Download our latest research white paper on Understanding the Environmental Impact of Tube and Shell Fouling in Heat Exchangers and learn how leading institutions are closing the gap to carbon neutrality by leveraging an alternative solution.
Innovas’ Ongoing Contribution to Sustainability
Helping Our Customers Improve the Health of Our Earth
In our business, the key to success for any efficiency or energy savings solution is that it must provide cost savings to a degree that it generally pays for itself in less than 3 years. Admittedly, when we at Innovas look at the value our products provide, we look first to economic payback but there are other important dimensions of value that the Helios TCS provides including labor hour savings, increased equipment longevity and positive environmental impacts. Together, we call these “Multiple Dimensions of Value”.
While we are proud of the complete value equation our products provide, perhaps the most rewarding impact related to the Helios is its positive environmental impact. Specifically, the Helios enables savings of countless tons of GHG emissions equating to removing the pollution of thousands of cars from the atmosphere and planting millions of trees that clean the air. Broadly speaking, shell and tube heat exchangers are fundamental components of the world’s economy and contribute to the production of electricity, gasoline, manufactured products, food and air conditioning. Disturbingly, 97% of these heat exchangers are subject to energy robbing fouling translating to billions of tons of GHG emissions released into earth’s atmosphere.
So how does the Helios TCS mitigate waste and pollution? By preventing fouling from infecting shell and tube heat exchangers in the first place. Let’s explain further. Shell and tube fouling, as described in our fouling video, creates an insulation barrier between the cooling liquid and the liquid needing to be cooled causing more energy needed to operate the shell and tube system.
For example, waste due to heat exchanger fouling causes the typical commercial air conditioning energy bill to increase 5% to 12% more per year than if the heat exchange tubes were maintained clean. The connection to the environment? Inefficient heat exchange requires extra fuel burn to make the extra energy to accommodate the fouling effect causing release of more pollutants into our atmosphere.
As you can see from above, we are working every day, every hour, every minute to reduce the burden shell and tube fouling places on us all through the continuous work done by our Helios Tube Cleaning System.
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.”