How to ensure efficient energy management in industrial electric pipeline heating system? The customer's challenge

A chemical company, whose production processes depended on precise temperature management, faced a technological challenge. Their existing supplier of heating equipment, supplied them with high-quality tubular heaters that were necessary to maintain the right conditions in the pipelines transporting chemicals. However, the company realized that relying solely on one manufacturer carried the risk of production downtime in the event of supply problems or equipment failure.

As a result, they began looking for a second supplier that could provide energy control and temperature monitoring solutions that were compatible with their existing systems. The main goal was to find a partner that would provide reliable power controllers and temperature limiters, working with heating systems.

How has the integration of power controllers and temperature limiters increased the operational safety of the pipeline heating system? Our solution

In response to the customer's specific needs, we came up with an advanced solution that integrated perfectly into their industrial pipeline heating system. Pipeline heaters, crucial for maintaining the right temperature in chemical processes, are controlled by our single-phase thyristor power regulator. This regulator operates in such a way that it delivers power in controlled cycles, allowing the heating power to be precisely adjusted to meet current needs. This prevents sudden temperature spikes and protects pipelines from overheating. During the initial startup of the trace heating system, the maximum heating power is precisely set using an external potentiometer, allowing operators to precisely adjust the parameters to meet the requirements of chemical processes.

To ensure complete system safety, we have also provided electronic safety temperature limiters. These sensors monitor the temperature in the pipelines and immediately shut down the heating system if the temperature exceeds a certain safe limit. With this solution, the system is protected from potential overheating failures, further increasing the reliability of production processes.

The system is also monitored by an external display device that measures the current flowing through the pulse group circuit. If the current exceeds a set limit, the system automatically triggers an alarm, allowing quick intervention and preventing potential damage. To ensure that the system operates flawlessly, service personnel regularly conduct tests during which they briefly increase the power to its full value, simulating the full load on the system. Conducting these tests is simplified by a simple mechanism that allows them to be performed at the touch of a button, without having to change the actuator configuration. This method minimizes the risk of entering erroneous data.

With this comprehensive solution, encompassing both precise power control and advanced temperature control and protection, the JUMO system has not only integrated with the customer's existing infrastructure, but also significantly increased the safety, reliability and stability of the plant, providing full control over critical operational parameters.

What are the benefits of precisely controlling the heating power of an industrial pipeline heating system? Customer benefits

Precise control of the heating power in a pipe heating system has provided a chemical industry customer with a number of important benefits. With the ability to adjust the heating power according to current needs, the system effectively prevents sudden temperature spikes, minimizing the risk of overheating pipelines and protecting valuable chemical materials. This solution not only extends the life of the infrastructure, but also increases operational safety.

Efficient power management translates directly into energy savings, allowing the customer to make precise use of energy and reduce operating costs. This ensures that exactly the amount of heat required by the process is delivered, optimizing production and increasing efficiency.

The monitoring system, supported by an external display device and electronic temperature limiters, ensures immediate response to any irregularities. As soon as there is a danger, the system automatically shuts down or signals an alarm, allowing quick intervention. In this way, the customer avoids production downtime and maintains continuity of operations - crucial in the chemical industry.

The solutions we have provided not only improve the quality of production, but also increase the company's operational flexibility. Thanks to full compatibility with the existing infrastructure, implementation is quick and efficient, allowing the customer to make a smooth transition to the new system without risk of disruption.

About the author

My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.

Comments

We encourage you to leave your comments via the form below. They will be posted online once they have been approved through our review process.