Thermal fluid systems: Monitoring matters

ATEX (Atmosphère Explosible) and DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) legislation stipulate that firms that operate thermal fluid systems must monitor and manage the condition of their systems in order to protect employees from risk of fire or explosion. PUWER (Provision and Use of Work Equipment Regulations) stipulates that all installations, including thermal fluid systems, are operated correctly and properly maintained.

Regularly monitor the condition of thermal fluid 

Thermal fluids are typically oils, and each has a flash point - the minimum temperature at which, in the presence of ignition sources such as light switches, pump failure or sparks, its vapours will ignite. In order to prevent ignition, it is essential to ensure that each oil’s flash point remains within safe parameters.

While most companies are aware that thermal fluid systems operating above the flash point of the fluid within must be maintained according to legislation, 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 operating temperature at installation become flammable.  

Regular fluid sampling and analysis is required to ensure that minimum flash points are not reached.

Use long-lasting thermal fluids

Employing a thermal fluid with a high flash point combined with chemical stability, prolongs the period for which it may be safely used, making it cost-efficient.

This summer, TFS launched TFS Magma Ultima and its food grade sister, TFS Thermaltrans FGS, two semi-synthetic heat transfer fluids with flash points in excess of 260°C. The chemical composition of these ensures a considerable level of stability, allowing the fluids to resist for longer the process of degradation and consequent flash point reduction.

Recondition rather than replace thermal fluid

Historically, the only option for firms whose thermal fluids required flash point restoration was total replacement. TFS offers a cost-effective alternative in the form of reconditioning: HTfluidfit extends fluid life by a factor of at least 10, saving customers up to 70% of their thermal fluid costs.

Using patented 'flash evaporation' technology, TFS’ rigs remove volatile organic compounds (VOCs) from the oil, returning it to a safe condition.

Employ a long-term risk management strategy

Only a continuous risk assessment and management approach to thermal fluid system monitoring and maintenance will ensure a system’s safe and efficient operation and ATEX, DSEAR and PUWER compliance at all times.  

TFS creates for its clients bespoke risk assessment and management plans, and the explosion protection documents that form part of the plans enable clients to prove their safety credentials to insurers and so reduce their premiums.

TFS this year celebrates its 20th anniversary, and one of the things it will be doing is developing its risk-management offer further.