Heat Transfer Fluid O&M

14/03/2023
Content
1. Heat Transfer Fluid Basic Principles
2. General System Design Considerations
Heat Transfer Fluid 3. Fluid Specifications and Operating Parameters
Operations & Maintenance

4. Review of Fluid Degradation Issues
Industrial Lubricants Training Program
5. Fluid & System Maintenance Review
Presentation to XXX 6. Fluid Flow Dynamics

DD.MM.YY
© 2020 Petroliam Nasional Berhad (PETRONAS)

All rights reserved. No part of this document may be reproduced in any form possible, stored in a retrieval system, transmitted and/or disseminated
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© 2020 Petroliam Nasional Berhad (PETRONAS) |
1 2
Heat Transfer Fluids
• Also know as:
 Thermal Fluids/Thermal Oils

 Heating/Cooling Fluids
 Hot Oils
• Able to generate high temperatures at low system pressures
Heat Transfer Fluids • Offer safety, low maintenance & extended operating lifetimes
Heat Transfer Fluid Operations & Maintenance
• Highly efficient, non-corrosive & allow for accurate temperature regulation
and uniformity
Overview of Key Topics – Session 1 of 2
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Fluid Classifications Typical Applications Utilizing Heat Transfer Fluids
Chemical Natural Gas

Food Processing
Processing Processing
Concentrated Plastic Liquid Storage

Solar Power Manufacturing Tanks
Engineered
Hot Mix Asphalt Pharmaceuticals
Woods
Textiles Die Casting
© 2020 Petroliam Nasional Berhad (PETRONAS) | © 2020 Petroliam Nasional Berhad (PETRONAS) |
5 6
Basic System Elements
General System Design Elements

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HTF System Layout Heat Source/Sink
Fuel Fired Heaters:

 Typical Design: HTF recirculates through cylindrical coils. Gas or oil-fired burner fires into the
center of the coils system
 Electric Heating
 Typical Design: Electric heating elements are immersed into circulating fluid
 Watt-density important:
 Typical max watt-density of 20 watt/in2 with 1.2-2.5 m/s velocity
 Waste Heat Recovery
 Biomass
 Direct Expansion Exchangers
 Chillers
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Circulating Pump Expansion Tank
 Operating temperatures up to 316oC Allows for thermal expansion of HTF

 Standard air-cooled centrifugal pump Location: high point in system
Vented to the atmosphere
 Operating temperatures above 316oC Key to low-system pressures
 Canned or mag-drive pump Fluid low-level switch is key safety feature

Low HTF volume (leak?)
 Y-Strainer/Side Stream Filter to protect Restricted flow (plugged lines?)
against wear Settled carbon buildup in tank
Inert gas (nitrogen) blanketing optional
Highly Recommended at bulk fluid operating temps above
260oF (130oC)
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Piping & Valves Recommended System Options
 Block valves – minimize fluid draining  Overflow Tank
 High point vents, low point drains  Control of potentially violent discharge of
hot fluid from expansion tank vent
 Pressure & temperature gauges on all loops  Should be closed-head & adequate size
 Inert Gas Blanketing System
 3-way valves or 2-way valves with back pressure control
 Side-stream Filtration Unit
 Filters designed for high temperatures
 10-20% bypass flow
 • Insulation
 Non-porous, closed-cell insulation
 5-8 cm away from connections/fittings
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Common Heated Processes

 Jacketed Reactors Hot Rolls for Converting
Hot Presses
 Liquid Storage Tanks
Commercial Ironers
 #6 Oil, Liquid Asphalt
Reboilers
 Plastics Molding Tools
Distillation Units
 Thermal Fluid Fryers Extruders Fluid Parameters
 Solar Collectors
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Fundamental Product Specifications Process Considerations
 Operating Temperature Range  Existing system?

 Maximum Operating Temperature  Compatibility issues with existing fluid?
 Minimum Operating Temperature  Continuous process?
 Minimum Start-up Temperature  Continuous exposure to high temps, accelerated
 Climate/Environment breakdown
 Other Considerations:  Local Climate
 Level of impurities (fouling @ high temps)  Cold weather areas, low startup considerations
 Specialized additive packages (typically narrow  Open to atmosphere?
the operating range)
 Preference to Synthetic vs. Mineral Oil base?  Oxidation is an issue
 Irritating vapor odor?
 Heat/Cool cycle necessary?
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Engineering Fluid with a Purpose High Purification
Balancing primary factors is an effort to create a desired functionality, The level of thermal fluid purification goes
targeting an ideal ratio of key product features beyond toxicity considerations, removing the
 Thermal stability impurities that catalyze fluid degradation &
foul equipment surfaces when continuously
 Heat transfer efficiency
exposed to high operating temperatures.
 Product purity
Benefits of Higher Purification:
Ancillary features to be considered
 Extended fluid service life
 Expansion rate
 Flash/Fire points  Reduction in maintenance activities
 Oxidation resistance
 Lower risk of equipment failure
 Start-up temperature
 Vapor pressure  Greater consistency in performance
 Cost vs. Performance
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Heat Transfer Efficiency - Inside Film Coefficient (hi) Heat Transfer Efficiency - Engineering Fluid Performance
 Fluid Inside Film Coefficient (hi) is used to represent the heat transfer efficiencies of each fluid  Efficiency (hi) determined by ideal combination of:
at a given set of operating conditions (fluid temp, flow dynamics, etc).
 Low Viscosity (μ)
 High Density (ρ)
 Considering all other operating conditions to be equal, the heat transfer efficiency of each fluid  High Thermal Conductivity (κ)
can be directly related to any other product at any given temperature by comparing calculated  High Specific Heat Capacity (Cp)
Inside Film Coefficients.
 Considerable advantages in Viscosity, Density,
Thermal Conductivity and Specific Heat Capacity will
 The higher the Inside Film Coefficient, the more efficient the Heat Transfer Fluid at the given result in better Heat Transfer Efficiency
set of operating parameters. characteristics at any proposed operating
temperatures and flow conditions.
 Calculated using established correlations between thermophysical properties and process-  Quality thermal fluid manufacturers take great care
specific flow dynamics (pipe size, fluid velocity, etc) in engineering fluids that balance the most effective
ratio of these key characteristics.
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Thermal Stability Thermal Stability - Summary
 ASTM D6743: Thermal Stability of Organic Heat Transfer Fluids

 Simulates the thermal degradation that occurs at the interior walls of fired-heater tubes When tested under identical conditions, superior heat transfer fluids display lower
the Degree of Decomposition values
 Test Temperature: Fluid Maximum Film Temperature
 Length of Test: 500 hours (continuous)
 Thermal Stability measures resistance to the irreversible damages to fluid properties that are
caused by long term exposure to heat More thermally stable fluids have significantly higher percentages of usable fluid
 Degree of Decomposition reflects the overall thermal degradation of the stressed fluid. The remaining at the conclusion of the testing period
lower the Degree of Decomposition, the better the Thermal Stability of the heat transfer fluid
relative to other fluids te.sted under the same conditions
When compared to competitive fluids, greater Thermal Stability will result in higher
heat transfer efficiency over time, longer fluid life and lower potential for system
damage and safety hazards when proper operating conditions are followed
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Technical Support
“Fluid degradation either reduces the safety margin or

Fluid Maintenance increases the amount of maintenance required.
Heat Transfer Fluid Operations & Maintenance Fluid degradation over time is inevitable, the goal is to
minimize the rate at which it happens.”
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Thermal Fluid Maintenance Degradation: Visual Example
Issues that Impact the Fluid/System
 Thermal Cracking (Overheating)
 Proper Start-up and Shut-down
 Oxidation
 Contamination
Key Maintenance Practice:
 Fluid Analysis Program
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14/03/2023
Visual Example: Solid Carbon Thermal Cracking (overheating)
Occurs when too much heat is applied to fluid & molecular bonds are broken (cracking) – Film
Layer.
 Leads to formation of “Low Boilers” (thinner fluid)
 Pump Cavitation; possible seal problems
 Excessive Low Boilers can Reduce Flash Point/AIT
 Reduced Heat Transfer Efficiency
 Probable Causes:
 Low Flow
 Flame impingement
 Excessive recirculation through heater
 Improper Start-up & Shut-down
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Preventing Thermal Cracking Proper System Start-up

Ensure that fluid is designed for Maximum Operating
Temperature of the Process  At low temperatures, fluids are more viscous and not as thermally efficient
If operating temp is 10oC over recommended max bulk temperature, fluid
life is cut in half
 Quick temperature rises cause thermal cracking at heated surfaces
 Start up slowly to keep heater from going to high fire until fluid viscosity drops to 10 cP
 See fluid & equipment manufacturer for recommendation
Maintain design flow rate through the heater at all times
 Once turbulent flow is reached, raise set-point at larger increments up to designed operating
temperature
 Turbulent flow typically starts at 80oC for most HTFs
Always follow proper Start-up and Shut-down procedures
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Proper System Shut-down Oxidation
 Turning off the circulating pump while at high operating temperatures could result in raising the  Occurs when Hot Fluid is continuously exposed to air.
temperature above the maximum bulk temperature of the fluid, which results in severe thermal  Accelerated Degradation
cracking within the heating chamber.
 Oxidation increases Rapidly at temps above 90oF
 Doubles with every 10oC rise in bulk fluid temperature
 Keep the main circulating pump operating when heater is powered down.  Increases in Fluid Viscosity, Sludge formation
 Probable Causes (Expansion Tank)
 At 95oC or less, the circulating pump can be shut off.  Elevated temperatures
 Fluid Flow directed into reservoir
 Warm-up valve should be CLOSED unless water is actively
being removed from the system
 Tank Insulated???
33 34
Visual Example: Sludge Preventing Oxidation
 Keep the Expansion Tank temperature below 65oC.
 Never Insulate the outside of the Expansion Tank.
 Ensure fluid bypass valve (warm-up) is closed under normal operating conditions.
 Install nitrogen blanket when tank temperature cannot be kept below 65oC.
 Install a cold seal pot.
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Contamination Special Case: WATER

 Speeds up degradation & complicates operation
 Introduced to the system by:
 Pump cavitation/failure, pressure issues, seal wear, fouling, filter plugging
 Drums left outside for extended periods
 Transfer pumps
 From System  Off-line equipment (i.e. filter carts)
 New system components
 Metals, varnish, old fluid, solids, etc.  Moisture from atmosphere
 From Environment  Water creates operating nightmares

 Water (drums, system, atmosphere)  Pressure fluctuations
 Flashing creates hot fluid discharge
 Damage to equipment (pump impeller, expansion tank)
 From User (most common)
 Improper fluid introduction
 Must be Boiled Out (time consuming process)
 Industrial fluids(lubes, hydraulic fluids, glycols, etc.)
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Cleaning Fouled Systems
 Should only be considered when operating/performance issues are verified by professional

fluid analysis
 Two distinct methods:

 Dedicated solvent cleaner
Common Maintenance Scenarios
Heat Transfer Fluid Operations & Maintenance  Drain, clean, flush, refill
 On the fly” additive cleaner
 % of system volume, cleans over time without dedicated interruption to Production

 Disposal of waste oil needs to be considered
 Local regulations apply
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Proper Fluid Changeout Compatibility Concerns
 Draining Systems  Materials of Construction

Before draining your system, have the fluid analyzed by the manufacturer to determine if flushing or cleaning  Polymers/Seals/Gaskets etc.
is actually necessary. If it is, you’ll get more of the solids/sludge out by keeping the fluid as hot as possible
(87ºC — 98ºC) while draining. Also, run the pump until cavitation occurs…this keeps system contaminants
from settling out.  Fluid/Fluid Compatibility
 Existing Fluid Replacement (TEST !)
 Charging Systems  Top off vs. drain/recharge considerations
Throttle the block valve on the main pump discharge for cold circulation (or cycle a gear pump on and off) to  Miscibility
prevent pump damage. Add fluid when the pump cavitates and slowly increase the flow rate until the entire  Reactivity
system is full. Make sure you fill all the loops.  Contamination – degradation/maintenance
contaminants
 Heater Startup
Increase the system temperature slowly to between 98ºC and 120ºC. Pump cavitation and expansion tank  Water (aqueous cleaners, moisture contaminants)
“geysers” mean there is water in the system. The only way to completely remove water is to flash it to the
atmosphere. System is dry when pump is stable at suction temperature of 110ºC.
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Routine Physical Monitoring
System Observations
• Listen & Look
• Gauge readings
• Set points & operating conditions
Differential Pressures
Fluid Flow Dynamics
Exhaust Stack Temperature Heat Transfer Fluid Operations & Maintenance
Periodically Record Readings
• Monitor & Report Changes
• Monitor flows & pressures
Signs of Degradation
FLUID ANALYSIS !!!
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14/03/2023
Fluid Flow, Heat Transfer & Breakdown Critical Focus: Heated Pipe Wall*
Heat Transfer Energy Movement *any heated transfer surface at the system heat source
 Heat is ENERGY
 Need proper FLOW to move that energy  Heat Source (fired heater, electric element, etc.) is the area of Highest Energy Concentration
Typical Heat Transfer ENERGY MOVEMENT:  Primary area where thermal fluid most prone to thermal breakdown
 Fluid needs to be at high (TURBULENT) flow to efficiently transfer heat energy out of heater
45 46
Turbulent Flow & Reynolds Number Flow & Degradation
Reynolds Number (Re)

1st Law of Thermodynamics:
 Accounts for inertia & viscous forces to identify the state of fluid flow (dimensionless)
 High Re = more turbulent flow = better heat transfer • Heat Energy not transferred out of the heater via bulk fluid movement needs to
go somewhere: Energy to Break Fluid Molecular Bonds
 Re > 10,000 = turbulent flow regime • CRACKED (overheated) FLUID
Occurs at FILM LAYER
• Highest heat flux + fluid flow is substantially lower along the wall surface
Low Re contributors:
• High viscosity fluid
• Low operating set point for fluid flowrate
• Stagnant fluid/flow impeded by plugged lines
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Proper Fluid Flow: TURBULENT, CONTINUOUS Cracking HTF – Film Layer Fouling
High heat flux at pipe wall (heated surface)

will not be conveyed effectively into the bulk
fluid flow and out of the heating chamber
when flow is too low for efficient heat transfer.
This energy concentrated at the film layer will

then be focused on breaking molecular bonds
& degrading the fluid – COMPOUNDING
PROBLEM
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Additional Fluid Flow Considerations Enhanced Thermal Fluid Experience - In Summary
 Pressure Differentials (through heater) Heat Transfer Fluids play an integral part in the production of many of the essential elements that we rely on
in of our daily lives in addition to the fundamental processes that our industry depends on
 Pumps
 Sizing Selecting the proper fluid for an operation is crucial
 Cavitation • Choose the right fluid to optimize...
• Operating specifications
 Cold Spots (low flow areas) • Equipment design
• Budget, etc
 Blocked sections • Superior fluids will feature the most effective combination of
 Friction factors at fittings • High purification
• Heat transfer efficiency
 Pressure drops • Thermal stability
 Extreme Low Flow

Enhanced Service Experience
 Insufficient Volumes • Maintain a close working relationship between Customers, HTF supplier, & OEMs
 Possible cracked heater tubes - FIRE • Know system & operation inside & out: monitor, react, report
• Properly maintain the system & fluid. FLUID ANALYSIS IS KEY
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14/03/2023
Thank you for your passion!
53

Heat Transfer Fluid O&amp;M

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14/03/2023

1. Heat Transfer Fluid Basic Principles

2. General System Design Considerations

Heat Transfer Fluid 3. Fluid Specifications and Operating Parameters

Operations & Maintenance

5. Fluid & System Maintenance Review

Presentation to XXX 6. Fluid Flow Dynamics

© 2020 Petroliam Nasional Berhad (PETRONAS)

Heat Transfer Fluids

• Also know as:

 Thermal Fluids/Thermal Oils

Overview of Key Topics – Session 1 of 2

© 2020 Petroliam Nasional Berhad (PETRONAS) |

Fluid Classifications Typical Applications Utilizing Heat Transfer Fluids

Chemical Natural Gas

Concentrated Plastic Liquid Storage

Textiles Die Casting

Basic System Elements

General System Design Elements

Overview of Key Topics – Session 1 of 2

© 2020 Petroliam Nasional Berhad (PETRONAS) |

HTF System Layout Heat Source/Sink

Fuel Fired Heaters:

Circulating Pump Expansion Tank

 Operating temperatures up to 316oC Allows for thermal expansion of HTF

 Canned or mag-drive pump Fluid low-level switch is key safety feature

Piping & Valves Recommended System Options

 Block valves – minimize fluid draining  Overflow Tank

Common Heated Processes

Overview of Key Topics – Session 1 of 2

© 2020 Petroliam Nasional Berhad (PETRONAS) |

Fundamental Product Specifications Process Considerations

 Operating Temperature Range  Existing system?

Engineering Fluid with a Purpose High Purification

Thermal Stability Thermal Stability - Summary

 ASTM D6743: Thermal Stability of Organic Heat Transfer Fluids

“Fluid degradation either reduces the safety margin or

Overview of Key Topics – Session 1 of 2

© 2020 Petroliam Nasional Berhad (PETRONAS) |

Thermal Fluid Maintenance Degradation: Visual Example

Issues that Impact the Fluid/System

 Thermal Cracking (Overheating)

 Proper Start-up and Shut-down

Key Maintenance Practice:

 Fluid Analysis Program

Visual Example: Solid Carbon Thermal Cracking (overheating)

Preventing Thermal Cracking Proper System Start-up

Always follow proper Start-up and Shut-down procedures

Proper System Shut-down Oxidation

Visual Example: Sludge Preventing Oxidation

 Keep the Expansion Tank temperature below 65oC.

 Never Insulate the outside of the Expansion Tank.

 Install a cold seal pot.

Contamination Special Case: WATER

 From Environment  Water creates operating nightmares

Cleaning Fouled Systems

 Should only be considered when operating/performance issues are verified by professional

 Two distinct methods:

Overview of Key Topics – Session 1 of 2

© 2020 Petroliam Nasional Berhad (PETRONAS) |

Proper Fluid Changeout Compatibility Concerns

 Draining Systems  Materials of Construction

Routine Physical Monitoring

FLUID ANALYSIS !!!

Heat Transfer Fluid O&M

Heat Transfer Fluid O&M