Working effectively as a closed-loop system with minimal intervention, thermal fluid systems are often perceived to be low maintenance because of their stability and reliability.
However, with rising operational costs, changing environmental regulations and increased competition, uptime and process efficiency are more critical than ever.
That’s why manufacturers should take proactive steps to maintain their heat transfer fluids and system, says Dave Dyer, Technical Sales Engineer at thermal fluid experts Global Heat Transfer.
Thermal fluid systems typically run well for many years with limited intervention.
However, all thermal fluids degrade with time; as such, a reactive maintenance strategy means that any degradation or build-up of contaminants may go unnoticed until it significantly impacts operations, leading to reduced efficiency and/or a drop in quality.
When problems arise or production levels drop, engineers may have to resort to a quick fix to minimise downtime, such as turning up the heat of the system — increasing resource and energy consumption.
This, combined with the risk of downtime, means that many facilities are moving away from reactive and towards a more proactive approach.
Reactive to proactive
Implementing a proactive thermal fluid maintenance strategy that’s tailored to the system’s specific needs enables engineers to better understand and maintain it. Proactive maintenance can help to improve uptime, conserve resources and extend the lifetime of both fluid(s) and equipment.
By assessing existing practices and considering common failures or pain points, manufacturers can identify potential areas for improvement. The maintenance plan should include regular inspections of core components, preventive maintenance tasks, increasing staff knowledge and predictive analytics.
By identifying potential issues during these inspections, engineers can intervene promptly.
Proactive maintenance enhances operational efficiency by preventing equipment failures and minimising unplanned downtime, allowing for smoother production processes and increased productivity.
Beyond operational efficiency, proactive maintenance promotes sustainable practices by reducing waste, emissions and energy consumption.
Adhering to proactive fluid maintenance procedures can optimise performance, extend equipment lifespan and reduce the regularity of thermal fluid changes, helping to reduce waste and conserve energy.
Furthermore, by extending equipment lifespan and optimising fluid performance, proactive maintenance helps manufacturers reduce long-term maintenance costs and improve overall profitability.
Fluid maintenance
Regular fluid monitoring is a key part of proactive maintenance because, once the thermal fluid enters the system, it is no longer visible. Sampling fluid when the system is closed, hot and circulating will help to provide an accurate representation of what’s happening inside.
Analysis of the fluid sample enables engineers to determine if there are any immediate signs of degradation. Engineers can also track sample data with time to identify trends in performance and contamination levels to better monitor fluid condition.
By monitoring trends, engineers can schedule maintenance, devising a plan regarding how to intervene, with options such as fluid dilution or filtration available to address changes in fluid condition as needed.
Installing a filtration system that can remove solid carbon deposits or other contaminants can help to improve the condition of the existing fluid and reduce wear on system components caused by contaminants.
Remote condition monitoring tools can further support thermal fluid management. By continuously tracking fluid condition, engineers can access real-time data from any location. Maintenance engineers can receive alerts as soon as fluid condition changes, so that they can address it quickly before a problem occurs.
Knowledgeable staff
Having a well-trained team of engineers that’s proficient in operating and maintaining equipment is integral to improving maintenance procedures.
Increasing team understanding about the heat transfer system and thermal fluid equips engineers with the knowledge and skills necessary to anticipate and address potential issues before they escalate.
Training on key activities, such as thermal fluid sampling, maintenance, safe handling and storage of fluids and system checks, ensures that employees are aware of what’s required for compliance and proactive maintenance.
Training on safety, PPE and where to access equipment such as fire extinguishers and spill kits in case of a leak is also important. Comprehensive training on proactive maintenance not only prevents costly downtime and extends equipment lifespan, it can also help to conserve resources, reduce energy consumption and maintain uptime.
Safeguarding your system
When signs of thermal fluid degradation appear, engineers can install complementary components to address any issues. Insulation, for example, can minimise heat loss, decrease energy consumption and improve facility temperature control, extending the lifespan of both the fluid(s) and the system.
Another possible situation is a build-up of light ends, short chain hydrocarbons that can form as a degradation product of thermal oil, which lower the flash point of the fluid and can be detrimental to health and safety.
A light ends removal kit (LERK) installed within the system effectively captures and removes these volatile compounds, further extending the lifespan of the fluid.
Even with diligent maintenance, after years of service a thermal fluid will eventually degrade to a state at which it must be replaced.
At this point, a thermal fluid specialist can help to dispose of the fluid as sustainably as possible by repurposing or reprocessing the material for a different application or industry when possible.
By implementing procedures that improve proactive maintenance and system efficiency, manufacturers not only minimise downtime, they can also conserve resources, reduce costs and minimise emissions when possible, resulting in a more resilient manufacturing process.