PLANT MANAGEMENT
Thermal fl uid testing can be complex so expert guidance is advisable
by working with dangerous substances. If this fl uid is left unattended, for example, fl uid degradation – where thermal oils can be broken down into carbon molecules that stick to the pipes – can occur, reducing heat transfer effi ciency. If not monitored eff ectively, degradation may go unnoticed until it causes signifi cant production issues and system failure, leading to costly downtime and risk to health and safety. Instead of reacting to issues, regular
thermal fl uid sampling and analysis enables businesses to proactively monitor fl uid condition and intervene before issues impact production, extending thermal oil lifespan and reducing maintenance costs.
TESTING TIMES Clive Jones explores the ins and outs of thermal fl uid analysis H
ow do you know when a kitchen sink is about to clog and overfl ow? Most residential pipes are hidden, so food waste and product
build-up can go unnoticed until it leads to damage. In manufacturing, leaving pipework unmonitored can lead to unexpected downtime and safety issues, particularly when working with thermal fl uids, so proactive monitoring is the best way to prevent these problems. Here, we outline the steps of thermal fl uid analysis for proactive fl uid monitoring and how businesses can use the results to increase fl uid lifespan. T ermal fl uids are designed to operate eff ectively for many years, but over
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time, operating at and maintaining high temperatures means that the oil will naturally degrade. T ermal fl uid analysis provides a deep dive into the condition of the oil and allows businesses to gain expert advice about how to eff ectively maintain the fl uid and the system. Analysis also ensures health and safety compliance with the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) of 2002 and UKEX (formally the Explosive Atmosphere Directive ATEX 137 in the UK). To comply with relevant safety
regulations, such as DSEAR in the UK, manufacturers must take proactive steps to reduce the risk of fi re or explosion caused
ANALYSING A SAMPLE Eff ectively monitoring heat transfer oil condition requires engineers to regularly take samples of the oil and send it to a specialist for analysis. Historically, thermal fl uid experts conducted seven tests, however, in our experience conducting eleven tests provides results that best refl ect the reality of what’s happening inside the system. Once the sample arrives to an impartial lab for testing, an analytical chemist will look at its appearance, looking at the colour and for any particulates in the fl uid. Fluid colour can range from clear and bright, which is common to newer fl uids, to hazy, which can be a sign of high-water levels, to dark, which shows there is a high level of carbon build up in the system. T ese initial observations are confi rmed in later steps to ensure the thermal fl uid specialist provides the best recommendations. Testing the water content of the oil is
vital to regulatory compliance. Any water in the system and oil will convert to steam and expand, increasing the pressure in the system. By analysing water content, analysts and heat transfer fl uid specialists can advise on how best to reduce the risks associated with high pressure. T e next step is to test viscosity and assess the impact the fl uid has on the system pumps. If a fl uid is too thick, fl ow rate will reduce, increasing the pressure on the pumps. T is reduced fl ow rate can create hot spots in the system, leading to inconsistent heating or cooling of products that results in waste products, increased damage to the system and rising maintenance costs.
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