Safety First: Duct Heater Leak Response Guide

Introduction: Picture this scene. Production is running normally in the workshop. Suddenly, an alarm sounds in the control room. Or, an operator smells something burning. Maybe even steam or smoke is seen near the air duct. These are classic signs of an industrial duct heater leak.

At this moment, any hesitation or wrong move can lead to downtime, equipment damage, or even safety accidents.

Industrial duct heaters https://8ruiyan.com/en/all-air-heaters/ are the core of heating, drying, and other systems. Their stable operation is critical. A leak usually signals a serious internal problem.

This article explains the emergency steps, post-incident investigation, and preventive measures for a leak. It helps you minimize risk and loss.

Part 1: Emergency Response — The First 30 Minutes

Once a leak is confirmed, stay calm and follow these steps. Remember: “Safety First”.

Step 1: Shut Down Immediately

1. Press the Emergency Stop button. Cut power to the whole system or the heater subsystem immediately. This is the fastest way to stop the heating.
2. Notify the control room. Report immediately: “Duct heater leak at [Location]. Emergency shutdown activated.”

Step 2: Cut Off the Supply

• Close the relevant valves based on heater type:
  • Electric Heater: Power is already off. Focus on preventing electrical fires.
  • Steam/Thermal Oil Heater: Quickly close the inlet and outlet valves. This is crucial. It stops the flow of hot, pressurized media.

Step 3: Ventilate and Evacuate

1. Start ventilation: Activate the workshop exhaust fans. Remove any smoke or steam from the leak.
2. Set up a barrier: Place clear warning signs around the leak area. Keep unauthorized people away.
3. Evacuate if needed: If there is heavy smoke or fire, evacuate personnel according to the emergency plan.

Step 4: Assess and Report

• From a safe distance, have a specialist observe the leak situation.
• Report to management and the safety department at once. Activate the equipment failure response plan.

Part 2: Investigation and Repair

After the emergency is over, don’t just “fix the leak”. You must find the root cause.

Common Leak Causes:

1. Tube corrosion or wear: Media flow gradually wears down the tubes until they break.
2. Cracked welds: Heat cycles or vibration cause welds to crack over time.
3. Control failure: Faulty sensors or controls make the heater run too hot or under too much pressure.
4. Freezing damage (steam/water heaters): Leftover water freezes and cracks the pipes after shutdown.
5. Installation stress or vibration: Poor installation or machine vibration damages connections.

Professional Repair Steps:

1. Isolate and cool down: Ensure the system is fully off and cooled to room temperature.
2. Professional inspection: A certified technician finds all leaks and assesses the damage.
3. Replace damaged parts: Replace the entire faulty unit. Simple patches can hide future problems.
4. Full system check: After replacement, check the controls, sensors, fans, and other parts.

Part 3: Prevention

The best response is to prevent leaks altogether. A good maintenance plan is key.

1. Regular checks: Visually inspect the heater regularly for rust or cracks.
2. Professional testing: Do a full shutdown check at least once a year. Include pressure tests and resistance checks.
3. Calibrate instruments: Regularly calibrate temperature and pressure sensors.
4. Follow procedures: Stick to correct startup and shutdown sequences. Do not override safety limits.
5. Winter protection: For idle systems in cold weather, drain all water or use heating tapes.

Заключение

A duct heater leak is a serious warning. By knowing the right steps to take, finding the real cause, and doing regular maintenance, you can protect your operation.

Safety is the top priority. We hope this guide is useful for your team.

For further consultation, please contact our technical team for expert advice.

Whatsapp:86-19106101570

wechat:86-19106101570

email:fob@jsryan.com

http://www.8ruiyan.com