Case Study: Controlling Heat Hazards from Steam Systems in an Industrial Setting

Problem and Impact

1. Heat Sources:
   • Steam control system components: valves, strainers, heat exchangers, and steam pipes
   • Heat radiation from metal surfaces
2. Effects on Employees:
   • Excessive sweating
   • Fatigue
   • Stress from cumulative heat exposure throughout work hours

Causes

1. Steam Control System:
   • Control valves lack insulation
   • Surface temperatures radiating heat reach 180-200°C
2. Work Environment:
   • Work area temperatures range from 37-39°C
   • Some areas lack ventilation, causing room temperatures to reach 40°C

Improvements

1. Heat Management:
   • Install removable insulation on all steam control system components
2. Ventilation:
   • Install air supply fans for employees in specific areas
3. Reducing Direct Heat Contact:
   • Install CCTV for remote system monitoring in certain areas, reducing the need for direct employee presence

Results of Improvements

1. Temperature:
   • Surface temperature of steam control components reduced to about 35-45°C
   • Area temperature decreased by approximately 3-5°C
2. Safety:
   • Reduced risk of accidents from both direct and indirect heat contact

Lessons Learned

• Managing heat at the source (steam system) is an effective method to reduce risks and improve the working environment
• Using removable insulation is a good option for systems requiring regular inspection and maintenance
• Problem-solving should encompass heat reduction, ventilation, and minimizing direct heat contact
• Technology like CCTV can help reduce risks for employees

Additional Recommendations

• Develop a regular maintenance plan for heat insulation and ventilation systems
• Consider improving the overall room ventilation system, especially in areas with temperatures reaching 40°C
• Train employees on heat hazards, self-protection methods, and proper use of personal protective equipment
• Consider using automatic temperature control technology to increase energy efficiency of the steam system
• Study the feasibility of utilizing waste heat in other factory processes
• Consider implementing rotational work schedules to reduce the duration of continuous exposure to high heat for employees.