Guide to Maintaining Thermal Fluid Systems

The Importance of Regular Heating System Service
Inspecting Your Thermal Fluid System's Parts
Thermal Fluid Maintenance
Contact Sigma Thermal for Thermal Fluid System Services

Thermal fluid systems provide a reliable, cost-effective heating option for facilities requiring direct or indirect heating. Thermal fluid heating systems run on a closed loop, continuously circulating fluid to maintain stable temperatures at lower pressures. When thermal fluid can’t move through the system properly, this can disrupt operations and lead to costly repairs. Likewise, cracking and oxidation can reduce system efficiency and lead to safety risks. Flushing, draining, and charging thermal fluid can help prevent major issues and impact the overall performance of your heating systems.

Learn how regular thermal fluid system maintenance can maximize uptime and prevent costly shutdowns. We’ll discuss what symptoms to look for and discuss preventative measures that can extend the service life of your system.

Guide to Maintaining Thermal Fluid Systems

The Importance of Regular Heating System Service

While modern thermal fluid systems facilitate easy installation and efficient operation, they require regular maintenance. Sludge and contaminants can build up over time, negatively affecting the system’s integrity. Alternatively, loose connections or weak spots in piping can disrupt critical system processes. Scheduling regular maintenance can address these issues before they cause additional problems. It also reduces the risk of costly system shutdowns and unplanned downtime.

Remember that certain environmental factors, such as harsh weather conditions in outdoor applications, should also be evaluated. These could put further stress on your thermal fluid heating system.

Inspecting Your Thermal Fluid System's Parts

Inspecting individual parts for wear or damage is important for thermal fluid heater maintenance. This process involves the following key steps:

Routine Visual Inspections
Regular maintenance isn’t the only way to prevent costly issues with your heating system. Visual inspections play a significant role in preventative maintenance. You can monitor system performance and energy usage to determine if any elements cause your systems to operate inefficiently. Regularly inspecting your facility’s thermal fluid heater can help you pinpoint weak spots in the system. Familiarize yourself with all functional components, including those on the heater’s exterior. If you see increased operating costs associated with your heater or heating system, a Sigma Thermal expert can help identify the source of performance issues.
Yearly Service Inspections
In addition to visual inspections, you should also schedule annual service inspections. These promote safety and efficiency in your systems. Professional inspections can also minimize the risk of health and safety risks at your facility.

A specialist can look closely at the unit to confirm that the components are working properly. In addition to inspecting the heater, they will also look at the following:
- Insulation: Thermal fluid heaters require adequate insulation to operate efficiently. Our specialists can ensure the insulation is secure and in working condition.
- Piping: Thermal fluid heating systems often use a significant amount of piping to circulate fluid through the heating system. An expert can help identify any leaks or weak areas requiring repairs or replacement.
Planning and performing upgrades or modifications allows managers to strategically address problems that have accumulated over time. Our engineers can assess your needs and suggest upgrades and modifications to optimize your system’s performance.

Thermal Fluid Maintenance

While maintaining thermal fluids may not be the first thing plant managers consider, doing so is critical to ensure reliable thermal fluid system performance. Proactive measures can help you detect sudden changes in the quality of thermal fluids and improve the overall efficiency of your heat transfer systems.

A specialist should regularly sample thermal fluid to assess its condition. Fluid sampling can detect degradation, which occurs when fluid is heated past its boiling point and continually exposed to oxygen. Degraded oil forces pumps to work harder, which wastes energy and can hinder performance. Sampling can also reveal increased levels of carbon and other contaminants that can reduce the efficiency of thermal fluid. By addressing problem areas early, plant managers help reduce waste and remain compliant.

When a performance problem is detected early, inexpensive maintenance methods can be used to restore the fluid’s physical properties. However, severe degradation can take more work to reverse. Replacing degraded fluid can leave behind undissolved contaminants. The new fluid picks up these contaminants, acting as a solvent and dissolving harder deposits in the walls. Further degradation can lead to system failure and the shutdown of your system operation, which may require lengthy downtime if a replacement heater is needed.

Symptoms of Fluid Degradation or Contamination

The following are signs of possible fluid degradation or contamination:

Higher pressure drops
Longer batch times
Fluid leaks
Pump cavitation
Longer heat-up or cool-down times
Expansion tank overflow
Changing temperatures in process exchangers
Gurgling noises
Relief from PSVs
Changes in fluid odor or color
Seal failures
Plugged vessel jackets or instrument lines
Corrosion in pipes or valves
Plugging or fouling of pipes
New vibrations
Failure to start at lower temperatures
Heater bundles that cannot be removed
Reduced flow rates
Over temperature alarms

Types of Thermal Fluid Degradation

Several different types of fluid degradation can impact system integrity:

Thermal Stress Degradation
Specific deficiencies can reveal damage caused by thermal stress. This type of damage occurs when surface temperatures exceed levels that fluid molecules can handle, which causes those fluid molecules to break down. Common root causes of thermal stress degradation are high heat flux rates, low fluid flow conditions, or high-temperature excursion.
Oxidation Degradation
Testing can reveal damage caused by oxidative degradation. This type of degradation occurs when fluid is exposed to oxygen at high temperatures. Oxidative degradation can lead to the formation of weak acids and cause sludge to build up in the system.
Event-Related Degradation
Event-related degradation occurs when an outside contaminant enters the system. Adding the wrong make-up fluid (or adding contaminated make-up fluid) can damage otherwise functional heating systems. Undetected process equipment leaks can also lead to thermal stress and oxidative degradation.
Age-Related Degradation
As thermal fluid ages, degradation will inevitably occur. Many operators replace a percentage of the total fluid volume with new fluid every year. This process is known as “sweetening” and can be done as part of a fluid rehabilitation program. Testing can quickly tell you whether it’s time for a full replacement if you are unsure how old your thermal fluid is.

Contact Sigma Thermal for Thermal Fluid System Services

Choosing a well-engineered thermal fluid system is just the first step in optimizing performance. Proactive maintenance will help you get the most value out of your thermal fluid systems and improve efficiency in the larger system. It can also prevent costly shutdowns and ensure compliance with insurance requirements.

At Sigma Thermal, we provide aftermarket solutions that maximize productivity and extend the service life of your process heating equipment. Our maintenance, retrofitting, upgrading, and OEM replacement services will keep your heating systems working the way they should.

Contact us today to learn more about our thermal fluid heating systems and related products. You can also request a quote based on your specific project needs.

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