Tube Brushing & Descaling
Mechanical cleaning of heat exchanger tubes to remove mud, algae, and scale. Essential for chiller efficiency.
Heat Exchange Recovery
Fouled tubes insulate the heat transfer process. Annual brushing is the single most effective maintenance task for chillers.
Approach Temp
Lowering approach temperatures to design specifications.
Head Pressure
Reducing compressor lift and electrical demand.
Energy Cost
Clean tubes significantly reduce kW/Ton consumption.
Reliability
Preventing nuisance trips on high-pressure days.
Rotary Cleaning Process
We use variable-speed rotary shaft machines with water flush to clean every inch of the tube.
Head Removal
Draining the vessel and removing water box heads.
- Rigging & lifting
- Gasket removal
- Safety lockout
Rotary Brushing
Running a rotating nylon or brass brush through each tube.
- Full length pass
- Water flush
- Debris extraction
Inspection
Visual check of tube condition and rifling.
- Light test
- Scale check
- Sample collection
Closure
Reinstalling heads with new gaskets.
- Torque specs
- Leak check
- Return to service
10-20%
Efficiency Gain
Required
Annual Service
Measurable Performance Recovery
The energy savings from a single tube brushing often pay for the service within the first month of operation.
Frequently Asked Questions
How often should commercial chiller tubes be brushed?
Annual tube brushing before peak cooling season is the industry standard for water-cooled chillers. Facilities with aggressive water chemistry or open cooling towers may require semi-annual service. BAM recommends scheduling based on approach temperature trending—a 1°F rise in approach indicates measurable fouling that warrants immediate cleaning.
What if mechanical brushing alone cannot remove the scale?
BAM implements a chemical descaling circulation prior to brushing for hardened calcium carbonate or silica deposits. Inhibited acid solutions are selected based on tube metallurgy—copper, cupronickel, or stainless steel—to dissolve mineral scale without substrate damage. This two-stage approach recovers tubes that brushing alone cannot restore.
Do you clean both condenser and evaporator tube bundles?
Yes. While condenser tubes foul more frequently due to open-loop tower water, evaporator tubes also accumulate biological growth and glycol-side deposits. BAM services both bundles using appropriately sized nylon or brass brushes with continuous water flush to extract all debris from the tube interior.
How does tube fouling affect chiller energy consumption?
Even a thin deposit of scale or biofilm on tube walls insulates the heat transfer surface and raises head pressure. This forces the compressor to work significantly harder, increasing kW/ton consumption by 10–20%. BAM's tube brushing restores design approach temperatures and reduces electrical demand from the first hour of post-cleaning operation.
What inspection is performed after tube brushing?
BAM performs a visual light test through each tube to verify scale removal and identify any pitting, erosion, or tube wall thinning. We collect fouling samples for analysis when requested and document tube condition with borescope photography. This data informs your capital planning and helps predict re-tube timelines.
How long does a chiller tube brushing project take?
A single chiller typically requires 1–3 days depending on the number of tubes and severity of fouling. This includes head removal, rotary brushing of every tube, visual inspection, gasket replacement, and hydrostatic leak testing before return to service. BAM sequences multi-chiller plants to maintain cooling capacity throughout the project.
Ready to Restore Performance?
Our restoration engineers are ready to evaluate your facility and provide a documented assessment.
Request a Site Visit