Chemical and Hydrodynamic

Chemical and Hydrodynamic Cleaning of Cooling and Water-Cooled Air Conditioning Condensers

In cooling and air conditioning systems, the condenser is the Achilles’ heel of the facility in terms of maintenance requirements.
The condenser requires regular attention, and neglecting it can lead to a reduction in the system’s cooling capacity, up to complete shutdown. Additionally, a significant portion of the system’s energy losses occurs at the condenser.

Unclean heat transfer surfaces cause high head pressure on the refrigeration compressor and reduce cooling efficiency.
Significant resources are invested in keeping heat transfer surfaces clean, either during system operation using on-line cleaning systems or by preventing scale buildup through cooling water treatment.
However, these cleaning or scale-prevention methods do not completely eliminate the need for periodic condenser cleaning. Proper maintenance can increase the intervals between cleanings but cannot completely replace them.

See also: Cleaning of Cooling Towers

Chemical Cleaning Method

Chemical cleaning of the water side deposits is typically performed using a controlled acid solution circulated through the cooling passages. Most water-cooled condensers are of the tube-and-shell type, where cooling water flows inside the tubes and refrigerant flows in the shell surrounding the tubes.

Chemical cleaning must involve the correct selection of acid type, appropriate acid concentration, and correct dosing of an inhibitor. Several types of inhibitors are available on the market, differing in their protection level of healthy metal. The inhibitor should be added to the solution immediately before introducing the acid; it is not sufficient to rely solely on the supplier’s claim that the acid “contains inhibitor,” as the inhibitor’s effective lifespan in acidic solution is short.

There are methods to test the effectiveness of the inhibitor in protecting healthy metal, and these tests should be conducted at the start and during the chemical cleaning process.

Before chemical cleaning, to ensure successful cleaning, all passages throughout the condenser tubes must be open for acid flow. If there is any doubt, one must remove a condenser cover and flush the inside of each tube until all tubes have free passage. This is especially important for condensers where on-line chemical cleaning is used with cleaning balls, as balls may become stuck in some tubes.

Laboratory monitoring during chemical cleaning is mandatory. Several parameters can be measured to track the chemical reaction and determine when it is complete. This monitoring can also detect abnormal changes in the solution that require immediate stoppage of the cleaning.

Completion of chemical cleaning is determined based on laboratory test results. After cleaning, the system must be drained and both the used solution and the system neutralized using a neutralizing agent. The system must always be flushed with clean water in circulation until complete neutralization is achieved. Neutralization levels should be measured using a pH meter.

After chemical cleaning, one condenser cover should be removed, and the inside of each tube flushed using high-pressure water through a rotating nozzle at the end of a flexible lance. The lance is inserted into each tube, and the nozzle progresses along the entire tube length until it exits the other side.

Chemical cleaning is performed at water pressures ranging from 150 to 1000 bar, although typically, 500 bar is sufficient.

Chemical Cleaning – Process Complexity

Chemical cleaning is a complex procedure that requires the services of a professional and experienced engineering company. The work of such a company does not end even after the cleaning process is complete; it is also expected to monitor chemical concentrations and possess the appropriate equipment to neutralize and treat effluents and solutions.
The chemical reaction process is monitored by a mobile field laboratory to ensure professional cleaning. Once a professional company completes its work, you can rest assured that all deposits dissolved during the chemical cleaning process will be removed, and the system's operation will return to maximum efficiency.

Of course, to ensure the engineering company is prepared to perform the work as expected, it is advisable to verify exactly what their offered services include and what technologies and methods they use to complete their work.

The Principle of Hydrodynamic Cleaning

Hydrodynamic cleaning is based on a relatively simple principle – however, for its implementation, specialized technological equipment and a professional company are required, along with the ability to operate the equipment professionally and safely.
The cleaning is made possible by a device featuring a flexible hose with a nozzle at the end, providing an extremely high-pressure water stream. This allows the nozzle to thoroughly wash all grease and deposits from the system. Therefore, many consider this method particularly effective for cleaning heat exchanger tubes, tanks, reactors, piping, and various systems.

Hydrodynamic Cleaning – What is it Exactly?

In any cooling or air conditioning system, the condenser plays a vital role and is a frequent point of maintenance. To ensure the proper and continuous operation of the cooling system, we must regularly inspect the condenser and focus on maintenance, specifically cleaning. When the heat transfer surfaces are not clean, the system's operation becomes less effective.
Hydrodynamic cleaning is an efficient solution for cleaning internal surfaces where deposits and greasy dirt accumulate. Laor Engineering Ltd. performs hydrodynamic cleaning using specialized equipment aimed at complete removal of all debris. With Laor Engineering, a thorough and efficient cleaning is performed using safe, environmentally friendly, and effective methods.

What is Hydrodynamic Cleaning?

Hydrodynamic cleaning techniques are required in cases where high-quality cleaning of internal surfaces with greasy dirt and deposits is needed. The cleaning is performed with specialized machines featuring a nozzle that delivers a water stream at immense pressure.
The goal of hydrodynamic cleaning is the complete removal of all grease stains and deposits. With professional hydrodynamic cleaning, you will succeed in effectively removing accumulated dirt while shortening system downtime.

Who Can Perform Hydrodynamic Cleaning?

Hydrodynamic cleaning services are performed by companies specializing in professional industrial cleaning that possess the necessary equipment. After investing significant resources in equipment, particularly cooling systems, it is essential to take the correct maintenance steps to prevent damage from scale, oxides, and brines. Professional and thorough maintenance treatment increases the intervals between maintenance sessions, leading to cost savings and preventing operational shutdowns.

To achieve the best results and quickly return the plant to full functionality, you must wisely choose a professional, available, and experienced company that uses appropriate professional equipment. Laor Engineering Ltd. is one of the market leaders in performing hydrodynamic cleaning and other maintenance services for industrial plants and institutions. The professional team at Laor Engineering specializes in hydrodynamic cleaning, chemical cleaning, steam boiler cleaning, heat exchanger cleaning, and the cleaning of tanks, pipelines, and systems. You are invited to call Laor Engineering now for more details and to schedule a consultation.