FEATURE BOILERS, BURNERS & CONTROLS
THERMAL FLUID SYSTEMS: managing risk of fire and explosion
Manufacturing plants operating thermal fluid systems must proactively manage the risk to employees from fire and explosion, says Richard Franklin of Thermal Fluid Solutions
A
n estimated 3,000 companies within the UK’s process industries operate
thermal fluid systems to transfer heat around their manufacturing plants. ATEX and DSEAR health and safety legislation stipulates that these firms must proactively manage the risk associated with their systems in order to protect their employees from risk of fire and explosion. These companies need to adopt a continuous risk assessment and management programme and how doing so can save money and lives. The heat transfer media used in thermal fluid systems is typically mineral or synthetic oil. The systems’ operating temperatures are invariably higher than the ‘closed cup flash point’ of the media; in the presence of a source of ignition, the fluids could ignite. Where such systems operate under high pressure any leaks from the pipework at points such as flanged joints can create mists or sprays which can create an explosive atmosphere outside the system. Thermal fluids operating above their
flash points are classified as hazardous substances as are those handled below their flash points but under pressure. Whether inside or outside thermal fluid systems, on ignition volatile atmospheres result in fires and explosions and European ATEX (Atmosphère Explosible) legislation - implemented in the UK via DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) - stipulates requirements for the protection of workers against such incidents arising from the presence of hazardous substances in the workplace.
DEGRADATION OF ORGANIC THERMAL FLUIDS While most companies are aware that thermal fluid systems operating above the flash point of the fluid must be maintained according to DSEAR many do not appreciate that organic thermal fluids based on mineral oils degrade over time. Degradation can cause a fluid’s flash point to decrease as ‘light’ materials with lower flash points than the heat transfer fluid itself are generated, reducing the flash point of the fluid overall so that fluids that were not flammable at the
22 SEPTEMBER 2016 | FACTORY EQUIPMENT
identify and manage potential leak points, for example. The importance of adherence to DSEAR cannot be overstated. Over a 10-year period clients of insurer FM Global experienced 54 fires and explosions caused by thermal oil. In February 2010 the thermal oil boiler at a wood processing plant in Northern Europe exploded, killing three people. Thermal Fluid Solutions (TFS) has been
helping firms within the process industry to achieve and maintain legislative compliance for 20 years, minimising and managing their risk. It has clients across a range of sectors including food, wood panel, petrochemicals and fine chemicals such as Premier Foods, Dow Chemical Company, Pfizer and Airbus. While TFS’ development of bespoke
operating temperature at installation become flammable.
REGULAR FLUID SAMPLING AND ANALYSIS DSEAR demands that the risks inherent in the use of flammable fluids are assessed and eliminated or reduced. Regular fluid sampling and analysis is required to ensure that flash points are not exceeded. If necessary, oil must be replaced or
conditioned so that a safe flash point is restored. The thermal fluid systems themselves need to be scrutinised to
TFS rigs recondition customers’ thermal oil in order to maintain appropriate flash points
Regular fluid sampling and analysis is required to ensure that flash points are not exceeded
comprehensive continuous improvement plans enables clients to meet DSEAR standards, the explosion protection documents that form part of the plans enable clients to prove their safety credentials to insurers and in turn reduce their premiums. One of the main elements of TFS’ work is the reconditioning of customers’ thermal oil in order to maintain appropriate flash points. The company was the first to offer this service which is a quick, cost-effective, environmentally sustainable alternative to total fluid replacement: HTfluidfit extends fluid life by a factor of at least 10, saving customers up to 70% of their thermal fluid costs. Since its launch as Heat Transfer Systems in 1996 TFS has reconditioned over 10 million litres of thermal oil across 150 systems in 15 countries, saving customers in excess of £20 million in the cost of replacement oils, excluding the cost of disposal and downtime. DSEAR compliance requires ongoing commitment to risk management but with retained help from the right specialist provider, this commitment need not be onerous and can save a lot of money.
Thermal Fluid Solutions T: 0800 917 9274
www.thermalfluidsolutions.com
/ FACTORYEQUIPMENT
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