One of the most significant pieces of equipment in a manufacturing plant is the heat exchanger. Energy can be transferred and the manufacturing process can operate smoothly using heat exchangers. Heat exchanger operation and maintenance, however, pose possible safety risks in addition to its critical function. Unexpected occurrences may occur if such safety risks are not appropriately addressed. As a result, it is critical to understand heat exchanger safety measures in order to operate and maintain them safely.
Alaqua is a US corporation that is a processing equipment supplier. It was established in 1989 and incorporated in 1993. We have more than 25 years of experience in the supply of sanitary, food grade, and ASME codes such as the evaporator, crystallizer, distillation equipment, solvent recovery systems, spray dryers, and heat exchanger makers worldwide.
Heat Exchanger Safety Hazards
There are a number of possible risks associated with heat exchangers. It might happen during the design, operation, or maintenance phases.
Hazardous substance leakage, cold metal embrittlement, explosion, fire, and uncontrolled reactions are all risks connected with incorrect heat exchanger operations.
Meanwhile, the heat exchanger can still act as a safety threat in the event of an explosion, fire, or hazardous substance exposure while it is being serviced.
Safety Precautions: Heat Exchanger
Improper design, operation, or maintenance of a heat exchanger might provide a safety risk. You must be cautious during these three periods. To avoid mishaps, please adopt the following heat exchanger safety precautions:
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During the Design
- Make sure you’ve determined the heat exchanger’s kind, temperature, pressure, material compatibility, fluid nature, supports, gas vent, drain, and structural design. Mechanical integrity issues might arise as a result of poor design.
- The gasket material should be taken into consideration. To prevent leakage, the material, gasket type, and thickness all must match.
- It is possible that the temperature and pressure levels will rise abnormally. Create a heat exchanger that can survive this type of environment.
- The heat exchanger must be built in a way that allows for easy maintenance.
- By adding a safety relief mechanism, you can avoid overpressure.
- Insulation must be used to cover a particularly high-temperature surface.
- Install an alarm system if possible.
- It’s critical to be grounded.
- When constructing a heat exchanger for hydrogen peroxide, remember to take particular precautions. An inclined structure is required for such a heat exchanger in order to remove gas that occurs during normal operation.
- Foulant build-up causes tube blockage. Pressure might build up inside the heat exchanger as a result of this.
- Keep an eye out for corrosion-induced tube leaks. A reaction may occur if fluid from the hot and cold sides combine. Corrosion inspection, monitoring, and leak detection are all critical.
- If a slurry or polluted liquid flow reaches the heat exchanger, erosion and leakage may occur. To separate solids from liquids, use a filter.
- Keep the heat exchanger from being over-pressurized. Ensure a seamless start-up and shutdown. Stick to the standard operating procedure.
- Avoid skin burns by staying away from hot surfaces.
- When maintaining a heat exchanger, follow the steps. Ensure that all inlet valves are securely fastened and tagged.
- Let the heat exchanger’s pressure go down. Check to see if the pressure gauge reads zero.
- Empty the heat exchanger of any dangerous chemicals.
- When choosing a chemical cleaner for tube cleaning, be cautious. Corrosion and leakage result from poor choices.
- If you’re cleaning the tube side using a mechanical approach, be careful not to damage it. People might be hurt by mechanical cleaning as well.
- To avoid leaking, carefully install a new gasket, focusing on the head. Leakage will result from poor installation.
- After the maintenance job, a hydrostatic test is necessary. Because a lot of pressure will be exerted, take care to complete this work carefully.
The biggest unsolved problem in heat exchanger functioning is fouling and corrosion. Even while fouling deposition issues and their economic effect are major concerns, there is still a lack of knowledge among relevant authorities. Furthermore, the consequences of corrosion are diverse and varied, and their impact on the efficient, dependable, and safe functioning of equipment or buildings is sometimes more significant than the mere loss of metal.
Cleaning methods and controls play a critical role in lowering production costs in the manufacturing business. Chemical consumption, maintenance labor, downtime loss, and water wastage all drive up production costs dramatically. As a result, the relevant authorities must recognize the necessity of corrosion control and fouling cleaning in the industries, as well as enforce a specified cleaning technique.
Alaqua is an evaporator, crystallizer, solvent recovery system, distillation equipment, spray dryers, and heat exchanger equipment supplier worldwide. Apart from processing equipment suppliers, we also provide our services for equipment fabrication, installation and commissioning services, retro-fitting, personnel training, troubleshooting, and field services. Contact today for any queries and information!