Heat Transfer

Fluids and Systems

Department Editor: Rebekkah Marshall

STARTUP FLUID ANALYSIS

1. Verify control and safety systems: It is vitally im- Fluid testing helps detect system malfunction, fluid contamination, moisture, thermal
portant to verify all control and safety systems degradation, as well as other factors that impact system performance (see Table). For
are calibrated and ready for operation and are systems operating near the fluid’s maximum temperature, annual analysis is suggested.
functioning properly
2. Check for leakage Test result Potential effects Possible cause Possible
3. Remove moisture from the system, using dry, actions*
compressed air or other suitable means. Fill the Viscosity Poor heat-transfer rate, de- • Contamination 4, 5
system with heat transfer fluid increase posits, high vapor pressure, • Thermal degradation 4, 5
4. System filling pump cavitation • Fluid oxidation 3, 4
a. Fill the system to desired level avoiding any Total acid System corrosion, • Severe oxidation 3, 4
unnecessary aeration of the fluid number deposits • Acidic contamination 4, 5
b. Open all valves, then start the main circula- increase
tion pump in accordance with the manufac- Moisture Corrosion, excess system • System leaks 2
turer’s recommendations. Allow for thermal increase pressure, pump cavitation, • Residual moisture in 2
expansion of fluid in determining the cold mechanical knocking new or cleaned unit
charge level • Unprotected vent or 2, 3
c. Circulate the heat transfer fluid through the storage
system for about 3 to 4 hours to eliminate air Insoluble Poor heat transfer, wear of • Contamination 1, 4, 5
pockets, and to assure complete system fill solids pump seals, plugging in • Dirt 1, 4
before firing the heater increase narrow passages • Corrosion 1, 3, 5
5. Start the heater • Oxidation 1, 3
a. Bring the system up to temperature slowly to • Thermal stress 1, 4
help prevent thermal shock to heater tubes, Low- and Pump cavitation, poor heat • Low boilers 2
tube/heater joints and refractory materials; high-boiler transfer, excess system • High boilers 4
and allow operators to check the function- increase** pressure, deposits • Contamination 4, 5
ing of instruments and controls. The slow * For detailed guidance on actions, please consult with your fluid engineering specialist.
heat-up will also allow moisture trapped in ** For an excellent discussion on low and high boilers, please consult Ref. [4].
all sections of the system to escape as vapor.
Inert gas should sweep the expansion tank to Possible actions blasting, wire brushing, or high-pressure
remove noncondensables and residual mois- 1. Filtration: Small diameter particles sus- water jetting. For process contamination,
ture to a safe location. Hold the temperature pended in heat transfer fluid can be ef- consult with your fluid supplier for sug-
stable above 100 °C (212 °F) until no signs fectively removed via filtration. Filters with gested cleaning methods
of moisture remain (knocking or rattling of 100-Mm or less nominal-particle-removal
pipes, no moisture from vents, and so on) ratings should be considered for initial
b. Bring the system to operating temperature, SHUTDOWN
system treatment. Continuous filtration
put the “users” online, and place the expan- through 10-Mm rated filters can maintain Prevent overheating of fluid due to residual
sion-tank inerting system into operation system cleanliness heat in the heater.
c. The fluid should generally be analyzed within 2. Venting: If low boiler concentration and/ 1. Shut off burner completely with the circu-
24 h of plant startup and annually thereafter or moisture is allowed to reach excessive lating pump still operating. Continue to
d. Check and clean startup strainers as needed levels in the fluid, problems such as pump run the pump at full capacity to dissipate
The system should be heated and cooled for at cavitation, increased system pressure and residual heat in the heater
least two cycles with the filter in place since the flash-point depression can occur. Intermit- 2. When the heater has cooled to the manu-
resulting expansion and contraction will loosen mill tent, controlled venting to a safe location facturer’s recommended low temperature,
scale. Reinsulate any surfaces left bare for leak- is a common solution to minimize the po- shut off the circulating pump and switch
checking purposes. tential for problems caused by excessive off required heater electrical controls
low boiler or moisture concentration 3. Caution must be exercised during shut-
3. Inerting: An effective method of minimiz- down to ensure that no area in the sys-
OPERATIONS ing fluid oxidation is to blanket the ex- tem piping is totally and completely iso-
Heaters: Proper fluid-heater operation will help pansion tank with a clean, dry, inert gas, lated. This will prevent a vacuum from
ensure long life of the fluid. Common heater prob- such as nitrogen, CO2, or natural gas forming, which could damage (implode)
lems include flame impingement, excessive heat 4. Dilution/replacement: Can be used to re- equipment
flux, control overshoot, low fluid flow, and interlock move some fraction (or all) of the fluid and 4. Operate heat tracing, if needed
malfunctions. replace with virgin fluid to maintain fluid
properties within normal ranges. Caution References and further reading
Piping and pumps: A leak-free system will help to
is advised when using reclaimed fluid, 1. Gamble, C.E., Cost Management in Heat
ensure safe and reliable operation. Some key fea-
Transfer Systems, Chem. Eng. Prog., July 2006
tures of a leak-free design are as follows: which can return degradation products pp. 22–26.
• Maintain valves and pump packing and seals and/or contaminants into the system
2. Gamble, C.E., Cleaning Organic Heat Transfer
• Avoid the use of threaded fittings (welded or 5. Cleaning: If a system flush is necessary, Fluid Systems, Process Heating, Oct. 2002.
flanged connections are preferred) several different methods are available. 3. Beain, others, Properly Clean Out Your Or-
• Realign pumps and retorque flanges once sys- Specialty-engineered, heat-transfer flush ganic Heat Transfer Fluid System, Chem. Eng.
tem achieves operating temperature after initial fluids may be used to remove sludge or Prog., May 2001.
system startup tar from piping/equipment. Hard car- 4. Spurlin, others, Defining Thermal Stability, Pro-
• Confirm with your fluid supplier what the proper bon deposits on heater surfaces (“coke”) cess Heating, Nov. 2000.
elastomers are. Not all elastomers are compat- generally require the use of mechanical 5. “Liquid Phase Design Guide,” Pub #7239128C,
ible with all heat transfer fluids cleaning techniques like sand or bead Solutia, Inc., 1999.

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