and reduce the regularity of thermal fluid changes, helping to reduce waste and conserve energy. Furthermore, by extending equipment lifespan and optimising fluid performance, proactive maintenance helps manufacturers reduce long-term maintenance costs and improve overall profitability. Fluid maintenance Regular fluid monitoring is a key part of proactive maintenance because once the thermal fluid enters the system, it is no longer visible. Sampling fluid when the system is closed, hot and circulating will help provide an accurate representation of what’s happening inside the system. Analysis of the fluid sample enables engineers to determine if there are any immediate signs of degradation. Engineers can also track sample data over time to better identify trends in performance and contamination levels to better monitor fluid condition. By monitoring trends, engineers can plan in maintenance, devising a plan for how to intervene, with options such as fluid dilution or filtration available to address changes in fluid condition as needed. Installing a filtration system that can remove solid carbon deposits or other contaminants can help improve the condition of the existing fluid and reduce wear on system components caused by contaminants. Remote condition monitoring tools can further support thermal fluid management. By continuously tracking fluid condition, engineers can access real-time data from any location. Maintenance engineers can receive alerts as soon as fluid condition changes, so that they can address it quickly before a problem occurs. Knowledgeable staff Having a well-trained team of engineers proficient in operating and maintaining equipment is integral to improving maintenance procedures. Increasing team understanding about the heat transfer system and thermal fluid equips engineers with the knowledge and skills necessary to anticipate and address potential issues before they escalate. Training on key activities, such as thermal fluid sampling, maintenance, safe handling and storage of fluids and system checks ensures that employees are aware of what’s required for compliance and proactive maintenance. Training on safety, PPE and where to access equipment like fire extinguishers and spill kits in case of a leak is also important. Comprehensive training on proactive maintenance not only prevents costly downtime and extends equipment lifespan, it can also help conserve resources, reduce energy consumption and maintain uptime. Safeguarding your system When signs of thermal fluid degradation appear, engineers can install complementary components to address any issues. Insulation, for example, can minimise heat loss, decrease energy consumption and improve facility temperature control, extending fluid and system lifespan. Another possible situation is a build-up of light ends, short chain hydrocarbons that can form as a degradation product of thermal oil, which lower the flash point of the fluid and can be detrimental to health and safety. A light ends removal kit (LERK) installed onto the system effectively captures and removes these volatile compounds, further extending the lifespan of the fluid. Even with diligent maintenance, after years of service a thermal fluid will eventually degrade to a point at which it must be replaced. At this point, a thermal fluid specialist can help dispose of the fluid as sustainably as possible by arranging repurposing or reprocessing of material for a different application or industry where possible. By implementing procedures that improve proactive maintenance and system efficiency, manufacturers not only minimise downtime, they can conserve resources, reduce costs and reduce emissions where possible, resulting in a more resilient manufacturing process. For further information please visit: http://www.globalhtf.com www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2024 23
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