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Ultrasonic cleaning

One of the major applications of high power ultrasonic


Commonly used frequencies between 20 KHz and 50KHz
.

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

Illustration of cavitations formation process

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

Ultrasonic cleaning equipments


Transducer
Tank
Generator

Transducer

i.
ii.
iii.

Used to convert electrical


energy to mechanical
vibration
The transducer can be fixed
in three ways:
Directly at the bottom of the
tank
Using transducer plate
Using submersible transducer
Piezoelectric ceramic crystals
commonly used as they can
transmit 70% to 90% of
applied energy to cleaning
liquid

Magnetostrictive
utilize the principle of
magnetostriction in which
certain materials expand
and contract when placed
in an alternating magnetic
field.

generally less efficient


than their
piezoelectric
counterparts

Piezoelectric

convert alternating electrical


energy directly to mechanical
energy through use of the
piezoelectric effect in which
certain materials change
dimension when an electrical
charge is applied to them.
Electrical energy at the
ultrasonic frequency is
supplied to the transducer by
the ultrasonic generator

Comparison
Blue Wave
Magnetostrictive

The Competition
Piezoelectric

Performance properties NEVER


degrade
Silver-brazed transducers NEVER
disbond
Metal to metal bond; MORE
EFFICIENT energy conversion
Heavy duty (316L) diaphragms
NEVER wear through (From
Cavitation Erosion)
Heavier mass; NOT susceptible to
variable loads
The ONLY Lifetime Guarantee in
the industry!

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

Console cleaning systems

Console cleaning systems


integrate ultrasonic cleaning
tank(s), rinse tank(s) and a
dryer for batch cleaning.
Systems can be automated
through the use of a PLC
controlled material handling
system.

Custom designed system

A wide range of options


may be offered in custom
designed systems
Large scale installations
or retrofitting of existing
tanks in plating lines, etc.,
can be achieved through
the use of modular
immersible ultrasonic
transducers.
Ultrasonic generators are
often housed in climatecontrolled enclosures.

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)

Automated ultrasonic cleaning


system

This system is designed to


clean intricate metal hearingaid components using a
neutral-pH solution at 60C
(140F) and three rinse stages
at 70C (160F). Basket
rotation (1 to 3 rpm) is used
during each stage to ensure
adequate cleaning and rinsing.
The system computer controls
all functions, including the
hoist, and allows for storage of
different process parameters
for different types of parts.

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

Ultrasonics Speeds Cleaning by Dissolution


+

Cavitation and implosion as a result of ultrasonic activity displace and


remove loosely held contaminants such as dust from surfaces. For
this to be effective, it is necessary that the coupling medium be
capable of wetting the particles to be removed.

Some contaminants are comprised of insoluble particles loosely


attached and held in place by ionic or cohesive forces. The effect of
ultrasonics is substantially the same in these cases.

The mechanical micro-agitation helps speed the dissolution of soluble


contaminants and break the attractive forces of insoluble particles

Figure 2 below illustrates the surface of the part being


cleaned has been represented as a flat.

(b) Cleaning Process

(a) Dirty Surface

(c) Mechanical Cleaning


i.e brushing

Procedures of Ultrasonic Cleaning


1st. Stage
Scale
Analysis

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

Maximizing the ultrasonic


cleaning effect
Cleaning- chemical selection
Temperature
Degassing

Temperature

Cavitation effect is maximized


in pure water at 1600F
However, optimum cleaning is
often seen at higher or lower
temperature because of the
effect that temperature has on
the cleaning chemical
As the general rules, each
chemical will perform best at
its recommended process
regardless temperature effect
on the ultrasonic

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

APPLICATIONS IN THE PLANT OPERATION


Depending on operation requirement, ultrasonic technique
has wide applications particularly to improve process
efficiency, retention time and cost. However for cleaning
and maintenance purposes, the technique is very useful
for:
(i)

Tube/Plate Cleaning (reboiler, heat exchanger, condenser


and column packing)
- to remove scale and fouling materials

(ii) Filter Cleaning


- to remove plugging materials in filter pores.
(iii) Sludge Breaking
- soften hard sludge in pit and tank

A.

Dynamics Ultrasonic Cleaning System(DUCS)


Flow Sequences (P&ID) - FPG Oleochemicals
Sdn. Bhd.

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

NPT male and NPT female

Dimension

1.5ft (H) x 1.5ft (L) x 3 inch (w)

Material

316L Stainless Steel

Layout requirement

..

Any configuration

SYSTEM CONFIGURATION
Five main section of DUCS, comprises of:
1)

Liquid container

- UOF accumulation tank


- 4 Diameter X 6 Height
- Made of SS 316L

2) Pipe fittings section

- Major piping and overflow piping is fabricated

from 1 SS 316L
and SS 316L respectively. Also including Pressure Control Valve
(PCV), Ball valves, Globe valves, Check valves and Quick coupling
system

DUCS major piping is


fabricated from 1 SS 316L
with threaded connection

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

Tube Bundle during


cleaning process

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.

Stabilizer Reboiler Tube (External/Internal Cleaning)


- Petronas Penapisan (Melaka) Sdn. Bhd.
Ultrasonics
Generator
Liquid (water)

Reboiler Tube

Portable Gun
Transducer

Frequency
Converter

Transducer
(immersed)

Stabilizer Reboiler Tube (External/Internal Cleaning)


- Petronas Penapisan (Melaka) Sdn. Bhd. (.Continue)
TA Manager

Harness. (Good Practices)

Operator holding
Portable Transducer

Cleaned
Section

Ruptured bubbles
(cavitation)

Inlet Electromagnetic
Flowmeter

Stabilizer Reboiler Tube (External/Internal Cleaning)


- Petronas Penapisan (Melaka) Sdn. Bhd. (.Continue)

Close-up view

Bundle cleaned with


ultrasonic and UOF
chemical

Lifting from Water Bath. Ready


for Hydrojet (Rinse)

Stabilizer Reboiler Tube (External/Internal Cleaning)


- Petronas Penapisan (Melaka) Sdn. Bhd. (.Continue)

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)

Ultrasonic Cavitation (Immersible Type)

U N IP EM

C.

ULTRASONIC APPLICATIONS
(iii)

Ultrasonic Cavitation (Plug-in Type)

U N IP EM

U N IP EM

Ultrasonic is not a technology of the


future. It is very much a technology of
today.

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