly longer than is represented in the embodiment of FIG. 1, so that the stiffening device 184 can be mounted there.

(40) FIG. 9 is a top view of the embodiment shown in FIG. 8.

(41) In FIGS. 10 and 11 are shown various obstacles in the form of incrustations 200, 202a, b, c inside the tubes 4. Beneath the respective tubes 4 is shown a schematic diagram of the torque D as a function of the distance z.

(42) FIG. 10 shows an obstacle 200 which cannot be dissolved.

(43) The torque D of the third driving device 52 is constant upon inserting the cleaning lance 14 into the tube 4 and it increases abruptly when the lance tip 15 encounters by its exit nozzle 16 an obstacle in the form of an incrustation 200. The torque is detected with the torque measuring device 120, which is arranged e.g. in or on the servomotor of the third driving device 52 (also see FIG. 6).

(44) This rapid increase is represented in the diagram of FIG. 10, this increase also marking the maximum depth of insertion E.sub.M.

(45) This obstacle 200 cannot be removed by means of the cleaning lance 14, so that the cleaning process of the tube 4 is broken off at this point. From the value of the torque D it can be determined that this is an insurmountable obstacle. The corresponding data, such as depth of insertion E.sub.M and torque D, are saved in the control device 100 or the storage and documentation device 102.

(46) FIG. 11 shows two smaller and dissolvable incrustations 202a, 202b and a continuous dissolvable incrustation 200c. When the cleaning lance 14 encounters the incrustation 202a with the lance tip 15, the torque D increases. If it succeeds in loosening the first incrustation 202a, the advancement of the cleaning lance 14 may be continued, so that the torque of the third driving device 52 again drops until the cleaning lance 14 encounters by its lance tip 15 the next obstacle in the form of the incrustation 202b.

(47) If the incrustation 202b there can also be loosened and removed, the torque again drops and the advancement may likewise be continued until the cleaning lance 14 encounters the third dissolvable obstacle 200c. After removing this obstacle 200c as well, the advancement may be continued further.

(48) From the torque curve, represented only schematically, one may therefore determine how intense the fouling or the incrustations 200, 202a, b, c are inside the tube 4. With the aid of the data E.sub.1, E.sub.2, and E.sub.3, one may then also locate the precise position where these contaminations occur.

(49) Thus, with the aid of all the data, a three-dimensional cleaning profile of the tube bundle 1 can be produced, from which the location of the incrustations 200, 202a, b, c and the degree of incrustation or fouling can be determined.

(50) A sample sequence of the cleaning of a tube bundle 1 may occur as follows:

(51) The individual guide rails 34,36 are delivered together with the cleaning device(s) 12 and the control device 100 and assembled on site to form a cleaning apparatus 10. First of all, the first guide rail 32 is mounted on the tube bundle 1 and then the second guide rail 34 is mounted on the first guide rail 32.

(52) The benefit of the cleaning apparatus 10, among other things, is that the guide rails 32,34 can be mounted on both horizontally oriented tube bundles 1 and on vertically oriented tube bundles 1. The cleaning apparatus 10 is far more flexible in application than the tube cleaning devices of the prior art, which are mounted for example on a wagon that has to be driven in front of the tube bundle 1 being cleaned, which is only possible in the case of horizontally arranged tube bundles 1.

(53) Next, we determine the angle offset a and lay out the work zone. For this, we drive to four corner points situated outside of the tube bundle 1. The end face of the tube bundle 1 is then located inside the work zone in which the cleaning device(s) 12 can travel.

(54) When this is a first-time cleaning process for a tube bundle 1, it is necessary to enter the geometry data in the control device 100. If this geometry data of the tubes 4 has been provided by the operator or manufacturer of the tube bundle 1 and has then been entered in the control device 100, the cleaning process may be started after the data entry, with the cleaning process starting for example at a reference tube 4c (see FIG. 3), which is approached manually. This may be, e.g., the first tube 4 of the first row of a tube bundle 1. The reference tube 4c may also be any given tube 4 of the tube bundle 1. If no geometry data is available, the geometry data is determined on site by means of a manual approaching of the tubes 4, and preferably the tubes 4 are also cleaned at the same time.

(55) If the cleaning device 12 drives up to a tube 4 which is closed with a plug, the cleaning lance 14 cannot be inserted into the tube 4. Corresponding information is then assigned to this tube 4, that the cleaning lance 14 was not able to enter it. This data is then saved in the storage and documentation device 102.

(56) If the cleaning lance 14 can be inserted into the tube 4 being cleaned, there are two possibilities. Either the cleaning lance 14 can be pushed in entirely to the opposite end of the tube 4. The cleaning may then take place as planned and this cleaning outcome is likewise documented by saving the raw data and the maximum achieved depth of insertion L.sub.E.

(57) If the tube 4 can only be partly entered, the cleaning does not take place as planned. The maximum achieved depth of insertion E.sub.M and optionally the occurring torques D are determined, so that further inferences can be made as to the degree of fouling. This data as well is then saved in the storage and documentation device 102.

(58) If it is successful in removing the fouling by means of the inserted cleaning lance 14, this also is saved and documented.

(59) When all tubes 4 of a tube bundle 1 have been approached, the cleaning process is finished.

(60) The method according to the invention ensures that no tube is accidentally forgotten, as may be the case with a traditional manual cleaning of the tubes. Furthermore, the cleaning method is distinguished in that the cleaning processes in the tubes can be carried out with any desired speed of advancement of the cleaning lance and the cleaning implement, so that no abrupt changes or interruptions in the cleaning occur.

(61) When several cleaning lances 14 are used at the same time, the cleaning time is further shortened. The cleaning device 12 will only move on when all cleaning lances 14 have left the tubes 4 approached by them. Especially when, for example, one of the cleaning lances 14 has been retracted ahead of time due to an insurmountable obstacle, it must wait for the other cleaning lance or lances 14 to have performed a complete cleaning of its (their) tubes.

LIST OF REFERENCE NUMBERS

(62) 1 Tube bundle 2 Flange 3 Fastening openings 4 Tube 4a,b,c Tube 5 Open end of tube bundle 10 Cleaning apparatus 12 Cleaning device 14 Cleaning lance 15 Tip of cleaning lance 16 Exit nozzle 17 Lance tube 18 Connection end 30 XY-displacement device 32 First guide rail (X) 34 Second guide rail (Y) 36 First driving device with trolley 38 Second driving device with trolley 39 Fastening means on flange 40 Support rail 41 Front end 42 Rear end 43 Leg 44 Groove 46 Lance guide element 47 Flexible connection element 48 Connection element 50 Propelling device 52 Third driving device 53 Driving wheel 54 Deflection roller 56 Driving belt 60 Rotation device 62 Rotary feedthrough 64 Rail element 65 Fastening plate 66 Fourth driving device 70 Supply hose 80 Supporting device 82 Suspension 83 Support frame 84 Support brace 86 Support frame crosspieces 88 Crosspieces, running rail 90 Traveling crab 92 Cable winch 94 Fifth driving device 96 Suspension means, cable 98 Holder 100 Control device 102 Storage and documentation device 104 Remote control 110 Measurement device 112 Measurement sensor 114 Sensor holder 118 Measurement markings on cleaning lance 119 Opening 120 Torque measuring device 150 Parallel line 152 Tube row 180 Supporting device 182 Stiffening device 184 Stiffening element 186 Stiffening plate 200 Incrustation 202a,b,c Incrustation