Warning Signs to Look for During Heating System Maintenance

Proactive heater maintenance is the key to getting the best performance and value out of your industrial heating system. Taking advantage of regularly scheduled maintenance saves you money, increases safety, and maximizes the operational efficiency of your heater.

  • Increase the longevity of your equipment
  • Improve safety & reduce risks
  • Increase efficiency
  • Repair small problems before they become large (and expensive)

 

Proper heater maintenance goes beyond simply cleaning equipment and flushing pipes. It’s important to understand and recognize the warning signs of any existing problems or potential issues.  Early detection means easy resolution, with minimal costs and shorter downtime for repairs or replacements.

Heater Warning Signs

Corrosion

Corrosion on the heater or in tanks and piping can quickly become a severe problem. Corrosion can cause deterioration, allowing debris to cause blockages, disrupting flow, or even contaminating the target medium.

Left untreated, corrosion can cause equipment failure. Leaks can appear in pipes and vessels, and heater elements can be damaged beyond repair. If heating elements require replacement due to corrosion, consider changing heater element materials, and/or using a corrosion-resistant sheath. 

Exposed Elements

Exposed heater elements can lead to equipment failure or combustion. If exposed elements heat trapped vapors, explosions are possible. Finding exposed elements requires an immediate solution. 

A good option to consider is using a float bulb or a low-level detection switch, automatically turning off the heater if the fluid levels drop too low. This prevents the risk of exposed elements igniting vapors. 

Fire RisksFire Triangle

In addition to exposed elements, it’s important to consider the fire triangle:

  • Oxygen
  • Heat
  • Fuel

When these three elements combine, there is significant potential for combustion. To keep operations safe, and to protect equipment, minimize the potential for these elements to interact.

Poor Connections

Loose, ill-fitting, or unsecured connections can lead to significant issues in a heater system. They leave the potential for leaks which can waste or damage product. As well, they can result in heat loss which reduces operational efficiency. They increase the risk of oxygenation, increasing the likelihood of corrosion and/or combustion.

Poor connections should be secured or replaced to improve efficiency and safety.

Test Safety Devices

Every time that you run scheduled maintenance on your industrial heating system, you should test all safety devices. The worst time to discover device failure is when something goes wrong. Without inspection, a faulty low-level switch, for instance, will only be detected once it is too late. 

Regular inspection of safety devices protects the product, equipment, and personnel.

Watt Density

During maintenance, it is also important to check watt density. If the density is not as expected, try to discover why the system is not performing properly. This may be the result of a buildup of debris on the heater, a blockage, or irregular flow. Resolve any watt density discrepancy to keep the heater from overworking, which increases operational costs and risks heater damage.

Electric Industrial Heating Systems

Wattco custom-manufacture electric heating systems for all major industrial applications. Electric heaters provide easier maintenance and improved performance over combustion heaters. As well, they have longer lifespans, optimum efficiency, and lower operating costs.

Contact Wattco today for industrial heater quotes and information.

Latest blogs

Common Industries that Wattco works with

Case Studies View All

Why is Mineral Oil Used in Thermal Heaters?
Thermal heaters, also known as thermal fluid heaters, employ the use of a thermal liquid such as wat...
Read More..

What to Use When Heating Wax
SituationA popular chemical compound that often requires heating is wax, which is an organic compoun...
Read More..

What is Passivation? Why do We Need to Passivate Flanged Heaters?
  Most of the parts of flanged heaters are made of stainless steel—an alloy that is mainly compri...
Read More..

What is a Digital Controller?
Control panels are essential elements of any electrical device. Control panels are especially i...
Read More..

Vegetable Oil Heating
Food Industries and Vegetable Oil Viscosity In Cleveland Ohio, a large food manufacturer called WATT...
Read More..

Wattco News View All

Electric Heating’s Best Kept Secret
Over the side immersion heaters are a type of industrial immersion heaters that use water resistant ...
Read More..

Press Release: New Location – LaSalle Quebec
LaSalle, QC, February 24 2018 – WATTCO INC, North America’s premier manufacturer of electric hea...
Read More..

Flanged Immersion Heaters in the Petrochemical Industry
Flanged heaters are commonly used for heating a variety of gases and liquids. These include heat tra...
Read More..

Electric Immersion Water Heater Industrial Applications
One of the most common tools for industrial heating applications is the electric immersion water hea...
Read More..

Wattco Control Panels In-Depth
Wattco control panels are designed to maintain reliable and efficient heat transfer in a heating sys...
Read More..

Most Popular Blogs View All