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How facilities managers can extend thermal fluid life

Thermal fluid is often an invisible asset in facilities, such as food, pharmaceutical or chemical processing plants - so it is easy to forget that the system requires regular maintenance to operate efficiently

Dave Dyer offers his advice for facilities managers who want to better understand their thermal fluid

According to the Consumer Electronics Association, users expect their smartphones to have a lifespan of five years. However, Recon Analytics reported that the average handset replacement time is actually around two and a half years. 

Understanding and mitigating the factors that reduce technology lifespan can elongate device life, leading to better return on investment. The same simple rule applies to operating and maintaining a heat transfer fluid system. 

There is a common misconception that thermal fluid systems that have been operating for a long time without a major incident are unlikely to break down.

The reality is that all heat transfer systems require regular maintenance and thermal fluid tests to ensure they are in good health.

Train staff

Facilities must have at least one staff member trained on heat transfer systems on site at all times to comply with the Dangerous Substances and Explosive Atmospheres (DSEAR) regulations and the Explosive Atmosphere Directive (ATEX 137). 

Training should cover basic system operations, such as start-up and shut down procedures, as well as a comprehensive list of what to check during regular surveys, including potential leaks, wear and tear, faulty gauges, heat and flow.

Increasing staff knowledge can also improve productivity. 

For example, in cold winter months the thermal fluid in the header tank can wax up and freeze, putting a strain on the pump during system start up and delaying production time.

An engineer could leave the main circulation pump running 24/7 with no heat from the heater, producing around 60 degrees of heat and keeping the thermal oil at a viscosity where it can flow through the system – allowing production to restart immediately.

Thermal fluid condition

If facilities managers do not carry out regular representative sampling and respond with corrective maintenance, problems can occur. 

A lack of regular sampling and maintenance means that carbon or acid build up goes unnoticed, leading to a lack of flow and overall, a less efficient system, which often impacts product quality and overall yield.

Fluid sampling and analysis gives an accurate record of thermal fluid condition. 

Engineers should ensure that the sample is taken correctly – if a sample is not taken from a hot, closed and live system it will misrepresent the fluid condition inside the system.

Regular sampling, done in-house or by external thermal fluid experts, can identify problems early on, giving the facility manager more time to rectify them.

For example, hydrocarbon chain breakdown can produce light ends that will reduce the flash point of the thermal fluid. Engineers can install a light ends removal kit to bring up the flashpoint of the oil before it impacts productivity and facility safety.

Thermal fluid top ups

The facilities manager should ideally have access to spare thermal fluid. This is because a thermal fluid system uses about five per cent of its volume each year. This fluid may also be urgently needed if there is a leak in the system.

If the company has a knowledgeable team of engineering maintenance staff, they can top the system up themselves. Failing that, the facilities manager should have an emergency contact that can assist them in tackling the issue.

Facilities managers should include sampling, surveying and training in their preventative maintenance plans for heat transfer systems. If your company does not have a team of thermal fluid experts, packages such as Global Heat Transfer’s Thermocare provides on-site and remote technical and engineering support, site specific staff training and regular sampling and analysis. Proactive maintenance ensures thermal fluid system lifespan and performance meet investment expectations, unlike mobile phones and gadgets that often fall short.

Dave Dyer is technical sales engineer at thermal fluid specialist Global Heat Transfer.

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