HEALTH & SAFETY
LEARN THE SYSTEM
GLOBAL HEAT TRANSFER
UNDERSTANDING HEAT TRANSFER
SYSTEMS SAVES TIME AND MONEY
Some paintings reveal more detail the
longer you look at them. At first, you see a
countryside landscape, then you spot a face
hidden in the scene. Optical illusions both
confuse and intrigue but there are other
systems that are more detailed than they
first appear. If manufacturers look in more
detail at their heat transfer systems, they
may find problems they could prevent. Staff training should include the basic
functions of the system and the best
practice for plant maintenance to optimise
productivity. Starting up and shutting
down a heat transfer system, for example,
are fundamental skills needed to ensure
efficient production.
In this article, Dave Dyer, technical sales
engineer at heat transfer specialist Global
Heat Transfer, explains how a detailed
understanding of a heat transfer system can
help manufacturers maintain efficiency and
prevent costly downtime. The main function of a heat transfer system
is to distribute heat around a facility and
to specific areas of the production line. The
heating process begins at the main heater,
which is comprised of a burner and coil
which is cited inside the heater. The burner
heats the coil containing the heat transfer
fluid. A pump circulates the fluid through
the system and controls the pressure. This
main circuit of the system allows the fluid to
travel around the plant efficiently, but more
components are needed to ensure the
system is safe and stable to use.
When operating in facilities that use heat
transfer systems, manufacturers must
ensure their plants run safely and efficiently
to meet equipment regulations. However,
in many ways, regulatory compliance is
only a minimum in terms of safety checks
and maintenance.
The better the operator’s understanding of
the system, the more able they are to spot
issues early and prevent costly downtime.
To avoid problems that cause safety
hazards and system failure, everyone in
a manufacturing plant should know the
specifics of the systems they work with.
THE INS AND OUTS
One of the most overlooked pieces of
equipment in the system is the gasket,
which connects flanges that seal the system
containing the fluid. At any sign of gasket
failure, the heat transfer system must be
shut down to prevent hazards and to isolate
the issue. Automatic valves are also in the
system to regulate temperature and adapt
to the product specifications.
SAFETY
A clean working environment aids
productivity and keeps workers safe.
Manufacturers can improve plant efficiency
by cleaning and fixing leakages immediately
as well as using the correct equipment based
on temperature and other environmental
factors. Leaving oil spills unattended or using
plastic equipment can be a health and safety
hazard.
As well as protecting workers through
cleanliness, purchasing and maintaining
safety equipment can improve the efficiency
of the heat transfer system. Spray guards are
used around flanges and known potential
leak points, causing the oil to coalesce back
to a liquid and rendering it non-hazardous.
This makes the leak safe but visible so
manufacturers can solve the issue.
RISK MANAGEMENT
Though a system is only required to have one
major and one minor service a year, plant
managers have a lot to gain from proactive
maintenance. Staff should proactively check
the system as frequently as possible to look
for wear and tear, leaks or other changes.
Some visual checks denote external issues,
yet visual cues such as inconsistent heating
of final products, may be an internal
maintenance issue. A lack of representative
fluid analysis and proactive maintenance
can lead to fluid degradation and carbon
forming in the system. Implementation of
a continuous maintenance programme for
thermal fluid, such as Global Heat Transfer’s
Thermocare, can reassure manufacturers
that it is not the fluid that has caused
production issues.
Looking at a heat transfer system alone
is not enough to maintain its efficiency.
Just like an optical illusion, studying
each component reveals more details.
With knowledgeable, trained staff and
preventative maintenance, manufacturers
can optimise productivity of their heat
transfer system, creating satisfaction for
workers just like when you spot both hidden
images in an illusion.
If you would like to learn more about
AB Dynamics and its products, please
visit www.globalheattransfer.co.uk
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PECM Issue 35