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CHEMICAL SAFETY Heat Transfer Systems and Safe Chemical Processing From proactive risk assessments to comprehensive training: A deep dive into ensuring safe and sustainable heat transfer in manufacturing facilities. BY TIM POWELL Manufacturers frequently employ heat transfer systems years, its efficacy decreases as it nears the end of its lifespan. This decline can lead to the introduction of by-products into to sustain the high temperatures necessary for various the system. Specific regulations outline guidelines for health forms of indirect heat transfer processes. Historically, facilities opted for steam-based systems because and safety managers to reduce the potential risks linked to this degradation, but this is often easier said than done. This is because water is readily available, affordable, and commonly regarded as once thermal fluid is introduced into the heat transfer system, it sustainable. However, achieving the temperatures required for industrial processes necessitated operating the system at extremely is no longer visible, allowing any underlying problems to remain unnoticed until they disrupt production. high pressures of around 1200 psi (83 Bar). This meant that, without adequate steam ventilation mechanisms in place, the pipes To manage risks effectively, health and safety managers should ran the risk of bursting and gaskets failing, allowing hot steam to closely collaborate with thermal fluid specialists to monitor fluid condition. Engineers should take a closed thermal fluid sample escape, and putting workers at risk. Thermal fluids, on the other hand, can safely maintain tem- when the system is hot, live and circulating, so they can accurate- ly assess the fluid’s status. Quarterly sampling and thermal fluid peratures at much lower pressure and can be tailored to applica- analysis help engineers monitor its condition. These findings en- tions. They are suitable for both heating and cooling applications, with temperature ranges spanning from -130 to +1112 degrees able health and safety managers, along with production and en- gineering managers, to track the fluid’s condition over time and Fahrenheit. adjust procedures to minimize the risk of incidents. While they offer a safer alternative to steam and are designed to deliver prolonged and efficient service, facilities employing In addition, facilities have the option to employ remote condi- heat transfer fluids should still adopt preventative measures to tion monitoring, which can improve proactive maintenance ef- extend fluid lifespan and meet safety standards. forts. Cloud-based remote monitoring systems use live, real-time To comply with industry regulations, manufacturers using analytics to diagnose potential issues. As soon as the system de- tects an anomaly, it warns maintenance personnel by sending an heat transfer fluids must take proactive steps to assess potential alert on their smart devices. This advanced technology empowers risks and implement measures, such as predictive maintenance and remote monitoring, to eliminate them as much as possible. engineers to prolong the safe and effective use of thermal fluid. Thermal fluid, while classified as a dangerous substance, can of- fer reliable service for many years when monitored and managed Facility Maintenance proactively. This can be a safer, more sustainable, and cost-effec- While the engineers will monitor fluid and system conditions to tive solution for manufacturers. maintain uptime, health and safety managers can also implement on-site protocols to protect workers from risk. Risk Management Promoting good housekeeping practices not only enhances productivity but also fosters a safe working environment. For While heat transfer fluid has an effective life expectancy of many Mia Stendal/Shutterstock.com 62 Occupational Health & Safety | OCTOBER 2023 www.ohsonline.com