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One good contactor, left, is next to one with blackened contacts
and scorched wire conectors.
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It is time for your annual plant shutdown. You have a large list of systems that
need preventive maintenance. There are motors, switchgear, conveyors, and boilers,
just to name a few. One system that is commonly overlooked is your process heating
system.
It, like all your other systems, requires preventive maintenance. Let us first look
at your electric heater. Almost all heaters are sealed at the factory to prevent moisture
from entering the refractory insulation. This sealant will degrade over time, allowing water
to enter the elements. Every electric heater, like a motor, should be electrically checked
before being brought aback on line. Examine the bussing for corrosion and wear. Any
impedance to flow of current to the elements will generate heat in the terminal housing.
Check the wiring for frayed or missing insulation. If you are heating a viscous or corrosive
solution, the element bundle should be pulled and examined for coking or flaking metal, and
cleaned as necessary. Finally, check the insulation on the heater and piping. If the
insulation is scorched or contaminated, the "K" value is greatly reduced. A fire can
even result if oil or other fluids are absorbed by the insulation.
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A flanged immersion heater shows scale buildup.
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Now that your heater is done, do not forget your control panel, it requires maintenance also.
Check contactors and replace the coils on an annual basis. You should energize the control
panel and look for "hot spots" with an infrared pyrometer. This will show you the electrical
connections that need to be retorqued. Look for frayed and scorched wiring, and replace a
necessary. Vacuum the dust from the inside of the enclosure, and do not forget to clean or
replace any intake filters in the panel.
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Heater insulation is contaminated by oil.
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When you finish these procedures, your process heating system should be ready for another
year of flawless service. If you are not comfortable performing these tasks, please contact
Gaumer Process Heaters. We offer a full range of customer care and repair options for any
make of heater and control system. Gaumer Process Heaters is located in Houston, Texas,
and is a major manufacturer of industrial process heating and control systems.
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