Over time, the molecules in a thermal fluid will break down by a process called thermal cracking and oxidation, creating volatile light ends, and heavy ends and organic acids. As well as causing the thermal fluid to degrade, thermal cracking and oxidation also produces carbon molecules that stick to the pipes and system, which reduces efficiency.

Furthermore, organic acids which results from the oxidation process are both corrosive and help to accelerate the production of carbon and fouling. Light ends lower flash points and increase risk of fire.

If a fluid and system are left unattended the fluid will potentially thermally degrade at a much faster rate. You may only notice this once it begins to impact production.

Once this occurs you must test and analyse a sample of the fluid and respond to the data with the appropriate intervention. If necessary, you must shut down production, drain, clean and flush the system and then purchase new fluid, which is a costly and time-consuming process.

Regularly monitoring of thermal fluid will extend the life of your fluid, slow degradation and reduce carbon deposition and fouling that will damage your heat transfer system and reducing risk by managing flash points as they change. Monitoring thermal fluid can also help you to optimise the system, reducing energy costs, improving health and safety and reducing downtime.

Regular sampling & analysis can also act as an early warning system, allowing you to anticipate the end of the fluid’s life. At this point, you can plan effectively for system and fluid management interventions.

Our Thermal Fluid Testing & Analysis service includes:

• Site visits from our experienced engineers to safely collect representative hot, closed samples in line with recommendations from the Health
• Safety Executive (HSE) and DSEAR / ATEX regulations and decanted under lab conditions
• A suite of 11 approved thermal fluid tests performed by a fully accredited independent laboratory
• Expert analysis based upon the individual case history of your system
• Expert interpretation of the data and advice on maintaining maximum system and thermal fluid efficiency
• Expert recommendations to ensure you comply with health and safety legislation
• Full report of our findings and recommendations where necessary
• A compilation of system trends and service history in order to pre-define thermal fluid performance

The main benefits to monitoring the condition of your thermal fluid are:

• Operate a safe business knowing your thermal fluid is analysed in line with DSEAR / ATEX requirements for the duration of the plan
• Reduce carbon deposition and fouling which will damage your system.
• Reduce downtime Typical manufacturing businesses lost if output is not maintained
• Reduce Costs Deterioration in your thermal fluid does not necessarily warrant instant replacement. There are a number of measures we can take to extend fluid life before it is classified as condemned, including filtration, light ends removal and thermal fluid dilution.
• Lower your environmental impact by producing less waste
• Reduce the risk of a health and safety breach by proactively monitoring and managing the condition your thermal fluid
• Comply with insurance requirements to monitor the condition of your thermal fluid
• Enjoy energy savings – carbon in your system will ensure you spend more on energy as carbon can’t be heated. Degraded oil in your system will draw more energy as your pumps work harder.
• Regularly assess the extent of system wear by taking regular thermal fluid samples
• Regular sampling serves as an early warning system for future events and enables you to plan effectively for system and fluid management interventions

Heat Transfer Fluid test, analysis and report service

The Global Heat Transfer heat transfer fluid analysis service includes the full suite of 11 tests, including Total Acid Number, Viscosity, Carbon Residue, Closed Flash, Open Flash, Fire Point to determine fluid condition and any detrimental changes which could affect production. Using a simple traffic light system (green represents a satisfactory condition and red highlights a caution) the fluid report details any risk to the safety of the plant as well as interventions required to improve fluid condition, extend the operating life of your fluid and heat transfer system.

The Heat Transfer Fluid Sample Kit can also be supplied as part of our condition monitoring and maintenance plan along with on-site training for your engineering, operations and health and safety team.

Heat Transfer Fluid Sample Kit

With extended use at high temperature a heat transfer fluid will thermally degrade and eventually need to be replaced, if unmanaged. Frequent testing and analysis will help you extend the operational life of your heat transfer fluid and heat transfer system. It will also help quantify the extent of flammable decomposition products in the heat transfer fluid in order to understand the risk they present to the safety of the plant or to define interventions that will mitigate their risk.

Our Heat Transfer fluid sample drawing kit provides everything you need to draw a representative, closed, hot and circulating heat transfer fluid sample in preparation for analysis.

Our Heat Transfer Fluid Analysis kit contains:

• Instructions to safely draw a representative sample
• Sample device to safely draw a representative sample
• Hanson fitting valve to connect to your sample point
• Containers to decant and return your fluid sample
• Return labels for the containers
• Hard wearing storage case