G K Infra Engineers
Engineers who make the world
E-18/A, GROUND FLOOR, SECTOR-8, NOIDA-201301 (U.P.), Mob.: +91-9873002807
E-mail :
[email protected] | Website : www.gkinfraatcs.com
Automatic Tubes Cleaning System
A 100% CHEMICAL FREE ENVIRONMENT FRIENDLY
CONDENSER TUBES CLEANING SYSTEM
SAVE ENERGY SAVE MONEY SAVE ENVIRONMENT
SCALING ENEMY OF EFFICIENCY
EFFECTS OF SCALING ON ELECTRICAL CONSUMPTION
SCALE THICKNESS FOULING FACTOR(FF)
0.000” CLEAN TUBE SCALE THICKNESS
0.006” 0.0005
0.012” 0.001
0.024” 0.002
0.036” 0.003
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
Savings Potential Calculation Basis:
From Figure-1.1: Increase in the condenser approach by 5 deg F (2.78 deg C) and corresponds
to increase in the fouling factor of 0.001
From Figure-1.2: 0.001 increase of fouling factor corresponds to 10% increase in power
consumption per ton (TR) of Cooling
Hence, 5 deg F (2.78 0C) increase in Condenser Approach/STD would correspond to 10%
increase in power consumption per ton (TR) of cooling
Therefore, 1 deg F increase in Condenser Approach would correspond to 2% increase in power
consumption per ton (TR) of cooling.
Similary 1deg C increase in Condenser Approach would correspond to 3.59% increase in power
consumption per ton (TR) of cooling.
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
DIFFERENT PARTS OF TUBES CLEANING SYSTEM
SKID:- THIS PART HAVE A PLC CONTROLLED BOOSTER PUMP AND CONTROL VALVES TO INITIATE THE INJECTION AND COLLECTION CYCLE. THE
COMPLETE SYSTEM IS SO PROGRAMMED TO INJECT AND COLLECT THE BALL IN SET INTERVALS OF TIME
WITH PUMP ATCS FOR MULTIPLE CHILLERS WITH PUMP ATCS FOR INDIVIDUAL CHILLER PUMPLESS ATCS FOR INDIVIDUAL CHILLER
CONTROL PANEL AVAILABLE IN TWO OPTIONS
MULTI COLOUR TOUCH SCREEN LCD SCREEN WITH PUSH BUTTONS
BALL TRAP:- MOST COMPACT DESIGN TO FIT IN ANY POSITION OF PIPE LINES. HOPDIP GALVANISED FOR MUCH LONGER LIFE. THIS PART IS
INSTALLED ON THE COOLING WATER RETURN PIPE LINE. ALL THE BALLS COMING OUT OF THE CONDENSER ARE TRAPPED HERE. IT DO NOT
HAVE ANY MOVING PARTS THIS ENSURES 100% RECOVERY OF BALLS.
BALL COLLECTOR WITH BALLS:- FROM THIS PART BALLS ARE INJECTED, RECOLLECTED, WASHED AND REST FOR NEXT CLEANING CYCLE
TO START. WINDOW ALLOWS TO EASILY MONITOR THE CONDITION OF BALLS AND REPLACEMENT OF BALLS.
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
GA OF ATCS
ATCS Working:- Sponge balls resting in the Ball Collector are periodically injected by the operation of a booster
pump and control valves mounted on a Skid. The balls are pushed into the condenser cooling inlet pipe. These balls
travel with normal condenser water flow the Balls pass through the tubes. While passing through the tubes ball
carry away all the Soft Scales and deposites accomulated on the inner surface of the tubes and so keep the tubes
continuously clean. The balls comeout of the condenser from the outlet side of the condenser to get trapped in the
Ball Trap. Ball trap is installed on the cooling water return pipe. Once all the balls are out of condenser and get
trapped, these are pulled back and washed in the Ball Collector by operation of the same booster pump and control
valves mounted on a Skid. The cycle is repeated every 15 to 30 mins to ensure 100% tubes get cleaned. The
operation is Fully Automatic with NO Human intervention and Controlled through PLC Controller.
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
GENERAL P & I DIAGRAM FOR INSTALLATION OF ATCS ON 5 CHILLERS 1:5
Header tapping shown may differ from as required at site.
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
SALIENT FEATURES
• We offer International Warranty. All Components are from Global Manufacturers. Spares are available
in any part of India or World. NO DEPENDENCY for spares on us. Spares/Service can be sourced from
open market.
• 100% Chemical Free System.
• Ball Collector and Ball Trap are HOT DIP GALVANISED for much longer life.
• TOWER LIGHT with buzzer for Annunciation from a distance in noisy atmosphere of Plant Room.
• SEVEN INCH Multi colour Touch Screen HMI.
• COMPLETE SYSTEM GRAPHICS on HMI Screen for easy monitoring of system.
• Same P&I diagram for Steam Condensers, Ammonia Condensers, Chillers, VAM etc.
• MULTIPLE CONDENSERS can be cleaned by Only One Skid. Maximum up to 5 working Condensers /
Chillers can be cleaned by only one skid.
• MAXIMUM SAFETIES for all the Operational Components. Apart from MPCB, MCB, Under/ Over
Voltage, Phase sequence and Single Phasing Protection are provided for Pump Motor Protection.
• In most of the sites NO WATER DRAINAGE from Common Header, can be installed on standby
condenser / chillers while other connected can continue working.
• ALERT on Balls change period.
• CHILLER BYPASS FACILITY.
• UNIVERSAL DESIGN OF BALL TRAP. Can be installed in Horizontal / Vertical pipeline OR at BEND of pipe.
• Ball Trap comes with Openable Cover for cleaning of mesh and Trap.
• Alert on Increase of Condenser Approach through Parameters monitoring on SCADA / BMS (optional).
• Fully SCADA / BMS compatible via Modbus (optional).
• Remote monitored/controlled (optional).
• Ball Counter (optional).
FEATURES AND SPECIFICATIONS KEEP US AHEAD OF COMPETITION.
GK INFRA ENGINEERS GK INFRA ENGINEERS COMPETITION
NO DEPENDABILITY ON US FOR SPARES, AS ALL THE SPARES HAS TO BE PURCHASED ONLY FROM
THE COMPONENTS BEING USED ARE THE TUBE CLEANING SYSTEM SUPPLIER. SPARE
MANUFACTURED BY GLOBAL MANUFACTURERS. ARE NOT AVAILABLE IN INDIAN OPEN MARKETS.
ALL ELECTRICAL COMPONENTS ARE OF LIMITED AVAILIBILITY OF SPARES. NECESSARILY TO
SCHNEIDER MAKE, BELIMO MAKE VALVES & BE PURCHASED FROM TUBES CLEANING SYSTEM
ACTUATORS, XYLEM/CG MAKE PUMP. ALL THE SUPPLIER ONLY. LATER AVAILIBILITY OF SPARES
SPARES ARE AVAILABLE IN ALL CLASS ‘A’ CITIES OF AND COST CAN BE AN ISSUE.
1
INDIA AS WELL AS GLOBALLY. ALL THE
COMPONENTS ARE COVERED UNDER
INTERNATIONAL WARRANTY. ALL THE SPARES CAN
BE SOURCED FROM OPEN MARKET.
PLC BASED CONTROL PANEL, DESIGNED AND PROPERITORY DESIGN OF CONTROLLER. IF GETS
DEVELOPED IN ASSOCIATION WITH SCHNEIDER FAULTY CUSTOMER IS BOUND TO BUY THE NEW
ELECTRIC. CONTROLLER ONLY FROM TUBES CLEANING
2
SYSTEM SUPPLIER. LATER COST OF SPARES CAN BE
A VERY BIG ISSUE.
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
RELAY BASED OUTPUT CONTACTS OF PLC. TRANSISTOR BASED OUTPUT, PRONE TO FAILURE
RUGGED AND RELAIBLE. EVEN WITH SLIGHTEST FLUCTUATION IN
VOLTAGE.
3
UNDER AND OVER VOLTAGE , PHASE SEQUENCE,
PHASE LOSE PROTECTIONS ARE PROVIDED. THESE
THREE PROTECTIONS ARE MUST FOR SEFTY AND NOT PROVIDED BY
4 SMOOTH OPERATION OF PUMP MOTOR
COMPETITORS
7" MULTY COLOUR TOUCH SCREEN HMI. LARGEST SOME SUPPLIERS USE MONOCHROMATIC HMI OR
SCREEN IN THE CATAGORY. FOR EASY AUTO/ LCD SCREEN. NO GRAPHIC SLD IS PROVIDED.
MANUAL OPERATION, TO CHECK THE STATUS OF
ALL THE WORKING COMPONENTS ON THE MIMIC
5 DIAGRAM, RUNNING DESCRIPTION OF FAULT
OCCURANCE, LOG SHEETS FOR HISTORY OF
FAULTS, RUNNING HOURS. WITH CHILLER/
CONDENSER BYPASS FACILITY ETC.
FOR STARTER WE USE INDUCTIVE CHATERRING NORMAL RATING CONTACTORS ARE USED
6 RATING POWER CONTACTORS HAVING LONGEST HAVING VERY LESSER LIFE CYCLE.
LIFE CYCLE IN THE RANGE
FOR PERIFERRAL SWITCHING WE USE PLUG IN TYPE RELAY CARD IS USED HAVING MANY RELAYS IN
RELAY WITH BASE. AN INDIVIDUAL RELAY IS USED ONE ELECTRONIC PCB. IF ONE RELAY SWITCH
FOR ONE INDIVIDUAL OPERATION. CONTACT GETS FAULTY WHOLE RELAY CARD NEEDS
RATING IS MUCH HIGHER THEN ACTUAL REPLACEMENT. WHICH IS VERY TIME
7 REQUIREMENT. A SPARE CONTACT IS ALSO CONSUMING ALSO THE COST IS GENERALLY OF
AVAILABLE FOR SOME REMOTE MONITORING AN ORDER OF Rs2,100/-. SOURCING THE RELAY
REQUIREMENTS. IF ONE RELAY GETS FAULTY, ONLY CARD WITH SAME SPECIFICATIONS COULD BE AN
ONE PLUG IN RELAY CAN BE REPLACED AT ISSUE. MIGHT NOT BE AVAILABLE IN OPEN
MINIMAL COST WITH Rs500/- MARKET.
BALL TRAP AND BALL COLLECTOR ARE HOT DIP EITHER PAINTED OR EPOXY COATED, MUCH
GALVANISED FOR MUCH LONGER LIFE. LESSER LIFE AS COMPARED TO HOT DIP
GALVANISING. WE HAVE PHOTOGRAPHS
AVAILABLE SHOWING LAYERS OF COATING PEALED
8 OFF FROM THE INNER SURFACE OF THE BALL TRAP
WITHIN 3 YEARS OF INSTALLATION AND SO
CREATING TROUBLE IN SMOOTH RETURN OF
BALLS FROM BALL TRAP.
TOWER LIGHT WITH BUZZER ON CONTROL PANEL NOT PROVIDED BY COMPETITORS BECAUSE OF
TO INDICATE SYSTEM WORKING HEALTHY / FAULT NOISY ENVIRONMENT IN CHILLER ROOM. THE
CONDITION. HEALTHY CONDITION GREEN LIGHT. OPERATOR DO NOT GET ALARM ALERTS AND ALL
ALARM CONDITION RED BLINKING LIGHT WITH THE CHILLER/ CONDENSER KEEP ON OPERATING
BUZZER ON. THIS LIGHT HELPS TO IDENTIFY WITHOUT CLEANING. THE PURPOSE OF
9
ALARM CONDITION EVEN FROM A DISTANCE. A INSTALLING TUBES CLEANING SYSTEM IS
TOWER LIGHT IS A MUST FEATURE AS THE TUBES DEFEATED
CLEANING SYSTEM WORKS UNDER VERY NOISY
ENVIRONMENT AND ALARM ALERT FEATURE
FROM A DISTANCE IS A NECESSITY.
ALL THE CHILLER SELECTION CONTROL VALVES ARE CHILLER SELECTION CONTROL VALVES ARE
INSTALLED ON THE SKID. INSTALLED AT THE BALL COLLECTOR i.e. NEAR
CHILLER. THIS INCREASES COST OF EXTRA
CABLING AND ARE PRONE TO ACCIDENTAL
10 DEMAGE.
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
24 V DC CONTROL VALVES ARE USED. MUCH EITHER SOLENOIDE VALVES OR 220V CONTROL
LONGER OPERATIONAL LIFE OF ACTUATOR VALVES ARE USED ARE USED. THE SPRING OF
MOTOR. NO THREAT TO HUMAN LIFE. ACTUATORS SOLENOIDE VALVE GETS LOOSE AFTER SOME TIME
WITH TRIPPING FEATURE, IF THE VALVE GETS AND SOLENOIDE VALVE GETS FAULTY. LESSER
STRUCK THE ACTUATOR TRIPPS. THIS IS OPERATIONAL LIFE. 220V IS HAZARDOUS TO
PROTECTION OF ACTUATOR MOTOR IS TO HUMAN LIFE. AGAIN THE MAKE BEING EITHER
11 PROTECT ACTUATOR FROM BURNING DUE TO IMPORTED OR LOCAL MANUFACTURER NOT
OVER LOAD. AVAILABLE IN OPEN MARKET. NO PROTECTION
FEATURE IN ACTUATOR OR SOLENOIDE AGAINST
BURNING DUE TO OVER LOAD, IF THE VALVE GETS
STRUCK.
MANUAL VALVES ARE PROVIDED FOR ISOLATION NOT AVAILABLE TO REPLACE ONE CHILLER
OF INDIVIDUAL CHILLER/ CONDENSER SELECTION SELECTION CONTROL VALVE COMPLETE TUBES
CONTROL VALVES. IN EVENT OF FAULT OR CLEANING SYSTEM REQUIRES ATCS SHUT DOWN.
REPLACEMENT OF CONTROL VALVE, CLEANING IN
REST OF THE CHILLERS CONTINUES. NO SHUT
12 DOWN OF TUBES CLEANING SKID IS REQUIRED.
BEST BRAND PUMP FOR BETTER EFFICIENCY, LESS SOME TIMES USES LOW QUALITY BRANDS LESS
NOISE AND LONGER LIFE. EFFICIENT MORE NOISE.
13
VALVE OPEN AND CLOSE FEED BACK BASED NO FEED BACK OF THE POSTION OF CONTROL
OPERATION OF PUMP. IN NO CASE THE PUMP CAN VALVES IS CONSIDERED, PUMP RUN ON TIMER .
BUILD OVER PRESSURE. THE PUMP MOTOR IS ALSO IN CASE CONTROL VALVE GET STRUCK IN MID
14 PROVIDED WITH PROTECTIONS OF MOTOR POSITION PUMP OR DO NOT MOVE AT ALL, PUMP
WINDING CAN GENERATE MORE PRESSURE AND DUE TO
OVER LOADING MOTOR GETS BURNED OR
DEMAGE THE SKID.
NO COMPLETE SHUTDOWN REQUIRED TO TO REPLACE THE BALLS IN ANY OF THE
REPLACE OR CHECK THE CONDITIONS OF BALLS COLLECTORS, COMPLETE TUBES CLEANING
ABOUT REDUCTION IN DIA OR ANY OTHER WEAR N SYSTEM NEEDS SHUT DOWN.
TEAR TO BALLS OR FOR REPLACEMENT OF BALLS,
15 SHUT DOWN OF COMPLETE SYSTEM IS NOT
REQUIRED. BALL REPLACEMENT CAN BE DOWN
WITHOUT SHUT DOWN OF CHILLER AND CAN BE
DONE ON INDIVIDUAL CHILLER WHILE ALL OTHER
CHILLERS KEEPS ON OPERATING.
ONE COMMON SKID CAN CATER UPTO 5 SOME SYSTEMS REQUIRE SEPARATE SYSTEMS
WORKING CHILLERS CONNECTED TO COMMON FOR EACH INDIVIDUAL CHILLER. MAKES THEM A
COOLING WATER SUPPLY HEADER. VERY EXPENSIVE PREPOSITION AND SOME
SYSTEMS CAN CATER TO A BANK OF MAXIMUM
16 OF 4 CHILLERS.
Y STRAINER IS PROVIDED AT THE SUCTION OF
PUMP. IT PREVENTS ANY DEBRIS TO ENTER THE
PUMP AND PROTECTS THE PUMP IMPELLER NOT PROVIDED BY
17
COMPETITORS
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
DUAL PLATE NRV AT THE DISCHARGE OF PUMP TO
PREVENT WATER HAMMERRING IN THE PIPE LINE
18
NOT PROVIDED BY
COMPETITORS
CONDENSER + ATCS ＝ Save Energy + Equipment Extended Life ＝MONEY SAVED
PLEASE NOTE YOUR QUERIES HERE BEFORE YOU FORGET
Specifications and features can change without prior notice for developing a better and cost effective product.
Actual Product may differ from what is shown in the pictures of this catalogue.
