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.
With a site assessment complete and all details recorded, it is then possible to agree on what contingency equipment is required with your back-up equipment supplier, as well as an activation plan.
For those manufacturers whose process cooling systems were specified to temperatures below those likely to occur in a heat wave, a short-term hire contract can deliver the process cooling boost needed to survive the summer unscathed. Even in non-manufacturing but critical applications such as server rooms or even the banking industry, failure isn’t an option and therefore installing a back-up chiller system, during summer months or expectedly busy periods, could be an ideal way to mitigate against any potential risk.
SPECIFICATION
When looking to commission a new process cooling system, the big factor to consider is balancing the overall cost of the plant versus the potential impact of downtime. Given the link between conservative or under-specification and summer downtime, manufacturers should come to expect the unexpected. In fact, it may be more cost-effective long term to opt for a system with a larger capacity that is guaranteed to operate effectively during seasonal temperature spikes.
And if you prefer to not invest the capital into fixed assets, long-term hire and its more flexible offerings are the right choice. With a long-term hire agreement, manufacturers can alter their mechanical cooling needs to suit the season. A cooling system with a higher power output can be ordered for the summer months, while that equipment can then be replaced with a more appropriate system, or even a rental boiler, during the colder times of the year.
Yet there are also even more flexible options in the rental schemes. This type of a complete packaged solution includes new equipment versus existing rental stock units, preventive and 24/7 emergency maintenance, replacements, and upgrades. The elements of the all-inclusive, monthly rate contract are tailored to the process’s needs and based on a detailed assessment by the service provider’s engineers. Manufacturers receive the right temperature control solutions for their process needs with the flexibility to adapt their capacity according to changing seasonal and operational requirements. Additionally, unlike in the case of a traditional long-term hire, they benefit from the flexibility to exchange and upgrade the equipment.
There is a fine line between accurate and under-specification, and these small margins are magnified when extreme temperatures hit. While UK manufacturers are challenged with keeping costs down, placing too much of a focus on this can leave them exposed to the devastating impact of mechanical downtime.
Thankfully, many of the issues can be negated with foresight and proper planning. With the market offering short and long-term solutions to suit all budgets, manufacturers, regardless of size or market, can keep their plant working efficiently and effectively when seasonal temperature spikes occur.