Heat Transfer Systems and Safe Chemical Processing
From proactive risk assessments to comprehensive training: A deep dive into ensuring safe and sustainable heat transfer in manufacturing facilities.
- By Tim Powell
- Oct 11, 2023
Manufacturers frequently employ heat transfer systems to sustain the high temperatures necessary for various forms of indirect heat transfer processes. Historically, facilities opted for steam-based systems because water is readily available, affordable, and commonly regarded as sustainable. However, achieving the temperatures required for industrial processes necessitated operating the system at extremely high pressures of around 1200 psi (83 Bar). This meant that, without adequate steam ventilation mechanisms in place, the pipes ran the risk of bursting and gaskets failing, allowing hot steam to escape, and putting 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 -130 to +1112 degrees Fahrenheit.
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 predictive maintenance and remote monitoring, to eliminate them as much as possible. Thermal fluid, while classified as a dangerous substance, can offer reliable service for many years when monitored and managed proactively. This can be a safer, more sustainable, and cost-effective solution for manufacturers.
Risk Management
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 thermal 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. These findings enable health and safety managers, along with production and engineering managers, to track the fluid’s condition over time and adjust procedures to minimize the risk of incidents.
This article originally appeared in the October 2023 issue of Occupational Health & Safety.