One of the most significant pieces of equipment in a manufacturing plant is the heat exchanger. Heat exchangers can transfer energy and facilitate the smooth operation of the manufacturing process. Heat exchanger operation and maintenance, however, pose possible safety risks in addition to its critical function. If we don’t appropriately address safety risks, unexpected occurrences may occur. As a result, it is critical to understand heat exchanger safety measures in order to operate and maintain them safely.

Alaqua, a US corporation, supplies processing equipment. 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.

Incorrect heat exchanger operations can lead to risks such as hazardous substance leakage, cold metal embrittlement, explosion, fire, and uncontrolled reactions.

Meanwhile, servicing the heat exchanger can still pose a safety threat in the event of an explosion, fire, or hazardous substance exposure.

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.
• Consider the gasket material. 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.
• Build the heat exchanger to facilitate easy maintenance.
• By adding a safety relief mechanism, you can avoid overpressure.
• You must use insulation to cover a surface with particularly high temperature.
• 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. To effectively eliminate gas generated during normal operation, the heat exchanger necessitates an inclined structure.

During 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.

During Maintenance-

• 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. Mechanical cleaning could harm people 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. Exert careful effort to complete this work due to the anticipated high pressure.

Conclusion:

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, retrofitting, personnel training, troubleshooting, and field services. Contact us today for any queries and information!