Prioritising thermal fluid safety in chemical processing
HEALTH & SAFETY A SAFER WORK ENVIRONMENT
GLOBAL HEAT TRANSFER
Prioritising thermal fluid safety in chemical processing
During chemical reactions , whether it ’ s reactor heating , polymer processing or distillation , maintaining the delicate balance of temperatures isn ’ t just a matter of efficiency , it ’ s a matter of safety — particularly when working with heat transfer systems . Here Tim Powell , thermal oil specialist at Global Heat Transfer , explores how effective health and safety protocols can contribute to a safer and more efficient work environment when working with heat transfer systems .
Historically , facilities opted for steam-based heat transfer systems because water is readily available , affordable and seemingly sustainable . However , achieving the temperatures needed for industrial processes required the system to operate at extremely high pressures of around 1200 psi ( 83 Bar ). This meant that , without adequate steam ventilation , the pipes ran the risk of bursting and gaskets failing , allowing hot steam to escape , which put workers at risk .
Thermal fluids , on the other hand , can safely maintain temperatures at much lower pressure and can be tailored to applications . They are suitable for both heating and cooling applications , with temperature ranges spanning from -90 to 600 degrees Celsius .
While they offer a safer alternative to steam and are designed to deliver prolonged and efficient service , facilities employing heat transfer fluids should still adopt preventative measures to extend
fluid lifespan and meet safety standards .
To comply with industry regulations , manufacturers using heat transfer fluids must take proactive steps to assess potential risks and implement measures , such as a Thermocare ® maintenance plan , to eliminate them as much as possible . Thermal fluid is classed as a dangerous substance , but when monitored routinely and proactively managed , it will give great service for many years .
Managing risks While heat transfer fluid has an effective life expectancy of many years , its efficacy decreases as it nears the end of its lifespan . This decline can lead to the introduction of by-products into the system . Specific regulations outline guidelines for health and safety managers to reduce the potential risks linked to this degradation , but this is often easier said than done . This is because once thermal fluid is introduced into the heat transfer system , it is no longer visible , allowing any underlying problems to remain unnoticed until they disrupt production .
To manage risks effectively , health and safety managers should closely collaborate with thermal fluid specialists to monitor fluid condition . Engineers should take a closed fluid sample when the system is hot , live and circulating , so they can accurately assess the fluid ’ s status . Quarterly sampling and thermal fluid analysis help engineers monitor its condition and inform health and safety managers on how to adjust procedures to minimise the risk of incidents .
In addition , facilities have the option to employ remote condition monitoring , which can improve proactive maintenance efforts . Cloud-based remote monitoring systems use live , real-time analytics to diagnose potential issues . As soon as the system detects an anomaly , it warns maintenance personnel by sending an alert to their smart devices . This pioneering technology empowers engineers to prolong the safe and effective use of thermal fluid .
For support and advice on how to get the most out of your heat transfer system , and prolonging the life of your thermal fluid , contact Global Heat Transfer .
For further information , please visit www . globalhtf . com
72 PECM Issue 68