97% of shell & tube exchangers are subject to fouling.
Shell and Tube heat exchanger fouling is a well known phenomenon. However, the true nature of fouling and its operational impacts are very often underestimated. Condenser tube fouling comes in four major forms and is found in up to 97% of operating shell and tube exchangers. Estimates place the cost of this unchecked fouling to the U.S. economy alone at over $70 billion. This vast amount of waste occurs despite operators belief that manual cleaning these exchangers will mitigate the problem. Fortunately, new technology from Innovas Technologies provides a solution to solve fouling related losses.
TONS CO2 Emissions saved
Avg Chiller Efficiency Gain
University of Wisconsin - Madison
The facilities team at UW–Madison places a premium on improving the efficiency and productivity of their central cooling plants.
George Mason University
George Mason University’s facilities team realized that Helios represented a significant tool to reduce Mason’s energy usage and carbon footprint.
Dominion Power, one of the largest producers and transporters of energy in the United States relies on Innovas Technologies, and the Helios TCS.
How the Helios TCS Works
The Helios Tube Cleaning System is installed on heat exchangers and keeps the tubes clean without time-consuming intervention. Specialized cleaning balls are injected at set intervals into the cooling water flow. The balls rub the tubes clean and are then trapped at the outlet of the heat exchanger, where they are prepared for the next cleaning cycle.
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Understanding Helios TCS Installation
Typical installations, such as central chilled water plants in hospitals or universities, require less than 20 man-hours and only 8 hours of process shutdown. Ball traps are available in a variety of shapes and flow configurations to integrate easily with existing pipe runs and available space for installation.
How long does it take to install the Helios TCS?
The Helios Tube Cleaning System is installed on heat exchangers and keeps the tubes clean without time-consuming intervention. Typical installations, such as central chilled water plants in hospitals or universities, require less than 20 man-hours and only 8 hours of process shutdown. Ball traps are available in a variety of shapes and flow configurations to integrate easily with existing pipe runs and available space for installation.
What is the average annual cost savings for a Helios enabled chiller?
Data shows that the average annual cost savings in energy production can range anywhere between $40,000 and $65,000 or more depending on the size of the chiller.
How does Helios improve sustainability?
Improving the efficiency of water-cooled chillers, central chilled water plants and heat exchangers saves both energy consumption and reduces the carbon footprint. Data shows that projected lifetime CO² emissions can be anywhere between 6,000 and 10,000 tons.
How does automatic tube cleaning reduce maintenance costs?
Replacing manual cleaning with automated tube cleaning technology has a tremendous impact on required maintenance. Because the Helios system continually keeps chiller tubes clean there is no requirement for lengthy manual tube cleaning and no disruption to chiller operation.
What impact does the Helios TCS have on reliability?
92% of chillers are subject to tube fouling. Because the Helios TCS proactively keeps tubes clean, both chiller capacity and reliability are improved substantially.
How are custom fabrication needs addressed?
Innovas Technologies has extensive capability to produce custom fabrication to adapt Helios installation within unique environments. This includes design | build, hydraulic testing, fabrication and commissioning of systems.
“We provide better cooling and at the same time, reduce the maintenance requirements of our chillers.”
“Savings include energy, maintenance and elimination of workload associated with fouling.”
“We used a third party to validate Innovas ’ savings numbers and they turned out better than claimed.”