The tropical zone is the warmest climate zone on Earth. In Singapore, the operation of HVAC/ACMV systems is essential year-round to uphold indoor comfort within buildings. HVAC systems account for approximately 60% of the total energy consumption in a typical commercial building. The implementation of energy-efficient designs and optimisation strategies for HVAC systems plays a crucial role in reducing energy usage, improving water resilience and generating cost savings. Given that HVAC systems in commercial buildings and industrial facilities consume a substantial amount of electrical energy and water, governmental agencies in various countries, including Singapore’s National Environmental Agency (NEA) and Building and Construction Authority (BCA), advocate for proper energy management of HVAC systems as a means to mitigate carbon footprints.
One of the biggest questions that’s constantly asked in the HVAC industry is: “Why is HVAC maintenance important?” The answer lies in understanding a major challenge faced by many (HVAC) systems in Singapore: fouling and scaling, which refers to the buildup of unwanted materials on the inner tubes’ surfaces of heat exchangers, and can significantly impact the system’s operational efficiency and resource usage.
In practical application, heat is dissipated to the cooling tower via the condenser. When the condenser water undergoes heat exchange in the cooling tower, it comes into contact with the surrounding air, leading to the capture of airborne particles by the condenser water. If scale or fouling accumulates on the inner tube surfaces, it hinders the heat transfer process. As a result, the water temperature of the condenser rises, aggravating the heat transfer driving force and diminishing the chiller’s efficiency. Over time, these particles deposit on the inner tube surfaces, giving rise to scaling or fouling.
Studies indicate that a scale thickness of 0.6 mm can escalate the chiller compressor’s power consumption by approximately 20% due to the slowdown of heat transfer. The combined impact of fouling and scaling triggers a chain reaction of issues within HVAC systems, such as decreased heat transfer efficiency and heightened operational expenses. In severe instances, fouling will harden and prevent the system from operating at its intended, energy-efficient state if untreated, resulting in system shutdowns and compromising building comfort levels. Hence, it is imperative to undertake preventive measures to avoid scaling or fouling and uphold the cleanliness of the condenser tubes. Generally, control over scale and fouling on condenser tubes is maintained through:
- water treatment
- water blowdown
- tube cleaning
Features and Functionality of the Hydroball System
This is where the Hydroball system, an automatic tube cleaning system (ATCS), serves as not only a proactive solution in combating fouling and scaling in HVAC systems but also to increase water resilience. Unlike traditional cleaning methods that require system shutdown, the Hydroball system utilises self-propelled cleaning spongeballs. These spheres, made from a specially formulated material, travel through the inner tubes using the inherent flow of water within the condenser. As they move, they dislodge and remove accumulated deposits.
Here’s how the Hydroball system effectively addresses these issues via its unique features:
- Dual Loop Design: The Hydroball system incorporates a patented “Dual Loop” design where the water supply and return loops are connected to the main water flow within the condenser, effectively preventing the mingling of hot & cold water streams and the re-entering of hot water into the condenser. This innovative approach serves to uphold chiller efficiency and optimise performance.
- Water Resilient Mechanism: In contrast to conventional manual flushing processes that consume large amounts of water, or other automated cleaning systems that discharge chemically treated water into drainage systems; the HydroBall system operates without water discharge through its “Water Resilient” mechanism. The automatic tube cleaning system by Hydroball is equipped with water resilience features such as water recycling, reuse and circularity, which not only support biodiversity but also aid in mitigating the impacts of climate change.
- Non-Powered System: The Hydroball system is a “Non-Powered” solution, signifying that it operates without the need for additional pumps, compressors, or diverters to sustain the cleaning process. Consequently, it boasts minimal moving parts and entails reduced maintenance and downtime for consumable replacements, rendering it an environmentally conscious solution.
Energy Efficiency Benefits of Hydroball System
By effectively preventing the accumulation of scale and fouling, this energy and water-saving HVAC system contributes significantly to improved energy and water efficiency. Here’s how:
- Optimal Chiller Performance: Clean heat exchanger tubes facilitate optimal heat transfer, ensuring the chiller operates within its designated efficiency range, translating to reduced power consumption.
- Reduced Resource Wastage: The Hydroball system enhances water management by eliminating water discharge during the cleaning process. This not only conserves water but also reduces wastewater treatment costs.
- Extended Equipment Life: By preventing harmful deposits from accumulating on the tubes, the Hydroball system helps extend the lifespan of heat exchangers and other HVAC components which directly leads to reduced maintenance and replacement costs.
However, the benefits of this sustainable HVAC solution extend far beyond immediate savings. The system serves as a pioneering automatic tube-cleaning solution for promoting environmental sustainability. This sustainable automatic tube cleaning equipment has received the prestigious 4-tick score, the highest rating, under the Green Building Product Certification Scheme by the Singapore Green Building Council (SGBC) with certification numbers SGBP 4114 and 3745. This recognition underscores HydroBall Technics’ commitment to providing eco-conscious solutions for the HVAC industry.
In essence, the Hydroball system represents a breakthrough in HVAC maintenance practices, offering an efficient solution to mitigate fouling and scaling issues. By ensuring clean heat exchanger tubes and promoting optimal chiller performance, the Hydroball system delivers significant benefits in terms of energy and water efficiency, operational advantages, and ecological sustainability. Its unique features make it a compelling choice for industries and facilities seeking to enhance their HVAC systems’ performance while reducing maintenance costs and downtime.
Discover the energy and water-conserving benefits and operational advantages that this automated system offers by scheduling a consultation with our experts at HydroBall Technics. Safeguard your HVAC system from the detrimental effects of fouling and scaling today.
