Hey I just punched a little over a thousand tubes on a chiller with it's marine box and end bell off. When I was done the senior tech noticed chunks of plastic from the tower in many of the tubes, just sorta sitting there.
Naturally, this led to some very uncomfortable conversation . It also landed me a second shift after work today punching those same tubes.
I can't blame him. Seems obvious that if there are pieces of plastic in the end of the tube, no brush went through to push them out. I was baffled myself. I knew I punched them all, and went all the way through. I did notice, though, that from time to time the speed feed was dragging a chunk out to my end.
Today I went back with a manual feed to re-punch. I punched for about two hours and took a bit of a break. When I did I found that the tubes I had just punched, which I over extended by over a brush length, still had chunks of tower plastic in them. The few which had most recently been done had the plastic laying along the wall of the tube, almost suctioned to it. As it dried the plastic would seem to pop back into place.
I brushed one seven or eight times with a fresh debris brush before it finally grabbed the plastic and kicked it out. I guess I'll be getting in the rest with some needle nose.
Have any of you guys ever seen anything like this before?