Top 10 Tips for Extending Fluid Life and Optimising Output

You can minimise the risk of loss of production and improve system efficiency by observing some simple procedures. In doing so you’ll reduce the chance of thermal cracking, oxidation and contamination of your thermal fluid.

Extend the life of your thermal fluid by following our top 10 tips;

Avoid Thermal Cracking

  1. Avoid Sudden Shutdowns - Allow fluid to circulate until the heater outlet temperature is a maximum of 120°C. If repeated power failures occur, consider connecting a pump to an auxiliary power source.

  2. Bring Cold Systems Up to Temperature Slowly
Cold fluid can overheat and crack if the heater operates at full power from start-up. Fluid temperature should be increased in 15°C increments until fluid viscosity is less than 10 CPS (check your fluid’s property table). Make sure this procedure does not heat up the system more rapidly than manufactures recommendations.

  3. Maintain Consistent System Pressure 

    A drop in pressure across the entire system should be calculated when sizing pumps. System by-pass valve response should be tuned to maintain design fluid flow rate under all process conditions. Filters and strainers should be properly located and monitored to prevent blinding.

  4. Maintain System Instrumentation - Failure of high temperature and/or low flow alarms not only cause overheating but can create potential for equipment fires. Regular system checks will help you identify any issues. 

  5. Check the Combustion Chamber- Improper flame propagation or burner alignment can cause overheating and potential equipment fires.

    Minimise Oxidation

  6. Keep the Expansion Tank Below 60°C - Smoke emitting from the expansion tank vent line is usually a sign that the expansion tank is too hot. Install a nitrogen blanket in the tank. Never continuously operate a system with the warm-up valve open. The tank itself and lines leading to it should be left uninsulated. 

  7. Maintain Positive Net Pump Suction Head (NPSH) at All Times - High vacuum due to flow restrictions (such as plugged strainers) can cause seal wear and allow air to be sucked into fluid.

    Minimise Oxidation

  8. Contaminants can promote fluid degradation as well as cause operational problems. Regular sampling of your thermal fluid will tell you if the thermal fluid in your system contains debris and will also ensure you operate in accordance with DSEAR / ATEX  health and safety regulations by monitoring flash points.

  9. System Cleaning - Complete draining from all system low points is required when using a flushing fluid such as Globaltherm™ C1. At least one full charge of new heat transfer fluid should be used to flush the system if complete draining is not possible.

  10. Daily Operation - Always use fresh thermal fluid to top up a system.

If you have a problem with your thermal fluid system don’t hesitate to contact us