Is it true that exchangers cleaned using Tech Sonic pass NDE without the need for re-cleaning?
Yes! Our record to date is spotless (pun intended). When a bundle is cleaned using our process, it is ready to pass NDE, every time. Our quality control ensures that we never send bundles to the inspectors that aren't ready for inspection. With a Tech Sonic washpad you can say goodbye to schedule disruptions, risk and added cost caused by incomplete cleaning.
How does Tech Sonic Cleaning work?
Tech Sonic Cleaning utilizes a combination of immersion in a patented ultrasonic bath with specifically designed aqueous chemistry, process, and hydroblasting to gently, quickly, and completely remove fouling from parts.
The ultrasonic field created in our Tech Sonic Ultrasonic Baths is computer controlled and combined with the in-bath heat exchanger rotation, the field spreads the energy throughout the bundle, improving cleaning performance.
The ultrasonic sound waves induce random cavitation bubbles over the surface of the part, which helps to loosen, dissolve or remove fouling from both the inside and outside surfaces of the exchanger tubing. After a period of immersion in the bath, the bundle is removed and transferred to our hydroblasting zone, where robotic shell- and tube-side blasting is used to rinse the loosened fouling away.
If necessary, this process can be repeated on large or extremely fouled bundles until the bundle is Clean As New.
Does Tech Sonic Cleaning Eliminate Hydroblasting?
Not completely, but by loosening fouling in the ultrasonic bath, we make hydroblasting much more effective. We use a combination of low- and high-pressure rinsing techniques as a part of the Tech Sonic Cleaning process. Typically, our process reduces the amount of high-pressure “hydroblasting” required by over 75%.
What Types Of Fouling Can Be Cleaned From My Parts?
We can address the common fouling materials found in refineries and chemical plants through the choice of suitable bath chemistry and procedure. This includes both hydrocarbon fouling, inorganic scales and corrosion.
What Happens To The Waste Generated During Cleaning?
The waste generated on a washpad using Tech Sonic cleaning consists of two parts - the washwater used in hydroblasting rinsing, and the spent ultrasonic chemistry. The volume of wahswater to be disposed of will generally be about 75% less than would normally be produced on a "traditional washpad". Most turnarounds will consume one "fill" of each of the surfactant and acid ultrasonic baths, with a typical volume of 60-80,000 litres (16-21,000 US Gal). These spent chemistries are normally neutralized on site and disposed of with the washpad rinse water. The normal volume of wastewater disposed of during the turnaround will be reduced significantly, saving on water use and wastewater treatment costs.
How Much Water Is Used?
On average, the Tech Sonic Cleaning process uses 75% less water per heat exchanger than traditional hydroblasting alone. On a washpad, the average water consumption per exchanger is less than 80,000 litres (20,000 US gal) and in our offsite facility (with recylcling), we use less than 8000 litres (2000 US gal) per heat exchanger.
How Long Does It Take To Clean A Heat Exchanger?
The answer depends strongly on the dimensions of an exchanger, the design of the exchanger, and how badly fouled it is. In general, based on acutal turnaround data where Tech Sonic is deployed, the average processing time for an exchanger is less than one shift, and the typical net cleaning time per exchanger is less than 2 hours. A typical Tech Sonic washpad can clean 8-12 exchangers per day with optimized asset handling.
How Do I Know If My Part Is Suitable For Tech Sonic Cleaning?
Any carbon steel, stainless steel, or other corrosion-resistant alloys, fouled with hydrocarbon or inorganic fouling may be suitable for Tech Sonic Cleaning. It must also be possible to immerse the entire part into the ultrasonic bath, which has a size limitation of 32’ x 76”, with a maximum weight of approximately 35 tons (part + fouling).
How Clean Can I Expect My Part To Be When Returned?
We guarantee 95% or better – that is, your part will be cleaned to bare metal on 95% or more of its surface area.
Can You Clean Aluminum or Galvanized Parts?
Maybe. We generally do not clean any parts with aluminum fins, but we do clean lots of other parts made from aluminum. Tech Sonic regularly cleans galvanized equipment like scaffolding.
I’ve Always Heard That Cavitation Is Bad – Why Is It Used In Ultrasonic Cleaning?
The cavitation normally associated with damage to pumps and valves is concentrated and constant in some liquid flows. Engineers try to design to avoid the potential erosion by this cavitation. In our baths, cavitation is random and distributed over the entire surface of the part, providing a gentle “scrubbing” action that loosens fouling and makes the cleaning of even the hardest-to-reach nooks and crannies fast and complete, without damaging the part.
What Cleaning Fluid Is Used?
We use a variety of proprietary aqueous cleaning solutions – including degreasers and organic acids - specifically chosen for the fouling on your parts. Our chemistries are safe, environmentally friendly, and proven effective over 15 years of cleaning thousands of parts of all types, shapes, and sizes.
Is The Tech Sonic Cleaning Process Safe On Metals?
Yes, we have designed our systems, chemistries, and processes to be safe on all metallurgies. We always ask about the materials of construction and we tailor our cleaning process to be safe on your parts.
Yes! Our record to date is spotless (pun intended). When a bundle is cleaned using our process, it is ready to pass NDE, every time. Our quality control ensures that we never send bundles to the inspectors that aren't ready for inspection. With a Tech Sonic washpad you can say goodbye to schedule disruptions, risk and added cost caused by incomplete cleaning.
Tech Sonic Cleaning utilizes a combination of immersion in a patented ultrasonic bath with specifically designed aqueous chemistry, process, and hydroblasting to gently, quickly, and completely remove fouling from parts.
The ultrasonic field created in our Tech Sonic Ultrasonic Baths is computer controlled and combined with the in-bath heat exchanger rotation, the field spreads the energy throughout the bundle, improving cleaning performance.
The ultrasonic sound waves induce random cavitation bubbles over the surface of the part, which helps to loosen, dissolve or remove fouling from both the inside and outside surfaces of the exchanger tubing. After a period of immersion in the bath, the bundle is removed and transferred to our hydroblasting zone, where robotic shell- and tube-side blasting is used to rinse the loosened fouling away.
If necessary, this process can be repeated on large or extremely fouled bundles until the bundle is Clean As New.
Not completely, but by loosening fouling in the ultrasonic bath, we make hydroblasting much more effective. We use a combination of low- and high-pressure rinsing techniques as a part of the Tech Sonic Cleaning process. Typically, our process reduces the amount of high-pressure “hydroblasting” required by over 75%.
We can address the common fouling materials found in refineries and chemical plants through the choice of suitable bath chemistry and procedure. This includes both hydrocarbon fouling, inorganic scales and corrosion.
The waste generated on a washpad using Tech Sonic cleaning consists of two parts - the washwater used in hydroblasting rinsing, and the spent ultrasonic chemistry. The volume of wahswater to be disposed of will generally be about 75% less than would normally be produced on a "traditional washpad". Most turnarounds will consume one "fill" of each of the surfactant and acid ultrasonic baths, with a typical volume of 60-80,000 litres (16-21,000 US Gal). These spent chemistries are normally neutralized on site and disposed of with the washpad rinse water. The normal volume of wastewater disposed of during the turnaround will be reduced significantly, saving on water use and wastewater treatment costs.
On average, the Tech Sonic Cleaning process uses 75% less water per heat exchanger than traditional hydroblasting alone. On a washpad, the average water consumption per exchanger is less than 80,000 litres (20,000 US gal) and in our offsite facility (with recylcling), we use less than 8000 litres (2000 US gal) per heat exchanger.
The answer depends strongly on the dimensions of an exchanger, the design of the exchanger, and how badly fouled it is. In general, based on acutal turnaround data where Tech Sonic is deployed, the average processing time for an exchanger is less than one shift, and the typical net cleaning time per exchanger is less than 2 hours. A typical Tech Sonic washpad can clean 8-12 exchangers per day with optimized asset handling.
Any carbon steel, stainless steel, or other corrosion-resistant alloys, fouled with hydrocarbon or inorganic fouling may be suitable for Tech Sonic Cleaning. It must also be possible to immerse the entire part into the ultrasonic bath, which has a size limitation of 32’ x 76”, with a maximum weight of approximately 35 tons (part + fouling).
We guarantee 95% or better – that is, your part will be cleaned to bare metal on 95% or more of its surface area.
Maybe. We generally do not clean any parts with aluminum fins, but we do clean lots of other parts made from aluminum. Tech Sonic regularly cleans galvanized equipment like scaffolding.
The cavitation normally associated with damage to pumps and valves is concentrated and constant in some liquid flows. Engineers try to design to avoid the potential erosion by this cavitation. In our baths, cavitation is random and distributed over the entire surface of the part, providing a gentle “scrubbing” action that loosens fouling and makes the cleaning of even the hardest-to-reach nooks and crannies fast and complete, without damaging the part.
We use a variety of proprietary aqueous cleaning solutions – including degreasers and organic acids - specifically chosen for the fouling on your parts. Our chemistries are safe, environmentally friendly, and proven effective over 15 years of cleaning thousands of parts of all types, shapes, and sizes.
Yes, we have designed our systems, chemistries, and processes to be safe on all metallurgies. We always ask about the materials of construction and we tailor our cleaning process to be safe on your parts.