Steps to improve heating efficiency in industrial installations

When it is winter time and the cold is pressing, plant managers often regret that during the summer season they did not look for a solution to improve the heating efficiency of their industrial facilities.

But no matter how cold it gets, there is still time to help you get through the winter months. We have drawn up a list of key aspects that you should take into account to improve the efficiency of heating in industrial installations and we have detailed it below:

1. Start by examining your system:

   It goes without saying that checking your heating systems during the cold months is a top priority. This will help your system reduce heating costs and operate more efficiently. To keep your system in good shape for this winter and next winter, you should inspect your heating systems regularly. Start by using maintenance checklists to organise the preventive tasks you need to complete on a daily, weekly, monthly and annual basis.

   Next, examine the components of your heating system:

   • Air and boiler components:
     • Examine flues for carbon build-up.
     • Analyse combustion to ensure that the flames burn efficiently.
     • Check safeguards to make sure they are working properly.
     • Look for cracks in the heat exchangers.
     • Remove and clean the burners.
   • Boiler components:
     • Look at the water pressure gauges to see if the calibration is synchronised.
     • Clean the boiler pipes.
     • Check expansion tanks for adequate air cushion and for flooding.

   By checking each component, you can ensure that each function or part is working properly. If you need help, call your trusted mechanical service provider.

2. Optimise outdoor air service

   Most buildings bring in more cold air than necessary, costing valuable energy to heat outside air in the winter. Reduce outdoor airflow rates to the minimum allowed by ASHRAE for each space - reducing this airflow will produce significant savings!

   It also considers the amount of cold outside air that is brought into the building and heated when no one is inside! Installing CO2 sensors in return air ducts and maintaining indoor CO2 levels will generate significant savings and comfort. Talk to a temperature control specialist today to see if your building is operating at an efficient outdoor air temperature.

3. How is the temperature?

   The optimum thermostat set point for the winter months is 20°C. Be sure to install tamper-proof thermostats to prevent unauthorised persons from adjusting temperatures. Without these, utility costs will increase as people manually raise and lower temperatures throughout the day.

   When spaces are to be unoccupied for an extended period of time, you should adjust your thermostat again. For intermediate times ranging from an hour to a few days, temperatures between 16-19°C are adequate. When buildings are unoccupied for a few weeks to a month, temperatures as low as 14°C are adequate.

4. Check the envelope of your industrial building

   One of the only things that can protect you against a severe cold is a tightly sealed building. Look for defects in areas that are sensitive to airtightness. For example, ageing seals, lack of insulation or gaps in windows and doors can wreak havoc on an otherwise efficient installation.

   Caulking and weatherstripping are excellent for sealing problem areas and can have a massive impact on the efficiency of your facility.

5. Heat recovery ventilator

   This can help reduce energy costs and reduce the demand on your equipment. By recovering waste heat in the exhaust gas, the fresh air introduced into the system is preheated.

6. Perform seasonal tasks

   Complete each task under the heading "Winter" during the summer season. This will ensure that your facility, as a whole, runs as efficiently as possible during this cold season. This list includes simple (but often forgotten) tasks such as replacing air filters and cleaning supply and return registers. By removing these items from the checklist, you will avoid potential blockages of build-up and improve energy efficiencyair quality and air flow.

7. Optimise warm-up times

   Set your building controls, smart thermostat or manually raise the facility temperatures to the determined baseline at least 15 minutes prior to occupancy. This will allow the room to return to a comfortable temperature. The thermostat can be set back to the determined setback temperature approximately 15 minutes before staff leave the building.

   Spaces that are not occupied often do not need to be heated to typical standards. Therefore, assess your building to see where occupancy will be low in the winter months. Reduce heat in these specific areas.

To learn more about improving the efficiency of heating in industrial installations, we invite you to learn about how to achieve energy efficiency in industrial buildings with preventive maintenance workas well as to subscribe to our Newslettera newsletter that provides you with technical content about the best technological solutions for industrial plants, focused on automation and maintenance.