While the UK wasn’t really known for heat waves, nearly every year a number of days see spikes in temperature upwards of 30°C, putting additional strain on the temperature control equipment at manufacturing sites across. As such hot days often exceed the nominal specification for a plant’s temperature control equipment like process chillers, cold storage and air-conditioning or HVAC units, those sites without a contingency plan are subject to extensive equipment failure and production downtime equivalent to hundreds of thousands of pounds.
Here are some of the main culprits to production downtime:
1. Overloading and under-specification. One of the chief causes of temperature control system failure is overloading of mechanical elements – particularly the compressor – to the point at which they can no longer deliver the level of cooling demanded. This often occurs because the nominal specification for the process cooling system’s maximum working temperature was too low.
2. Ageing equipment. While a chiller has an anticipated working life of between eight to ten years, it may drop to six or seven years if mechanical process cooling is required around the clock. Like any piece of plant, a chiller will deteriorate over time, and while it may be able to handle temperatures at the higher end of the nominal specification during its intended working life, it may not be able to do so once those years have passed.
3. Overlooking water management. Poor cooling fluid quality is a major factor in system downtime that often goes under the radar. While mechanical failings that occur in extreme temperatures will become immediately obvious, if the process cooling fluid becomes contaminated or strays too far either way on the pH scale, then it will quickly start to degrade the system’s internal workings. Overlooking regular testing will see a deterioration in a system’s heat transfer properties which will only worsen in periods of intense loading.
4. Staff overheating. While workers are only as good as their tools, if the temperature control equipment is struggling to cope with the effects of a heatwave, it’s highly likely that the people are too. Failing to invest in appropriate ambient air cooling for the wider working environment is a sure-fire way to see productivity dip when the temperature rises.
SOLUTIONS
Any number of small issues or flaws go unnoticed during periods of small-to-medium loading; yet, more often than not come to light under the strain of overloading, and ultimately result in breakdowns. Conducting a thorough service in advance of temperature spikes can ensure any potential red flags are identified and the necessary remedial work undertaken.
Also, be prepared. Understanding where the risks lie makes it much easier to find a Plan B. Conduct a site and operations audit to and make sure all the information is recorded, alongside any power or utility requirements, and that the information is made available to all those who require it. Should a crisis occur, information at your fingertips is key to ensuring downtime is kept to a minimum.