Fire risks in thermal oil systems are extremely low, thanks to decades of optimized safety measures and protocols. Both manufacturers and users understand the importance of proper design, operation, and maintenance to ensure the safety of personnel and equipment. At Pirobloc, we prioritize safety and provide efficient, reliable, and secure thermal fluid solutions.
**Common Causes of Fire in Industrial Hot Oil Systems**
1. **Leaks**: Poorly designed or maintained systems can develop leaks, often from faulty seals, gaskets, or hoses. If hot thermal fluid comes into contact with an ignition source—such as a motor, pump, or electrical panel—it can lead to fire. Small flange leaks can also pose risks, but using high-quality materials like graphite or fiber-reinforced Teflon can help prevent them.
2. **Insulation Fires**: Though rare, these occur when heat transfer fluid seeps into porous insulation (like mineral wool or fiberglass), which can then catch fire due to temperature or oxygen changes. Using closed-cell foam glass insulation at leak-prone areas significantly reduces this risk.
3. **Undetected Flow Loss**: A loss of flow in the system, combined with safety device failure, can cause dangerous overheating. If the system continues to operate without sufficient fluid flow, temperatures may rise beyond safe limits, leading to potential fires.
4. **Cracked Tubes**: Although rare, cracked tubes made from unsuitable materials can lead to serious fires. Proper material selection, such as ASME ASTM A106 Gr. B piping, is essential. Regular maintenance and fluid analysis help prevent oxidation and degradation that could lead to cracks.
**Assessing Fire Risk in Thermal Fluid Systems**
Three key parameters determine fire risk:
- **Flash Point**: The temperature at which vapors can ignite.
- **Ignition Point**: The temperature at which combustion continues.
- **Autoignition Temperature**: The temperature at which a substance ignites without an external flame.
While these values are important, most fires result from equipment failure, not the fluid itself. Insulation choices, flow issues, and maintenance play critical roles.
**Fire Prevention Measures**
To minimize risks, consider the following:
- Use closed-cell insulation like FOAMGLAS® around high-risk areas.
- Avoid porous materials near leak points.
- Replace leaking pump seals immediately.
- Ensure valves are positioned to allow leakage to drain away.
- Install low-flow shutdown systems on the burner interlock.
- Maintain proper ventilation and regularly inspect for leaks.
- Use containment berms and drip pans to manage spills.
Proper design, regular maintenance, and adherence to safety guidelines are essential for ensuring the long-term safety of any thermal oil system.
**The Role of Thermal Insulation**
Thermal insulation protects both personnel and equipment by reducing heat transfer and preventing flammable liquids from being absorbed. Closed-cell insulation, especially FOAMGLAS®, is the safest option as it prevents fluid from spreading and reduces auto-ignition risks.
In conclusion, while the chance of fire in thermal oil systems is minimal, proactive measures and expert guidance from companies like Pirobloc can further enhance safety. Always prioritize quality materials, routine checks, and proper installation to ensure a secure and efficient operation.
*Author: Carles Ferrer – Sales Director at Pirobloc*
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