What are the conditions for operating a thermal oil heater?
To operate a thermal oil heater, the direct operator must meet the following requirements:
– Have a certificate of operating capacity.
– Operate the thermal oil heater under the supervision of a competent person.
What should the operator pay attention to before starting the thermal oil heater?
– Have been handed over and read detailed operating manuals of the thermal oil heater and its ancillary equipment.
– Check the records related to the thermal oil heater for the effective date of the inspection, the maximum working pressure and the maximum allowable working temperature.
– Check the thermal oil heater and related equipment to ensure that the equipment is in normal operating condition.
– Check the fuel supply system.
– Clean all oil filters.
– Check that the oil level in the expansion tank is normal and that all pipes are clear and unobstructed.
– Check the electrical system.
– Check that the thermal oil heater unit is clean and well ventilated.
– Check the availability of fire fighting equipment.
Make a fire process of thermal oil heater:
– Before the fuel is supplied to the combustion chamber for combustion, the furnace must be cleaned and vented to eliminate all explosive mixtures accumulated inside the furnace. The ventilation process must be repeated each time before ignition begins.
– The time required to raise the temperature of a thermal oil heater in cold state to operating temperature should be as recommended by the manufacturer.
Issues to monitor when operating a thermal oil heater:
The following observational steps should be taken and continuously monitored when operating a thermal oil heater:
– Pressure, temperature and flow rate of the heat carrier oil.
– Oil level in the expansion tank.
– Burning condition inside the thermal oil heater.
– Hydraulic noises and bumps are heard in the pipes due to the presence of water in the heating oil system.
– The temperature difference between the outlet and inlet of the thermal oil heater.
– Any leaks found in the pipeline, level gauge, flange and shaft seal of the circulation pump.
– The operating conditions of the circulation pump.
Which thermal oil heater operating data should be paid special attention to?
The following parameters should be recorded at regular intervals:
– Inlet and outlet temperatures of the heat carrier oil from the heater.
– Heat transfer oil pressure of the pump and heater.
– Oil flow rate. –
Oil level at the expansion tank.
– Heat transfer oil pressure difference between filter inlet and outlet.
– Exhaust gas temperature.
– Circulation pump outlet cooling temperature.
Notes when the thermal oil heater is in operation:
Operators must observe the following precautions when a thermal oil heater is in operation:
– Do not destroy the safety valve seal or attempt to adjust the setting of the safety valve.
– Do not try to adjust the settings of the safety device such as removing the high oil temperature protection setting, removing the low oil flow rate protection setting, or removing the low oil level protection setting in the expansion tank.
– Do not operate the system on overpressure or overheat.
– Do not make modifications to the oil heater unless recommended by the manufacturer and required by the competent authority.
– All automatic safety devices should be checked periodically as specified in the manufacturer’s instructions, to ensure they are in good working condition.
– The oil heater and its ancillary equipment should be properly maintained at all times. Major overhauls should be carried out by a reputable engineering company under the supervision of a boiler inspector.
Process to turn off the thermal oil heater:
Operators must observe the following precautions when shutting down a thermal oil heater:
– After stopping fuel supply to the heater, the circulation pump must be allowed to operate for a period of time as recommended by the manufacturer to prevent the heating oil from being overheated by the residual heat energy stored in the furnace or other heat source.
– The coolant supply to the circulation pumps (if any) is not interrupted until the pump temperature has been lowered to the level specified by the manufacturer.
– It is recommended to close the fuel supply valve and secure the power supply to the furnace if the plant is stopped for a long time.
Routine furnace maintenance:
In order to maintain the good operation of a thermal oil heater, the following points should be observed:
Thermal oil samples should be obtained from the best system in the presence of the boiler inspector, and sent for laboratory analysis to confirm its maintenance during initial and each routine inspection. Thermal oil specification and analysis reports should be kept securely in one file for ready reference.
– Maintain daily recording of any thermal oil changes in a logbook and by a responsible person according to the correct procedure.
– It is recommended to regularly check the auxiliary equipment and related safety devices of the thermal oil furnace.
– The safety devices should be checked in the presence of the boiler inspector before renewing the inspection Certificate of inspection:
+ Set safety valve.
+ Low thermal oil flow: Emergency stop / alarm.
+ Maximum allowable temperature: Emergency stop / alarm.
+ Circulation pump / combustion system interlock.
+ Low level of thermal oil in the expansion tank: Emergency stop / alarm.
+ Flame off: Emergency stop / alarm.
+ High exhaust smoke temperature: Emergency stop / alarm.
Above are the information to keep in mind when operating a thermal oil furnace. Hope this article will bring useful information to readers.
KS – Boiler specializes in manufacturing, installing and maintaining industrial boilers:
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