How proactive heat transfer fluid maintenance impacts performance

16 December, 2024

Thermal fluid systems typically run well for many years with limited intervention. However, all thermal fluids degrade over
time, and so a reactive maintenance strategy means that any degradation or build up of contaminants may go unnoticed until
it significantly impacts operations, leading to reduced efficiency and/or a drop in quality.

When problems arise or production levels drop, engineers may have to resort to a quick fix to minimise downtime, such as turning up the heat of the system — increasing resource and energy consumption. This, combined with the risk of downtime, means many facilities are moving away from reactive and towards a more proactive approach.

Reactive to proactive

Implementing a proactive thermal fluid maintenance strategy, tailored to the system’s specific needs enables engineers to better understand and maintain their system. Proactive maintenance can help improve uptime, conserve resources and extend the
lifetime of fluid and equipment.

By conducting an assessment of existing practices and considering common failures or pain points, manufacturers can identify potential areas for improvement. The maintenance plan should include regular inspections of core components, preventative maintenance tasks, increasing staff knowledge and predictive analytics. By identifying potential issues during these inspections, engineers can intervene promptly.

Proactive maintenance enhances operational efficiency by preventing equipment failures and minimising unplanned downtime, allowing for smoother production processes and increased productivity.

Beyond operational efficiency, proactive maintenance promotes sustainable practices by reducing waste, emissions and energy consumption. Adhering to proactive fluid maintenance procedures can optimise performance, extend equipment lifespan 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.