SERVICES
FrothFlush — High-Energy Pipe System Cleaning Technology
Advanced flushing process for complex power plant piping systems, removing debris, slag, and corrosion deposits with unprecedented efficiency
Advanced Cleaning Technology for Critical Power Systems
FrothFlush is a breakthrough high-energy technique specifically engineered for power plant piping systems to remove loose mechanical debris, loosely adherent welding slag, and corrosion deposits from pipe surfaces. This innovative technology serves as an advanced replacement for conventional pigging operations, delivering superior results with enhanced efficiency.
The FrothFlush Process
FrothFlush operates by generating a specialized slug of water containing numerous air bubbles mixed throughout the fluid. This frothed slug is propelled through piping systems at velocities of 40 to 80 feet per second, with the air entrainment providing crucial cushioning effects that minimize movement impacts at tees and elbows.
FrothFlush Process Using Froth Former
Essential Component of SigmaCommissioning™ Protocol
FQE Power's FrothFlush process represents a cornerstone technology within the SigmaCommissioning protocol. Our breakthrough post-construction cleaning methodology stands as the most efficient pipe and complex systems flushing technology available, excelling in both cleaning and drying of critical power plant systems.
Primary Systems:
- Demineralized Water Systems
- Condensate Systems
- Boiler Feedwater Systems
- Closed Cooling Water Systems
Secondary Systems:
- Process Piping Networks
- Process Heat Exchangers
- Process Coolers
- Overhead Fin Fan Units
The FrothFlush process will quickly flush these systems utilizing a minimum quantity of demineralized water. This process is particularly effective in cleaning residual hydrostatic test water, iron salts, and other debris that contaminates these systems during the construction process.
Figure 1 - Typical Pipe before FrothFlush
Figure 2 - Froth Former and Air Receivers
Figure 3 - Typical Pipe after FrothFlush
The FrothFlush process injects slugs of two-phase “frothed” water at high velocities into the piping to be flushed. The effect of the high velocity combined with the surface tension of the bubbles in the frothed slug results in very high Reynolds numbers (indicating fully turbulent flow) at the pipe surfaces. Fully turbulent flow provides an effective scrubbing of pipe surfaces in the shortest amount of time without the need for chemical additives.
In practice, the volume of each slug is determined by the diameter of the pipe to be cleaned. The slug is formed in our proprietary slug former (Figure 2) and propelled into the pipe at 60-90 ft/sec (20-30 m/sec) with a discharge of compressed air. As the length being cleaned is constrained only by the amount of compressed air available, long lengths can be cleaned with a minimum of demineralized water.
In addition to using a very small amount of water, there are additional benefits provided by the FrothFlush.
- First, it easily conforms to changes in pipe diameter, enabling the cleaning of multiple pipe diameters without the need for a breakout at each change in diameter. See Figure 1 - shows the typical condition of the pipe.
- Second, it easily transitions into the branches of the piping system without significant temporary breakouts. See Figure 2 - shows the Froth former equipment.
- Third, the compressibility of the froth slug minimizes reaction forces transmitted to the tees, elbows, and reducers in the system being cleaned. See Figure 3 - shows typical results of cleaning a pipe like that in Figure 1.
THE RESULT: a scoured pipe surface that is free from debris and salts, ready for the process fluid and significantly fewer strainer fouling issues.
FrothFlush Video
The FrothFlush flushing process accelerates removal of debris through the 6" clear Schedule 40 plastic piping used for demonstration purposes only, 150 Gallons at 85 PSI.
Benefits of FrothFlush
- Less water consumed than conventional filled flushing techniques
- Less equipment required to reach a beneficial range of turbulence in piping systems
- Reactive forces are reduced or eliminated due to compressibility of froth slug
- Greater debris carrying capabilities because of the apparent viscosity of the two-phase slug
- Can be performed with minimal impact to adjacent work
- Eliminates safety issues associated with gas blowing on fuel supply piping
- Takes less time to set-up and perform than conventional flushing or pigging
Contact us to discover how FrothFlush technology can deliver superior cleaning results while reducing time, costs, and resource consumption for your next project.
