We took two Tasks – Commitments,
- To make Thermic fluid System safe-n-healthy TMe. safe to operate and Healthy with profits.
- To save Thermic Fluid from discard or waste.
These tasks took us to various companies all over India and abroad; to various sectors like Textile, Chemical, Pharma, Plywood, Glass, Automobile, Furniture, Edible oil, Rubber, Paints etc.
We conducted System Audits to make them Safe and Healthy, Trained people in operations, Packed valves to make them permanently leak free, Reduced Pump leakages to minimal, Improved Deaeration to stop degradation, Supplied Filtration systems and Online Chemicals to remove carbon etc. Thru these activities; We could save almost 14,00,000ltr of oil from replacement up to this year.
During these visits, we came across various lacunae in operations. This Series of articles is sharing of our knowledge, as an outcome of the same.
Please share you experiences, your expectation of topics and let us know any name is to be added.
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I was talking to my friends. Topic was Heating problem in Thermic fluid system installed in well known Industry. I was surprised to hear about problem because the system was well designed. It was operating quite efficiently, everything was in order. How come suddenly problem started?
The consultant said,” Yaar, They had some balance capacity in the Heater. They expanded and …..”
Friends, If you are expanding, It is important to plan in advance.
In case of Thermic fluid, following things are very important.
- Generation of heat.
- Carrying / Delivering heat.
- Absorption of heat.
Generation of heat:
Please ensure that there is excess capacity available on the heater. Consider Higher heat demand during winter / monsoon.
Simple way to check:
- Check if you are burning full rated fuel and stack temperature.
- What is On – Off frequency of heater.
It is critical to have good designed velocities at piping. We have to consider various numbers such as Reynolds no, Prandtl no, LMTD for proper heat transfer. Apart from selection of pipe, Gasket, Nut bolts, Insulation (Flanges have different method of Insulation in Thermic fluid system), ensure velocities. (Slower velocity also helps in settling of carbon)
We may have to put up additional secondary (Booster) pump to carry heat to utility. People prefer to have only one pump hence Increase capacity of Primary pump. This increases pressure drop,Leads to more power consumption. Motor HP will increase. Instead, Add secondary circuit – secondary pump for delivery of heat.
Again Surface cleanliness, velocity, time & turbulence will decide heat absorption.
Additional utility will increase total oil hold up. It will also add to additional expansion of oil. Hence we may have to design for additional expansion tank. Design tank in such a way that the tank temperature NEVER crosses 60°C. In some areas, we have found that the temperature initially crosses 90°C – 100°C which over a period of time reduces to 70°C. This still induces oxidation – degradation of oil.
Deaeration is another problem we face after expansion. As deaeration also needs designed velocity.
Ensure to install side stream filtration upto 5 micron only. This will work as kidney; filtering out unwanted floating carbon, viscous material, Dirt, Dust etc.
Check velocity, temperature differential required at utility. Sizing of nozzles indicate flow requirement. Length of pipes, bends and number of valves decide pressure drop. Accordingly, we may have to size the secondary flow.
Please take care of problems before expanding; Get higher oil life, Prevent loss of oil, Manpower cost, Avoid forced shutdown and enjoy the fruits of expansion – trouble free.