Thermal oil heater, is an indispensable heat conversion equipment in the industrial field. In the chemical industry, food processing, textile printing and dyeing, petroleum refining and many other industries, it bears the important task of providing a stable heat source for the process. Compared with the traditional steam heating system, thermal oil heater has a high heat transfer efficiency, accurate temperature control, can realize high temperature heating under low pressure and other significant advantages, which greatly protects the stability and efficiency of industrial production.
The working principle of thermal oil heater is based on the good heat conduction performance of thermal oil. When the system is running, the low-temperature heat-conducting oil enters the interior of the heater under the drive of the circulating pump, absorbing the heat generated by the burner combustion fuel or the electric heating element, and the temperature gradually rises. After the temperature rise of the heat transfer oil through the pipeline to the heat equipment, the release of heat to meet the process requirements, followed by a reduction in the temperature of the heat transfer oil and return to the heater, and so on and so forth, to achieve the continuous transmission and utilization of heat .
In-depth understanding of the causes of thermal oil heater failure is to ensure its safe and efficient operation of the key. On the one hand, accurately identify the causes of failure to help timely take targeted measures to avoid the expansion of the failure to protect the continuity of production, reduce the economic losses due to equipment downtime; on the other hand, to solve the root cause of the failure problem, can enhance the operating efficiency of the equipment, reduce energy consumption, improve the economic benefits of enterprises.
Once the thermal oil heater failure, the potential risks and hazards should not be underestimated. For example, equipment failure may lead to production interruptions, disrupting the entire production plan, affecting the product delivery cycle; serious failures may also lead to fire, explosion and other safety accidents, resulting in casualties and major property losses; thermal oil leakage will cause pollution of the environment, facing environmental penalties and ecological restoration of the pressure.
Thermal oil quality problems is one of the common factors leading to thermal oil heater failure. Heat transfer oil is easily contaminated during storage, transportation and use, such as mixing impurities, moisture or air. In addition, long-term high-temperature operation will cause the heat transfer oil to undergo cracking and oxidation reactions, resulting in carbon residue.
Deterioration of heat transfer oil quality will bring many serious consequences. The presence of impurities and moisture will destroy the heat transfer performance of the heat transfer oil, resulting in local overheating, and even cause the heating pipe burst; carbon residue accumulation will block the pipeline, increase the flow resistance, but also may cause fire hazards.
In order to solve this problem, it is necessary to establish a perfect heat transfer oil management mechanism. Regularly conduct a comprehensive quality analysis of heat transfer oil, testing its physical and chemical indicators, such as acid value, flash point, viscosity, etc.; to ensure that the storage environment of the heat transfer oil is dry and clean, to avoid prolonged contact with the air; in the new oil into the system before the injection of adequate pre-dewatering treatment to remove the water.
Overheating and flow abnormalities of the thermal oil heater mainly stem from the high temperature of the export oil and the low oil flow. Improper operation, temperature control system failure or load changes and other factors may lead to the export of oil temperature exceeds the normal range; and pipeline blockage, circulating pump failure or improper valve adjustment will result in insufficient oil flow.
Overheating and insufficient flow will trigger a series of adverse consequences. High temperatures will accelerate the deterioration of heat transfer oil, resulting in increased coking phenomenon, the formation of fouling in the pipeline and heating surface, reducing the efficiency of heat transfer; insufficient flow can not take away the heat in a timely manner, further exacerbating the situation of overheating, the formation of a vicious cycle, which seriously affects the operational efficiency of the equipment and the life of the equipment.
Prevention of such failures, need to strictly follow the operating procedures of the equipment, the export oil temperature control in the recommended range; regularly check the pipeline, valves and circulating pumps operating status, to ensure that the heat transfer oil has sufficient and stable flow.
Thermal oil leakage is mostly caused by welding quality defects, sealing gasket failure or improper installation of connection parts. Welding if there are pores, cracks and other defects in the system pressure, thermal oil is easy to leak from these weak points; sealing gaskets after long-term use, due to aging, corrosion and loss of sealing performance; pipeline connection if not tightened or the use of unsuitable sealing materials, will also lead to leakage.
Thermal oil leakage will not only cause media waste, there is also a great risk of safety and environmental protection. Heat transfer oil has flammability, leakage is very easy to cause fire when open flame; at the same time, the leakage of heat transfer oil will cause pollution to the soil, water and other environmental pollution.
To prevent leakage, in the process of equipment manufacturing and installation, high-quality welding materials and sealing gaskets should be selected to ensure that the welding process meets the standards; before the equipment is put into use, strict pressure tests are carried out to check the system's sealing; in the process of operation, regular inspections are carried out on the pipeline connection parts to detect and deal with potential leakage hazards in a timely manner.
In the case of sudden power outage, if the correct countermeasures are not taken, it is easy to trigger the failure of the thermal oil heater. When the power failure, if the fuel supply is not cut off in time, the fuel that continues to burn will cause the local temperature of the heater to rise sharply; at the same time, the circulating pump stops running, and the heat transfer oil can't circulate normally, resulting in heat accumulation.
These improper handling will bring serious consequences, such as the heating tube due to localized overheating and explosion, the risk of fire caused by high temperature will also increase dramatically.
To avoid such situations, a dual power supply system can be equipped to ensure that in the event of a main power outage, the backup power supply can be quickly switched to maintain the operation of critical equipment; a detailed emergency cooling program is formulated, which can be activated immediately after a power outage to reduce the temperature of the thermal oil heater through natural cooling or other auxiliary cooling methods, preventing the accumulation of heat.
Heat conduction oil operating in a long-term high-temperature environment, or contaminated by external impurities, deterioration reaction will occur. High temperatures can cause changes in the molecular structure of heat transfer oil, resulting in its decomposition and polymerization; pollution will accelerate the deterioration process, resulting in sludge and carbon deposits.
Fluid deterioration will lead to increasing sludge and carbon deposits in the system, clogging pipes and valves, increasing system resistance, reducing heat transfer efficiency, so that the equipment operating energy consumption rises significantly, seriously affecting production efficiency.
Prevention of fluid deterioration, the need for regular replacement of heat transfer oil, according to the frequency of use of equipment and working conditions, the development of a reasonable oil change cycle; to strengthen the real-time monitoring of the heat transfer oil system, once the sludge or carbon deposits found to exceed the standard, timely cleanup and treatment.
Circulation pump failure is mainly caused by mechanical failure, electrical problems or improper maintenance. Wear and tear of mechanical parts, bearing damage, impeller failure, etc. will affect the normal operation of the pump; electrical system short-circuit, disconnection, motor failure, etc. will also lead to the pump can not work; and the lack of regular maintenance, failure to lubricate the pump in a timely manner, cleaning and replacement of parts, will accelerate the damage of the pump.
Pump failure will lead to poor circulation of heat transfer oil, can not provide enough heat for the heat equipment, while making the thermal oil heater internal heat can not be taken away in time, resulting in overheating.
In order to reduce the occurrence of pump failure, should establish a perfect pump maintenance system, regular inspection, maintenance and repair of the pump; equipped with a standby pump, in the main pump failure can be quickly switched to protect the normal operation of the system.
Heat transfer oil at high temperatures will have a chemical reaction with the piping material, triggering corrosion; at the same time, the deterioration products of heat transfer oil and incomplete combustion of carbon particles generated will be deposited in the piping and heating surface, forming carbon deposits.
Corrosion will lead to pipeline wall thickness thinning, strength decline, and ultimately lead to leakage; carbon will hinder heat transfer, reduce heat exchange efficiency, increase equipment energy consumption.
Prevention of corrosion and carbon, need to regularly conduct a comprehensive inspection of the equipment, timely detection and treatment of corrosion and carbon problems; in the selection of equipment, give priority to the use of corrosion-resistant materials, such as stainless steel, etc.; optimize the combustion process to reduce the production of carbon particles.
Improper installation of the exhaust system or blockage of the exhaust port will cause the gas in the system to be unable to be discharged in time, resulting in pressure buildup. For example, the exhaust pipe is not reasonably designed, with bending and blockage; the exhaust valve is not properly opened or malfunctions.
Pressure buildup will not only affect the normal circulation of heat transfer oil, but also increase the safety risk of equipment operation, and may even cause serious accidents such as pipe burst.
To solve the problem of insufficient exhaust, it is necessary to ensure that the exhaust system is installed in accordance with the specifications to ensure that the exhaust pipeline is unobstructed; regular inspection and cleaning of the exhaust port and exhaust valve to ensure that it works properly.
Regularly check the insulation layer and pipeline of the equipment to see whether the insulation layer is broken and peeling off, and whether the pipeline is corroded, deformed, leaking and other problems, and repair and replace the damaged parts in a timely manner, so as to minimize the heat loss and prevent the leakage of heat transfer oil.
Every year, professional technicians are invited to conduct a comprehensive inspection and assessment of the thermal oil heater system, including equipment performance testing, safety device testing, thermal oil quality analysis, etc., to ensure that the various indicators of the equipment meets the operational requirements, and to detect potential faults and hidden dangers in a timely manner.
Regular debugging and cleaning of the burner, adjust the combustion parameters to ensure that the fuel is fully combusted to improve combustion efficiency; clean up the burner internal ash, carbon and other impurities, to prevent them from affecting the combustion effect and normal operation of the equipment.
Strictly in accordance with the instructions for the use of heat transfer oil and quality test results, develop a scientific and reasonable fluid analysis and replacement program. Regular sampling and analysis of heat transfer oil, according to the results of the analysis to determine whether the need to replace the heat transfer oil, to ensure that the performance of the heat transfer oil always meet the operational needs of the equipment.
Comprehensive and systematic training for operation and maintenance personnel to familiarize them with the working principle of the thermal oil heater, operating procedures, fault diagnosis and treatment methods. The training should cover the daily maintenance of the equipment, emergency procedures, safety precautions, etc., to improve the professional skills and safety awareness of the personnel.
Develop a detailed maintenance checklist for the thermal oil heater to clarify the content, cycle and standard of each maintenance work. The list should include items such as equipment appearance inspection, component performance testing, parameter monitoring, lubrication maintenance, etc., to ensure that the maintenance work is comprehensive, standardized and without omissions.
Thermal oil heater plays an important role in industrial production, but it faces a variety of failure risks during its operation. Poor quality of thermal oil, overheating and flow problems, leakage, improper handling of power outages, fluid deterioration, pump failure, corrosion carbon buildup, and insufficient exhaust may lead to equipment failure, bringing safety risks and economic losses.
By taking regular maintenance, active prevention and a series of effective measures, such as strengthening the management of heat transfer oil, optimize the operating parameters of the equipment, strict installation and maintenance standards, good personnel training, etc., you can significantly reduce the probability of failure, to ensure that the heat transfer thermal oil heater safe, stable and efficient operation. Enterprises should attach great importance to the maintenance and management of equipment, preventive measures to be implemented in the daily production, for the smooth progress of industrial production to provide a solid guarantee.
