Before diving into the topic, it's essential to understand that the risk of fire in a thermal oil system is extremely low. Over decades, safety measures and protocols for thermal fluid boilers have been refined to ensure maximum protection. Both manufacturers and users recognize the importance of proper design, operation, and maintenance to safeguard personnel and equipment.
At Pirobloc, we prioritize safety above all else in every thermal oil installation. Our commitment is to deliver products that are not only efficient but also safe and reliable, ensuring peace of mind for our customers.
**Common Causes of Fire in Industrial Hot Oil Systems**
While fires in thermal oil systems are rare, understanding potential causes is crucial for prevention:
**Leaks**
Leakages typically occur in poorly designed or maintained systems. They often stem from faulty components like seals, gaskets, or hoses. When a large amount of hot thermal fluid leaks and comes into contact with an ignition source, especially if the temperature exceeds the flash point, a fire can quickly develop. Common ignition sources include bearings, electrical panels, pumps, or motors located below the leak. If the ignition source is part of the leaking component, the risk escalates significantly.
Even small leaks at flanges can pose risks. Using high-quality graphite or fiber-reinforced Teflon gaskets can help minimize these issues, especially in high-temperature environments.
**Insulation Fires**
Although rare, insulation fires can occur when heat transfer fluid seeps into porous materials like calcium silicate, fiberglass, or mineral wool. These materials allow the fluid to spread, potentially leading to spontaneous ignition. This scenario is more likely if the insulation is damaged or punctured during maintenance.
To prevent such incidents, closed-cell foam glass insulation should be used at potential leakage points. Alternatively, avoiding insulation altogether in those areas is another effective solution.
**Undetected Loss of Flow**
A loss of flow can occur due to faults in the system, such as a failed pump motor or clogged filter. While this is uncommon, it can lead to fires if combined with a failure in the safety systems. If the boiler continues to receive heat without sufficient fluid flow, temperatures can rise rapidly, risking rupture and subsequent ignition.
To mitigate this, low-flow shutdown systems must be integrated into the burner safety interlock. This ensures immediate action if flow is disrupted.
**Cracked Tubes**
Though rare, cracked tubes can cause serious fires if the material is unsuitable. The recommended piping for coils is ASME ASTM A106 Gr. B Sch. 40. Cracks can form due to thermal cycling or overheating from internal deposits or flame exposure.
If the boiler is operating, leaked fluid may burn harmlessly. However, if the burner is off, the pressure from the expansion tank can cause fluid to accumulate in the combustion chamber, posing a significant explosion risk upon restart.
Regular maintenance, including fluid analysis, is vital to detect oxidation and prevent deposits that could lead to cracks.
**Assessing Fire Risk in Thermal Fluid Systems**
Experts use three key parameters to evaluate fire risk:
1. **Flash Point**: The temperature at which vapor ignites when exposed to a spark.
2. **Ignition Point**: The temperature at which a flame continues to burn.
3. **Autoignition Temperature**: The temperature at which a substance ignites without an external source.
While these metrics are important, most fires result from system failures rather than the fluid itself. Poor insulation, flow issues, or equipment malfunctions are often the real culprits.
**Fire Prevention Measures**
To reduce fire risk, consider the following steps:
- Use closed-cell foam glass insulation around potential leak points.
- Avoid porous insulation near critical areas.
- Replace pump seals immediately if a leak is detected.
- Ensure flanges are not insulated; use metal covers for personnel safety.
- Include low-flow shutdown on the burner safety interlock.
- Install alarms in the expansion tank to monitor oil levels.
- Centralize equipment and install containment berms.
- Keep drip pans free of liquid.
- Reduce boiler output in large heaters to avoid thermal cycling.
- Allow flexible hoses to move along their length.
- Maintain lubrication systems properly.
- Position valve stems sideways to direct leaks away from piping.
- Use recommended packing for valves.
- Install isolation and bleed valves for easy maintenance.
- Locate the overflow tank away from doors and control panels.
- Ensure adequate ventilation to prevent flammable vapors from accumulating.
- Avoid installing hydraulic lines near boilers.
- Create dykes around pumps, skids, and boilers to contain spills.
**The Role of Thermal Insulation in Fire Safety**
Thermal insulation plays a critical role in protecting both personnel and equipment. Closed-cell insulation, such as FOAMGLAS®, prevents flammable liquids from being absorbed and limits heat transfer. It also includes drainage holes to reduce fire hazards by allowing any leaked fluid to drain safely.
While FOAMGLAS® is the safest option, it can be expensive. Combining it with cheaper alternatives in low-risk areas is a cost-effective strategy. Regular inspections are essential to detect leaks early and ensure the integrity of the insulation.
In conclusion, while the risk of fire in thermal oil systems is minimal, proactive design, maintenance, and adherence to safety protocols are vital. Always inspect for signs of leaks, maintain proper ventilation, and follow manufacturer guidelines to ensure a safe and efficient operation.
*Author: Carles Ferrer*
Carles Ferrer is an industrial engineer from the Universitat de Barcelona. As the sales director at Pirobloc, he has played a key role in developing thermal fluid projects across more than 80 countries.
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