TAPROGGE GMBH

About TAPROGGE

For more than 50 years, Taprogge has been operating in the sector of optimization of water circuits, particularly in power stations, seawater desalination plants, refrigeration and industrial plants. In this special field the company is the international market leader with its inventions in process technology and plant engineering. Today the company offers to the market comprehensive solutions with benefits optimized to suit the specific project. The skilful reciprocal integration of all components of such a comprehensive solution has a synergetic effect.

Innovation

During 50 years of company history Taprogge generated several hundreds of international patents and is therefore undoubtedly the leading innovating power in the special operational field of the enterprise. Some of the technical milestones that have had a decisive influence on today's design of major technical water circuits are:

- 1949 Invention and first installation of the tube cleaning system patented by J.Taprogge ("Taprogge System")

- 1968 Technical realization of the first generation of large cooling water debris filters basing on turbulence technology

- 1983 Development of the first filter generation basing on pressure-relieved backwash technology ("PR-BW technology")

- 1987 further development of the pressure-relieved backwash technology to the high-performance filter

- 1993 Technical realization of the first condenser monitoring system ("CMS")

- 2003 Development and realization of comprehensive solutions for the pre-treatment of reverse osmosis plants

Quality

Taprogge Products are tested in our own technological centre as to technical perfection and maximum safety. The international quality demands are met by us in a particular way.
Taprogge can refer to the following certifications (among others):

• Performance as per DIN EN ISO 9001:2000
• Safety of design by fulfilling the requirements of the European Pressure Equipment Directive 97/23/EC (up to Module A1)
• Approval KTA 1401 for nuclear systems
• Certification as specialized welding workshop of the top level DIN EN 729-2
• Certification as per SCC (management system for safety, health and environmental protection) for our after sales service section

IN-TA-CT (Integrated Taprogge Concept)

In this special field of optimization of water circuits, particularly cooling water circuits in power stations, sea water desalination, refrigeration technology and industry, Taprogge with its innovations has been setting the world technological standard since 1953, above all by its highly effective technologies for filtration and water extraction, as well as by the Taprogge System, today the world-wide synonym for on-load cleaning of heat exchangers and condensers.

The intelligent integration of individual solutions has a highly positive effect on the development of further synergies. For this purpose we have developed IN-TA-CT (Integrated Taprogge Concept). IN-TA-CT addresses the needs of architect engineers and contractors, whereas IN-TA-S looks after the operators' needs.

IN-TA-CT provides financial benefits to architect engineers, contractors and purchasers:
Planning realized by Taprogge clearly demonstrates that the highly effective IN-TA-CT modules contribute to more intelligent layouts of the mechanical cleaning chain in cooling water systems which reduces capital expenditure. By its modular structure, IN-TA-CT enables a flexible adaptation to budget, safety philosophy and function.

IN-TA-CT is made by Taprogge - which means that is comes from a single source. Reduced administration, low handling cost and reduced processing time are the consequence.
IN-TA-CT provides new process safety by guarantees within the scope of the integral system. Traditional interface problems are avoided.

As an IN-TA-CT user you have an automatic back-up by the quality features and unlimited world-wide acceptance of Taprogge, the market leader

Intake Systems

Processes for Water Extraction
Systems for water extraction are the interface between nature and technology. Their main task is to protect the pumps by separating particulate substances and civilization debris from surface water.

To respond to the conditions fixed by nature, but also to optimally adapt to further filtration-technological demands of the entire system of water technology, TAPROGGE offers a complete and flexible construction set by its single and multi-stage systems for water extraction.

Filtration

Filtration systems protect installations in water circuits located downstream (such as, e.g., heat exchangers, membrane plants and other process equipment) from blockage or damages by particulate fouling (macro fouling). Taprogge's modular filtration program provides answers to all kinds of demands upon the special filtering task. Be it sea, river, or process water, our range of filters is the ideal match with your requirements in terms of capacity, space, safety features and financial budget.

Tube Cleaning

Problems in cooling water circuits are caused not only by macro fouling in tubes of condensers or heat exchangers but also by inorganic or organic layers (micro fouling).
Such problems are mastered by the "Taprogge System" named after its inventor Josef Taprogge. It has been the world standard for many years. By means of sponge rubber balls that are oversized in relation to the tubes to be cleaned and circulate through the tubes, fouling is removed which results in a permanently good heat transfer.

Taprogge Systems are specifically adjusted to the particular demands of the fields of application.

Monitoring

Monitor - Channeling
Within the scope of IN-TA-CT the monitoring modules serve for the monitoring and prevention of system malfunctions and an increase of efficiency of the components monitored.

IN-TA-S (Integrated Taprogge Services)

With IN-TA-S, Taprogge sets new standards by meeting the latest demands that have been created through the structural changes of competitors' markets in the international power station and water business. As a result IN-TA-S has been extended by important service modules which have direct impact on the operational results, above all in offering superior possibilities of the optimization of plant operation by our Remote Monitoring schemes and new options of outsourcing within the scope of contracting models. IN-TA-S assists operators in a comprehensive and reliable way during the whole lifetime of their systems, covering not only installation, operation and maintenance but also permanent optimization and monitoring, including large-scale upgrades for lifetime extension of the IN-TA-CT modules.

IN-TA-S is of outstanding importance for the operators by providing additional, long-term benefits that translate into permanent financial economies:

Taprogge technology is process technology. With the purchase of the system you first receive the tool enabling you to operate your plant more efficiently. However, the extent of the efficiency increase and thus of the commercial benefit depends on the operational mode that is optimal for the relevant application. As a user of Taprogge technology you are entitled to make use of IN-TA-S and receive on-site competence and expertise.

Competence requires knowledge and experience. In this respect IN-TA-S is unparalleled because for the optimal adjustment of the systems and the improvement of your performance IN-TA-S can rely on a data bank that is unprecedented the world over and contains information on more than 5,000 Taprogge applications. Our plus of competence is your plus of performance gain.

By the modular structure of the individual IN-TA-S services you can choose the scope of our work to match your specific circumstances.

Taprogge offers you local availability. Simply rely on IN-TA-S centers in 10 regions of the world, dual sources from our two production centers, as well as our IN-TA-S remote centre.

As an IN-TA-S user you can automatically rely on IN-TA-CT and all further quality features the name of Taprogge stands for. Of particular benefit in this respect is the modular compatibility created by IN-TA-CT: because you as an IN-TA-S user start from the foundation of IN-TA-CT you conserve your investment by cutting your cost at the same time.

Efficiency in the Shape of a Ball

IN-TA-S centers in 10 regions the world over provide you throughout the year with all that is necessary for the right ball selection, its timely availability, and the optimized operation of a tube cleaning system. Special Taprogge programmes ensure the professional management of your requirement. The result: transparent evaluation of needs, stockpiling at favorable cost, as well as timely availability of the parts on site. Of course, you may also receive optimization support by remote monitoring and control of your systems from our IN-TA-S Remote Centre. This is particularly fast and cost-saving.
Benefit
How much the right ball selection and continued optimization by Taprogge experts translates into thermal and financial benefits is shown by the following practical example: For a power station with 300 MW turbine capacity and 6,000 base load hours per year, a turbine efficiency gain of 1% and more can be reckoned with, which given an electricity price of 0.03 € per kWh - results in economies of 540,000 € per year. If, for reasons of faulty ball selection or insufficient ball optimization, the efficiency gain is only 0.9%, the annual economy is only 486,000 € - which is by 54,000 € less than in case of optimal recommendation. Conclusion: the optimal ball selection magnifies the benefit to millions (based on the total lifetime of the power station).
Interesting Facts around the Cleaning Ball

Ball Selection and Optimization

For the determination of the type of cleaning ball and the mode of operation, Taprogge uses special in-house software that reflects the application experience of meanwhile more than 5,000 Taprogge cleaning systems. Essential parameters of calculation are: tube material, tube geometry, water velocity and temperature, water biology and chemistry, as well as hydraulic and design data of the installed system. If necessary, those calculating instruments are complemented by the special, additional IN-

TA-S Modules:

• Diagnostics on site (condenser inspection and ball distribution tests)
• Diagnostics in the Taprogge Technological Centre (tube examination)
• Consultancy in application engineering (with solutions to special questions of fouling, scaling, and corrosion), and performance of client-specific schemes (abrasive ball cleaning, ferrous sulfate dosing, monitoring of cooling tube conditions).

Available Range of Cleaning Balls

Taprogge’s standard range of products includes balls in diameters from 14 - 44 mm. Approx. 6 million cleaning balls are permanently ready for delivery. Other sizes can be supplied on request.

Ball Distribution

The distribution of the cleaning balls and thus the cleaning frequency of the individual cooling tubes are influenced by the ball distribution in the cooling water inlet pipe, the flow conditions in the water boxes and especially by the properties of the Taprogge balls adapted to those parameters. Through mixtures of different ball types with adjusted sinking velocity the distribution is optimized even further.

Ball Lifetime

Essential factors of influence for the ball life are: tube roughness, degree of fouling of the tubes, as well as type of fouling. That is why the degree of wear of a cleaning ball fluctuates between a few days and approx. 4 weeks, depending on tube condition.

Applications of IN-TA-CT & IN-TA-S

IN-TA-CT in Power Stations with Once-Through Cooling

In places where water is sufficiently available, once-through cooling is the most economic form of cooling. According to this principle, surface water is extracted from the sea, river, lake or canal, pumped to the turbine condensers (main cooling water circuit) and to the coolers of the auxiliary circuit, and subsequently transported back to its origin.

This type of cooling is characterized by the fact that the used surface water contains dissolved and undissolved impurities which, depending on the location of the pre-screening system and also on the relevant season, can strongly fluctuate in their quantity and composition. Unless effectively treated, such impurities can impair the availability and efficiency of the cooling system. With IN-TA-CT Taprogge has created a comprehensive solution for continuous availability and highest efficiency. IN-TA-CT has a modular structure and, in the case of once-through cooling, is fully effective due to the following functions:
Lean systems for water extraction which may be executed as single-stage or multi-stage system (the latter is represented here). They serve as pump protection. Whereas earlier, traveling band or drum screens were required for prescreening, the today's high-performance filters developed by Taprogge and installed downstream eliminate such major equipment requiring high capital cost and a high extent of maintenance. The result is that both the cost of the civil construction and the cost of mechanical components are greatly reduced.

High performance filters of the PR-BW series developed by Taprogge are arranged immediately upstream of the object to be protected in order to provide optimal protection of main and auxiliary condensers. Obstructions of tube sheets and leakages caused by tube erosion are effectively counteracted. Technically harmonized with the systems for water extraction, they enhance the availability of the cooling system.

Taprogge Systems for continuous tube cleaning automatically and continuously avoid the formation of deposits and scaling (micro fouling) within the cooling tubes that could impair the heat transfer. In such a way, they are specially aimed at increasing the thermal efficiency of the cooling system.

IN-TA-CT is ideally complemented by IN-TA-S, Taprogge's integrated service system.

IN-TA-CT in Power Stations with Closed Circuit Cooling

Where there is insufficient natural water source available, recirculative cooling is recommended. With the recirculative cooling, cooling water is extracted from the basin of a cooling tower and delivered through the cooling circuit by a pump. The water heated up in the condenser is then cooled in the cooling tower. The water losses, caused by evaporation and desalting, are compensated by treated make-up water.

In contrast to once-through cooling, fouling is more defined in terms of type and quantity but by no means easier to handle. Macro fouling is caused typically by the ingress of foreign matter into the cooling tower basin, and by construction parts of the cooling system itself. A further problem results from evaporation losses of enriched salts dissolved in the water (thickening) where by hard precipitation (scaling) in the cooling tubes is favored. For this type of cooling as well, the modular components of IN-TA-CT offer a comprehensive scheme for effective operation with highest availability:
Lean coarse screen systems in the cooling tower outlet serving as pump protection.
Taprogge Debris Filters installed immediately upstream of the condenser or auxiliary cooler to be protected provide optimal protection from macro fouling and highest availability of the cooling system. To avoid cooling water losses, the filter discharge water is re-treated and then re-fed to the circuit.

Taprogge Systems for continuous tube cleaning are aimed at maintaining thermal efficiency, particularly by preventing scaling problems.

IN-TA-CT is ideally complemented by IN-TA-S, Taprogge's integrated service system.

Applications of IN-TA-CT and IN-TA-S (Continued)

IN-TA-CT in Seawater Desalination according to the MSF Principle

The major part of the drinking water of the world produced from seawater is generated according to the MSF principle (Multi-Stage-Flash Evaporation). Salt water is taken from the sea and, in evaporator stages connected one after the other, are separated into distilled water and highly concentrated brine.

In addition to the requirement to protect the water pumps from coarse debris and the evaporator tubes from impairment due to macro fouling, the solution to micro fouling problems, particularly the precipitation of hardness-causing salts (scaling), resulting from the high temperatures in the evaporators, constitutes a major problem. Solving this technical problem will ensure optimum efficiency of the process of drinking water production. The modular components of IN-TA-CT offer a comprehensive solution - effectively and at highest availability:
Lean systems for water extraction which may be executed as single-stage or multi-stage systems (the latter is represented here), are the first step according to IN-TA-CT. They serve as pump protection. In contrast to earlier solutions, IN-TA-CT does not require traveling band or drum screens in the pre-screening stage because this task is accomplished much more effectively and better by high-performance filters installed downstream. The result is that both the cost of the civil construction and the cost of mechanical components are greatly reduced. Additionally, the footprint of the entire pre-screening is much smaller with IN-TA-CT.

Taprogge high-performance filters are of double importance - firstly as a protection for the evaporators of the heat rejection section from obstructions by fouling carried in by the seawater, and secondly in the make-up water circuit for filtering scaling films chipped off. This concept enables maximum availability to be achieved.

Taprogge Systems for continuous cleaning of evaporator tubes serve primarily for the prevention of scaling films which impair the heat transfer. That is why they are applied - independently - in the heat rejection section as well as in the heat recovery section where they increase the efficiency and reduce the cost in terms of water chemistry.

IN-TA-CT is ideally complemented by IN-TA-S, Taprogge's integrated service system. 

IN-TA-CT in Membrane Plants

In recent years, membrane-technical processes have made spectacular inroads into the vast fields of water technology. In addition to reverse osmosis (RO), established for many years, membrane technology applies above all to the processes of micro, ultra, and nano filtration (MF / UF / NF). Major technical applications, in particular those where natural water serves as the water source, are, above all, seawater desalination, municipal drinking water supplies and the production of water of high purity for technical purposes, for instance the production of boiler feed water.

Recent experiences have shown that an effective pre-treatment upstream of the membrane plants is a decisive precondition for the success of membrane-technical processes. The primary goal is to create a suitable protection for the membrane plants, so that blockage by particulate fouling contained in the make-up water is avoided. This is where IN-TA-CT provides a comprehensive solution consisting of two modules:
Designed as a single-stage system for water extraction, TAPIS is a lean and thus very compact solution for the pump protection. In contrast to earlier solutions where large-scale traveling band or drum screens were required for the pre-screening stage, this task is accomplished more effectively today by high-performance filters installed downstream. Large complicated machinery, requiring huge capital cost and extensive maintenance can be eliminated. The result is that both the cost of the civil construction and the cost of mechanical components are greatly reduced. Additionally, being a submerged system TAPIS avoids the cost of disposal of debris associated with traditional pre-screening plants.

Designed as a single-stage system for water extraction, TAPIS is a lean and thus very compact solution for the pump protection. In contrast to earlier solutions where large-scale traveling band or drum screens were required for the pre-screening stage, this task is accomplished more effectively today by high-performance filters installed downstream. Large complicated machinery, requiring huge capital cost and extensive maintenance can be eliminated. The result is that both the cost of the civil construction and the cost of mechanical components are greatly reduced. Additionally, being a submerged system TAPIS avoids the cost of disposal of debris associated with traditional pre-screening plants.

With this combination IN-TA-CT provides the basic pre-condition for membrane operation without impediments from macro fouling.

IN-TA-CT is ideally complemented by IN-TA-S, Taprogge's integrated service system. 

Applications of IN-TA-CT and IN-TA-S (Continued)

IN-TA-CT in Industrial Water Circuits 

Be it in petrochemical, chemical, steel, cement, or paper industries, in refuse incineration plants and major heat pumps, or in numerous other industrial applications, IN-TA-CT has gained a firm footing in all of those sectors.

In industrial applications the cooling water volumes are generally smaller than in power stations yet nonetheless complex due to the great variety in the types of cooling systems and the types and quantities of the site-specific fouling contained in the surface water used. This calls for high flexibility in system lay-out. IN-TA-CT fulfils this requirement in a special way: by its modular structure IN-TA-CT can easily adapt itself to the requirements created by the relevant location and cooling water quantity.

If, for instance, once-through cooling with the extraction of surface water from the sea, a river, lake or a canal is being considered, TAPIS offers the ideal solution as a system for water extraction. This also applies to the extraction of surface water for the treatment of cooling tower make-up water in the case of closed, recirculative cooling (cooling tower operation). In both cases TAPIS has been designed for the protection of the cooling water pumps and, as a submerged system, avoids the discharge costs created by classic pre-screening systems.

To protect the heat exchangers installed downstream in the cooling water flow against macro fouling is the task of the Taprogge High-Performance Debris Filters PR-BW 100. They are arranged directly upstream of the heat exchanger inlet and prevent system shut-down for cleaning works and repair of leakages. In this way, the availability of the cooling water circuit is increased.

The Taprogge System for continuous, on-load tube cleaning complements IN-TA-CT. It avoids micro fouling in cooling tubes and is the decisive tool for thermal optimality. A highly specialized process technology offers flexible solutions for the fulfillment of the cleaning task to have the best possible effect on the various appearances of micro fouling with the different types of water and tube materials.

In this combination IN-TA-CT creates comprehensive solutions, without interfaces and from a single source. This generates process-technological safety, cuts planning and processing costs, and has a relieving effect on capital costs.

IN-TA-CT is ideally complemented by IN-TA-S, Taprogge's integrated service system.

IN-TA-CT in Refrigeration Plants 

The major application of refrigeration technology is for air conditioning systems. In particular in countries with high average temperatures and high humidity they constitute an essential requirement for the creation of a comfortable living space which is why they are indispensable for office buildings, hotels, hospitals, shopping centers, and airports. But refrigeration is also required for technical purposes, for instance in cold storage houses and in the electro technical and textile industries.

The process-technological input that is required by air conditioning units includes electrical power for the compressor and refrigeration for the condensation of the cooling medium. Cooling is generally effected by means of cooling water, depending on the relevant location either in the form of closed cooling circuit (cooling tower operation), or as once-through cooling.

According to the place and environment of the cooling tower, a limited amount of foreign matter can enter into the circuit in the case of closed circuit cooling which can be removed by simple separation devices. A special problem, however, with heat exchangers used for refrigeration is micro fouling which can occur in all forms (as sedimentation, bio fouling, corrosion, but also as scaling). As a consequence the heat transfer is severely impaired which in turn has a negative effect on the energy consumption of the compressors? That's where IN-TA-CT sets in - because by IN-TA-CT excessive energy consumption can be avoided.

By the IN-TA-CT-module CCS that has specially been developed for refrigeration plants and the cleaning of cooling tubes in air conditioning units, micro fouling is permanently avoided. Core of the process is the application-technological know-how of the mode of operation to be applied in the individual case to achieve maximum thermal efficiency. For this purpose the operator is supported by IN-TA-S, TAPROGGE's integrated service system, in the best possible way.

When considering that in commercially used buildings the air conditioning system is the biggest energy consumer with about two thirds of the total electricity consumption, it becomes apparent what contribution for energy saving can be provided by the IN-TA-CT-module CCS.