How to Clean the Condenser ? Maintenance Method for Condenser

The condenser is mainly a heat exchanger for environmental chamber, and the coolant is mainly circulating water, and the circulating water accounts for about 90% of the industrial water consumption. Different environmental chamber systems and different uses require different water quality. If you don’t know how to clean the condenser, If you want understand some maintenance method for condenser, This guidance article is a great choice for you !

In the factory, cooling water is mainly used to condenser system and cool products or equipment. If the cooling effect is poor, it will affect the production efficiency. Reduce the product’s defective rate and product quality, and even cause production accidents. Cooling water used by various industrial sectors has basically the same requirements for water quality. This has led to the rapid development of cooling water control as an application technology.

Let me explain how to clean the condenser ? The function, classification, operation technology of the condenser, maintenance method, troubleshooting method. Please keep to read below contents. If you have any question there, Please don’t hesitate to contact with us by email. We will answer your questions when we have received your mail. Thank you.

● The removal method of condensing temperature is too high. (Condensation temperature: the condensation temperature of the refrigerant in the condenser) ● Insufficient amount of cooling water: the high-temperature gas discharged from the compressor can not effectively reduce the temperature, so that the condensing temperature increases, it should add enough water ● The temperature of the cooling water is too high: the high-temperature gas discharged from the compressor can not perform heat exchange well, so that the condensing temperature rises, so it is necessary to take appropriate cooling measures for the cooling water ● The degree of vacuum and dryness of the refrigeration system is low, so that the condensing temperature is increased. Solution: The vacuum degree of the system should be increased. ● Condensation temperature is too high ● The amount of refrigerant in the system is insufficient: The refrigerant should be added according to the instructions ● Cooling water temperature is too low or the water flow rate is too high: It should be adjusted according to the coldness and temperature difference ● Condensation temperature is too low ● The scale formed in the condenser is mainly composed of a large amount of Ca, Ma and Na elements in the cooling water, bicarbonates, sulfates and chlorides, silicon dioxide and other impurities. The existence of these substances makes the water have a certain hardness, and after forming scale, the flow resistance of water increases ● As the heat exchange efficiency decreases, the condensing temperature increases, the cooling capacity decreases, and the power consumption increases. Severely caused the wall to become eroded. ● In order to prevent such accidents, clean water should be used. If the water quality does not meet the requirements, chemical water treatment should be used . If the cooling water is seawater, measures shall be taken in the design to prevent the seawater from corroding the pipelines and equipment and the adherence or blockage of aquatic organisms and plants in the seawater to the pipelines and equipment. ● Condenser too much scale

Condenser Troubleshooting Method

● First estimate the amount of detergent liquid Method 1, According to the condenser heat transfer area and scaling thickness × scale specific gravity after calculating the weight of × 4 is the amount of cleaning agent; Method 2, After the volume of the condenser and the volume of the cleaning line, ÷4 is the initial amount of cleaning agent; ● According to the condenser volume of the condenser, prepare a container for the cleaning agent, which can meet the circulation requirements. The inner surface of the container requires a clean and non-oxidized layer or a non-metallic material container; ● According to the internal circulation pressure requirements of the condenser, prepare an industrial centrifugal pump for circulation (pressure is not less than 3 kg), prepare the connecting line for the pump and the heat exchanger and the container, and if necessary, make a flange connection; ● Isolate the equipment system and discharge the water inside the condenser; ● After high-pressure water is used to clean the sludge, algae and other impurities left in the pipeline, according to the company’s requirements, hang the corresponding test piece in the system to test the dynamic corrosion rate and close the system. ● Ball valves (not less than DN25) shall be installed between the isolation valve and the exchanger, and the inlet and outlet shall be installed. Connect the transfer pump and connecting pipe to pump the cleaning agent from the bottom of the condenser and out from the top; ● Start pumping the required Intellilite cleaner into the condenser (the ratio can be adjusted according to specific conditions); ● Repeated cycle cleaning to the recommended cleaning time. As the circulation progresses and the sediment dissolves, the gases generated during the reaction increase, and excess air should be discharged through the purge valve at any time. ● With the discharge of air, the space in the condenser will increase, and appropriate water can be added. Do not inject large amounts of water at the beginning, which may cause water overflow; ● Periodically check the effectiveness of the cleaning agent, you can use PH test strips to determine. If the solution is maintained at pH 2-3, the cleaning agent is still effective. ● If the pH of the cleaning agent reaches 3 or more, it is necessary to add an appropriate amount of Intellitel cleaner. The pH of the final solution remained unchanged at 2-3 for 30 minutes, demonstrating that the cleaning effect was achieved; ● After the cleaning time is reached, the cleaning solution is recovered. And rinse the exchanger repeatedly with clean water until it is flushed to neutrality. Use PH test paper to measure PH value 6~7; ● After the cleaning is completed, it can be turned on. You can also press the test to see if there is a leak; ● After the equipment is stable, record the current media over flow, working pressure, heat transfer efficiency and other data; ● Comparing the changes in values before and after cleaning, it is possible to calculate the electricity costs, coal costs and other production costs saved by the company per hour and improve the work efficiency; ● If the company needs equipment for passivation prefilming, it can be operated according to the following process: ● The passivation pre-filming agent is pumped into the device at a 0.8% dilution (while the test piece is hung in the circulation tank), ● After 2 hours of cycle and 1 hour of soaking, the cycle cleaning is carried out for a total of 2 cycles. ● Continue soaking for about 10 hours (you can extend or shorten the soaking time according to the cleaning requirement) ● Detection of pre-film effect (carbon steel using the red dot method: copper sulfate reagent does not appear in the red spot within 6 seconds micro-pass, stainless steel using the blue spot method: potassium ferricyanide reagent within 10 minutes, no more than 8 blue spots as qualified) — Emissions — Water flushed to neutral (PH value 6 to 7 with PH test paper); ● After the passivation of the pre-filming, it is best to dry the system with a ventilating device such as a fan to ensure and enhance the passivation pre-filming effect. ● Note 1, Safety protection must be done before cleaning, such as wearing goggles, masks, rubber gloves, etc. ● Note 2, In the cleaning process, if the cleaning agent splashes into the eyes, flush with plenty of water immediately; ● Note 3, If milk is ingested during the cleaning process, milk should be quoted quickly; During the cleaning process, stainless steel standard test pieces can be hung into the cleaning container for corrosion rate detection; ● Note 4, After cleaning, the waste liquid can be recycled or neutralized and discharged into the sewage system for disposal.

Condenser Clean Procedure

● The saturated liquid of the refrigeration unit is cooled to a supercooled liquid. At the end of the condenser, the saturated liquid is further cooled to become a supercooled liquid, the pressure remains constant and the temperature is lower than traditional knowledge. ● This process also occupies a small part of the heat transfer surface of the condenser. Supercooled liquids are important for refrigeration systems, It can make the refrigerant between the capillary inlet or the expansion valve without generating steam, which is beneficial to improve the cooling effect. ● According to different cooling media, condensers can be divided into two major categories: air-cooled (air-cooled) and water-cooled. Household air conditioners and other small air-conditioning refrigeration equipment are used in air-cooled, water-cooled type is mainly used for large and medium-sized refrigeration equipment. ● Dry saturated steam condenses into a saturated liquid. When dry saturated steam flows in the tube, it condenses into a saturated liquid due to gradual heat release, and Pk and tk remain unchanged throughout the process. ● This is the main exothermic process in the condenser, most of the heat (latent heat) is released by this process, it takes up most of the heat transfer surface of the condenser. In this process, the refrigerant is gas and the two phases of the liquid coexist. ● Superheated steam is cooled to dry saturated steam. After the superheated steam enters the condenser, the exothermic initial stage, from the exhaust temperature to the condensing temperature, becomes dry saturated steam, and the pressure and temperature are Pk and tk, respectively. ● This process only takes up a small part of the heat transfer surface of the condenser. The fins of the condenser are mainly divided into slit type, corrugated row and plate type. ● Among them, the slit condenser works best, and its thermal efficiency is 1.6 times that of the corrugated line type. Due to its small size and light weight, it is widely used in room air conditioners.

Condenser Function

● Water-Cooled Type ● Air-Cooled Type ● Evaporation and Showering

Condensers Classification

● In water-cooled condensers, the heat released by the refrigerant is carried away by the cooling water. Cooling water can be passed through once or recycled. ● When using recycled water, a cooling tower or a cold pool is required. The water-cooled condenser has shell tube type, sleeve type, immersive type and other structural forms. ● Water-cooled chiller condenser is commonly used shell and tube condenser, shell made of 5mm thick steel pipe made of rust-proof treatment, pressure 20Kg/cm2. ● The heat exchange pipe adopts a highly efficient and efficient seamless copper pipe with a withstand voltage of 10 Kg/cm2. Both ends of the cover can be interchanged to change the direction of the water pipe, and the water flow is multi-loop. ● Each condenser and the capacity of the compressor cooperate with each other, the total heat transfer coefficient should be able to tolerate 0.00005Kcal/h square centimeter °C-1 fouling factor, condenser water pressure drop does not exceed 6.5mAq, straight-through water pipe easy to clean and maintain.

1. Water-Cooled Type

Condensers Types

● In an air-cooled condenser, the heat released by the refrigerant is carried away by the air. Its structure mainly consists of several groups of copper pipes. ● Due to poor air heat transfer performance, fins are often added outside the copper tube to increase the heat transfer area on the air side. At the same time, a ventilator is used to accelerate air flow and forced air convection to increase heat dissipation.

2. Air-Cooled Type

Condensers Types

● In this type of condenser, the refrigerant condenses inside the tube and the outside of the tube is simultaneously cooled by water and air. ● The evaporation and showering condenser as below photo mentioned. If you are not sure which cooling type condenser you need, Please inquiry to us !

3. Evaporation and Showering

Condensers Types

● First, when the refrigeration system is operating, all the valve parts of the condenser except the drain valve and the air release valve should be opened. ● Second, the maximum condensing pressure of the water-cooled condenser should not exceed 1.5 MPa (reference value). Otherwise, the cause should be ascertained and eliminated in time. 15 minutes after the compressor has been completely shut down, water supply to the condenser may be stopped. When the water is stopped for a long time in winter, the water should be kept clean to prevent freezing of equipment. ● Third, constantly check the cooling water temperature and water volume, cooling water inlet and outlet temperature difference is about 2-4 records, the general condensing temperature is higher than the cooling water outlet water temperature 3-5 °C. ● Fourth, the dirt on the condensing pipe wall should be regularly removed. The thickness of the dirt should not exceed 1mm, and it is usually cleaned once a year. ● Fifth, oil pollution occurs when fluorine leaks from the condenser. Should be promptly overhauled. ● Sixth, the placement of the vertical shell-and-tube condenser water separator should be appropriate. The water should be evenly distributed along the inside of the pipeline and the amount of water should be sufficient. ● Seventh, the cooling water of the horizontal shell-and-tube condenser should be taken in and out, and the cooling water must not be interrupted during operation. ● Eighth, when the evaporative condenser is in operation, the exhaust fan and the circulating pump should be started first, and the intake valve and the discharge valve should be opened. The water spout should be unobstructed, spray water should be even, and scale should be cleaned once a year. ● Ninth, the air-cooled condenser should always use compressed air to clean the dust on the wall and radiating fins to improve heat transfer efficiency. ● Tenth, when several condensers are used in combination, the number of condensers, the amount of cooling water required, and the number of pumps to be operated must be determined based on the parameters such as compressor load and cooling water temperature.

Condenser Operation Technology

● Cooling capacity + Compressor motor power / 200 ~ 250 = Condenser heat exchange surface ● For Example: (3SS1-1500 compressor) CT = 40 °C: CE = -25 °C Compressor cooling capacity = 12527W + compressor motor power; ● 11250W =23777/230 = Wind condenser heat exchange area 103m2 ● Wind condenser heat exchange area calculation method The area of the evaporator is based on the compressor cooling capacity (look-off coefficient of evaporation temperature °C x Δt relative humidity). ● Water condenser heat exchange area and wind condenser ratio = estimated 1:18 (103 / 18) = 6m2 For Example: There is a quick-freeze library 1 Kuwen-35°C 2 Quick-freezing amount 1T/H 3 Times 2/H 4 Quick-frozen substances (fresh fish) 5 Ambient temperature 27 °C 6 Equipment maintenance organization insulation board Calculation: 62°C×1000/2/H×0.82×1.23=31266 kcal/n 7 Can check compressor evaporation temperature CT=40 CE-40°C cooling capacity=31266 kcal/n ● Calculation method of cooling capacity: = Temperature difference × Weight / time × Specific heat × Equipment maintenance organization

Condenser Heat Transfer Area Calculation Method

For some applications, the gas must pass through a long tube (usually coiled into a solenoid) so that the heat is lost to the surrounding air. Thermal conductive metals such as copper are often used to deliver vapor. In order to increase the efficiency of the condenser, heat sinks are often added to the pipes to accelerate heat dissipation.

The heat sink is a flat plate made of a good heat-conducting metal. This type of condenser generally also uses a fan to force air through the fins and walk the tropics. In the refrigeration of a general refrigerator, the role of the compressor is to compress the lower pressure steam into higher pressure steam, so that the volume of the steam is reduced and the pressure is increased.