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Working principle
Cavitations
Conversion of electrical vibrations into
mechanical vibrations and to cause the
bottom of the tank to vibrate resulting
an intense agitation of the liquid
molecules contained in the tank. Thus
the violent disturbance in the liquid
results in the formation of cavities or
voids.
The cavitations in the liquid medium is
produced due to the propagation of
ultrasonic waves.
Due to the collapse of the cavitations,
a tremendous amount of energy is
released.
These energies produce an intense
local scrubbing action on the material,
which is immersed in the cleaning
liquid
Cleaning medium
Ideal cleaning medium should have low surface tension
and low viscosity for increasing effect of cleaning
Two types:
i) aqueous
-Used for removing common contaminants
ii) solvent (halogenated hydrocarbon)
-Used for removing solder flux, grease or heavy oil
Transducer
i.
ii.
iii.
Magnetostrictive
utilize the principle of
magnetostriction in which
certain materials expand
and contract when placed
in an alternating magnetic
field.
Piezoelectric
Comparison
Blue Wave
Magnetostrictive
The Competition
Piezoelectric
Performance properties DO
degrade
Epoxied transducers DO disbond
Epoxy bond DAMPENS energy
conversion
Light weight diaphragms DO wear
through (From Cavitation Erosion)
Lighter mass; Susceptible to load
variations
Not Even Close
tank
Generator
converts electrical energy from the line which is typically alternating current at
50 or 60Hz to electrical energy at the ultrasonic frequency.
Current ultrasonic generators nearly all use solid state technology.
There have been several relatively recent innovations in ultrasonic generator
technology which may enhance the effectiveness of ultrasonic cleaning
equipment.
square wave outputs, slowly or rapidly pulsing the ultrasonic energy on
and off and modulating
"sweeping" the frequency of the generator output around the central
operating frequency
adjusting a variety of output parameters to customize the ultrasonic
energy output for the task.
Procedure
The cleaning liquid either
aqueous or solvent is filled
in the tank
The transducer mounted at
the bottom of the tank for
generation of ultrasonic
wave
The vibrations are
transferred into the liquid
medium through the
stainless steel tank
(cavitations formation)
Advantages
Enhanced cleaning speed for both aqueous and solvent
medium
Less cost
It occupies less space and reduces labour
It can be occupied in cleaning hazardous substances
without the contact of the workers
Environmentally pollution free
High safety with less complaints
Chemical
Selection
Material
Compatibility
2nd Stage
Design
Layout
Layout
Approval
Develop
Procedure
Develop
JSA
3rd Stage
Bundle
Removal
Bundle
Installation
Equipment
Installation
Chemical
Soaking
4th Stage
Cleaning &
Monitoring
Scale
Analysis
Bundle
Lifting
Bundle
Rinsing
Planning
Temperature
Degassing
Degassing is done after the chemical is added is
accomplished by operating the ultrasonic energy and
rising solution temperature
Time required for degassing depends on tank capacity
and solution temperature
Degassing is completed when small bubbles pf gas
cannot be seen rising to the surface of te liquid
Ultrasonic power
The delivered
ultrasonic power to
the cleaning tank
must be adequate to
cavitate te entire
volume of liquid with
the workload in place
Excessive power may
cause cavitation
erosion or burning on
the soft metal parts
A.
System Specification
Power Requirement
..
220/240VAC
Generator Frequency
..
40 Khz, 500 W
Design pressure
..
30 Bar
Operating Pressure
..
15 Bar
Design Temperature
..
90 oC
Operating Temperature
..
25-85 oC
Piping Connection
Screwed type
Thread Standard
Dimension
Material
Layout requirement
..
Any configuration
SYSTEM CONFIGURATION
Five main section of DUCS, comprises of:
1)
Liquid container
from 1 SS 316L
and SS 316L respectively. Also including Pressure Control Valve
(PCV), Ball valves, Globe valves, Check valves and Quick coupling
system
4) Pumping Section
- Consist of one Centrifugal Pump and Diaphragm pump that used
to pump the UOF to the DUCS and to recycle overflow of UOF back to
the accumulation tank respectively.
Diaphragm Pump
Centrifugal Pump
5) Instrumentation Section
- Consist of Electromagnetic Flowmeter, Pressure Sensors,
overflow level sensor and analog pressure gauges.
PCV
Pressure Gauge
Outlet Pressure
Transducer
Inlet Pressure
Transducer
Inlet Electromagnetic
Flowmeter
Tube Bundle
cleaning skid
Chemical
holding tank
Tube Bundle
after cleaning
Cleaning Bath
Tube Bundle
after cleaning
Chemical
Cleaning Bath
BENEFITS
Reduces costs of cleaning, manpower, new bundles
and maintenance.
Estimated saving RM2 millions a year
Shorten period of maintenance from 7 days to 18 hours.
Reduces of risk exposed to toxic and hazardous chemicals.
The technique used friendly chemical i.e. UOF Remover
Used UOF Remover has moderate properties that meet
ETS specification.
B.
Reboiler Tube
Portable Gun
Transducer
Frequency
Converter
Transducer
(immersed)
Operator holding
Portable Transducer
Cleaned
Section
Ruptured bubbles
(cavitation)
Inlet Electromagnetic
Flowmeter
Close-up view
Model Faces
Loosen Scale
BENEFITS
Reduces costs of cleaning, manpower and maintenance.
Estimated saving 40% of ordinary cleaning cost
Shorten period of maintenance to 8 hours.
Increase heat transfer efficiency up to 50%. Reduces
flowing pressure drop up to 40%.
Reduces of risk exposed to toxic and hazardous chemicals.
The technique used friendly chemical i.e. Oxide/Coke Remover
Used UOF Remover has moderate properties that meet
ETS specification.
C.
ULTRASONIC APPLICATIONS
(i) Ultrasonic Cavitation (Clamping Type)
U N IP EM
U N IP EM
C.
ULTRASONIC APPLICATIONS
(ii)
U N IP EM
C.
ULTRASONIC APPLICATIONS
(iii)
U N IP EM
U N IP EM