APPLICATIONS OF LIQUID PHASE THERMINOL HEAT

TRANSFER FLUIDS

Virtually any process or manufacturing operation requiring heat transfer between 400°C

(750 °F) and -115°C (-175 °F) is a potential candidate for the application of Therminol heat

transfer fluids. Applications which involve any of the following requirements are particularly

well suited for the use of liquid phase heat transfer fluid:

• Carefully controlled high-temperature heating

• Multiple heat users within a single process or plant

• Heating of thermally sensitive materials

• Heating and cooling with the same system

• Cooling

• Operation where minimal operating supervision is available

ADVANTAGES OF LIQUID PHASE THERMINOL HEAT TRANSFER

FLUIDS

Therminol Heat Transfer FluidVersus Steam

Compared to steam, Therminol heat transfer fluids cost less to install, operate and

maintain. Low pressure thermal liquid systems utilizing Therminol fluids can significantly reduce

capital costs. The savings in eliminating installation of larger diameter vapor piping, special vent

piping, flash drums, pressure control devices and boiler feedwater treatment equipment can

amount to 25%-50% of the system cost. A second source of savings is in operation: thermal

1|Page
liquid systems require less maintenance, eliminate heat lost through draining of steam

condensate in supply lines, and do not usually require licensed operating personnel when

operated in a manner consistent with the recommendations in this guide (however, check local

codes). Therminol fluids have minimal potential for corrosion and fouling. Cost of chemical

treatment of boiler feed water is eliminated, as well as the environmental cost of boiler

blowdown water disposal.

Therminol Heat Transfer Fluid Versus Direct Fired Heating

Heat transfer systems utilizing Therminol heat transfer fluid eliminate the problems

associated with direct fired heating. Heat transfer fluid systems eliminate hot spots which can

overheat sensitive process material while providing close and accurate process temperature

control.

Heat transfer fluid systems also allow the major source of ignition (the heater) to be

installed remote from the process, reducing fire hazards and improving plant safety. With heat

transfer fluid systems using Therminol fluids, one heater can provide heat to any number of

users.

In summary, heat transfer fluid systems using liquid phase

Therminol heat transfer fluids offer the designer and the

Operator the following advantages:

• Simple to design

• Easy to operate

2|Page
• Low maintenance cost

• Minimal capital cost

• Energy efficient

• Eliminates multiple ignition sources

• Flexible operation (heats and cools)

Therminol Technical Service Program

Solutia offers a complete technical service program to assist the designer and the

operator of heat transfer fluid systems utilizing Therminol fluids. These services include:

• Fluid selection guidance

• System design assistance

• System commissioning and start-up assistance

• System monitoring and used fluids analysis

• Trouble-shooting and operating support

• Technical specialists based around the world

• System audit and leak detection services

• Fluid trade-in program (in some countries)

• System design/safety seminars

For further information about selection of products or evaluation of application, please contact

your Solutia heat transfer fluid specialist.

Our Technical Assistance toll-free number is 1-800-433-6997.

3|Page
Therminol Technical Literature

Solutia offers a complete library of technical literature, including technical data sheets,

Material Safety Data Sheets, system design data and more. Physical property data also is

available on PC-compatible CD-ROMs. Much of the information is also accessible through our

website at http://www.therminol.com.

PROCESS DESIGN FACTORS

ADVANTAGES OF PROPER DESIGN
Every thermal fluid system is different. Operating temperatures, flow rates, process

equipment, system components, and a host of other design details vary from system to system.

But one thing remains constant: properly designed and operated heat transfer fluid systems are

exceptionally reliable and economical. Well-designed systems are safer, start-up faster, deliver

better on-stream time, use less energy, and require less fluid. Especially important in selecting

the proper Therminol fluid for a particular system are the temperature requirements of its

operation. In any range, the fluids are suited for systems that must deliver uniform heat,

precise temperature control, and quick response to heating or cooling demand. While there is

nothing profoundly different or highly complicated about a system utilizing Therminol, certain

design parameters must be observed for the system to give good service life, to operate

efficiently, and to return all the benefits of heating or cooling with a nonpressurized liquid. The

basic engineering checkpoints of designing a system are five-fold:

4|Page
1. The heater: to control heat transfer rate to ensure consistent energy supply with minimal

fluid degradation.

2. The pumps and piping: to provide adequate system circulation, maintain the heat flux at

user stations and to ensure proper handling of the fluid.

3. The expansion tank: to provide for fluid expansion, venting and positive pump suction head.

A properly designed expansion tank reduces difficulties in start-up and contributes to trouble-

free system operation.

4. The process/safety controls: to ensure safe operation and effective use of the

heating/cooling system.

5. The materials and construction: to ensure compatibility, and proper layout and design. With

sufficient heater capacity, good control of flow at user stations and compatible materials, a

well-designed system can give reliable, efficient and precise delivery of heat. Proper selection of

fluid and a clean, moisture-free system allow minimum maintenance and trouble-free

operation.

SYSTEM FACTORS

Liquid heat transfer is basically heating or cooling an adequate quantity of fluid to a

practical working temperature and circulating it to user stations at a rate to control the

temperature of the user as required by the process. Thus, in designing a system, the following

requirements should be considered:

5|Page
1. Is the process a continuous or batch operation?

2. What is the energy demand and the temperature requirement of each energy user? The

cooling requirement?

3. How much heat transfer area will be practical or available at user stations, and what heat

transfer coefficient can be expected from the heat transfer fluid and the material being

processed at the user heat exchange surfaces?

4. Will more than one energy user be on stream at the same time? At the same temperature?

At different temperatures?

5. What heat losses will be expected in the physical layout of the system? What is the pressure

drop?

6. Can older equipment or less efficient heating systems be eliminated?

7. Are expanded heating requirements probable?

8. To what ambient conditions will the system be exposed?

9. Are personnel/property/environmental protection controls adequate?

A basic starting point is to estimate the energy balances and to determine the total

energy demand of the system. This will guide selection of the heater capacity and pump size,

determine the fluid operating temperatures, and indicate the type of Therminol fluid the

system will require.

6|Page
FLUID FACTORS

Therminol heat transfer fluids are chemically and thermally stable liquids. To achieve

optimum fluid life, users should observe the recommended bulk and film temperature limits for

each fluid. These limits are specified for each Therminol fluid on the individual product data

sheet.

When not subjected to contamination, i.e., moisture, air, process materials, etc., or heat

stress beyond their limits, Therminol fluids can give years of service without significant physical

or chemical change. Liquid phase Therminol fluids transfer heat by sensible mode rather than

by latent mode as with condensing vapor. Heated liquid, circulated at reasonable velocities over

a heat-using surface, can be a more efficient and more readily controlled method of heat

transfer than pressure or temperature-controlled condensing vapor systems. Therminol heat

transfer fluids are designed to have physical properties that enhance their value in liquid phase

heat transfer. Low vapor pressure and high boiling ranges permit operation at their maximum

recommended temperatures without the need to pressurize the system. The particular

chemical compounds in Therminol fluids have always been recognized as among the most

thermally stable.

All heat transfer fluids have a time-temperature decomposition relationship.

Decomposition of heat transfer fluid results in the formation of components which are both

lower boiling and higher boiling than new fluid. Low boilers should be periodically vented from

the system to a safe area (usually through a manual vent) from a hot operating expansion tank
7|Page
(see page 10). Therminol fluids are designed to produce vent able low boilers in the event of

decomposition. High boilers are soluble in the fluid up to a certain level and, before this level is

reached, the fluid charge should be replaced. The old fluid should be disposed of in an

approved manner or traded in to Solutia. As with any heat transfer fluid, the design of the

system must take into account the relationship between thermal energy from the source and

the thermal properties of the fluid, the fluid velocity and the heat transfer surface geometry.

The liquid film in immediate contact with the heat source surface (whether electric or fuel fired)

is subjected to higher temperatures than the bulk temperature of the fluid stream. Minimum

film thicknesses are achieved in fully developed turbulent flow.

The velocity and the associated turbulence of the circulating fluid, therefore, is a critical

determinant of how much fluid is subjected to the higher temperatures, and for how long. The

differential between the fluid bulk temperature and the film temperature is dependent upon

the fluid velocity over the surface of the heat source and the physical properties of the fluid

used. The maximum recommended bulk fluid use temperature and film temperature are given

in each Therminol product bulletin. Therminol fluids have high specific heat, high thermal

conductivity, high density and low viscosity, which make them efficient heat carriers.

In selecting both the heater and the fluid, the maximum fluid temperature – rather than

the average – should be considered and a reasonable safety margin allowed to enable the fluid

to give the longest practical service life. Therminol synthetic heat transfer fluids are formulated

to provide a strong and efficient link for both heating and cooling demands.

8|Page
Therminol fluids are available for use in a series of temperature ranges, with fluids capable of

operating as low as -115°C (-175°F) and up to 400°C (750°F).

FLUID SAMPLING

When operating Therminol fluids near their upper temperature limit, the system should

be monitored yearly for fluid quality to determine whether corrective actions are required.

When operating at temperatures 20°C (50°F) or more below the upper operating limit, routine

samples should be analyzed biannually. Fluid samples should be analyzed whenever fluid-

related system problems are suspected. Solutia will perform free sample analysis and indicate

necessary corrective action required should results be outside acceptable values for the fluid.

Special heat transfer fluid sampling kits can be requested through your Therminol fluid

specialist by calling 800-433-6997, or through our website, http://www.therminol.com.

Note: Most fluid samples should be taken from a flowing line and cooled below 93 °C (200 °F)

before placing In a clean sample

container (cooling fluids may require

lower sampling temperatures).

Mechanical Design Factors

THE HEATER

The heater, either electrical or

fuel fired, is a critical component in

designing a heat transfer system with

9|Page
Therminol. With the proper balance of heating capacity, temperatures and fluid velocity, the

service life of the heat transfer fluid is increased to the maximum. Again, good service life is

only achieved in systems protected from contamination with foreign material.

Two basic fired heater designs for

Therminol heat transfer fluids are

available: the liquid tube and the fire

tube types. In liquid tube heaters,

Therminol is pumped through the tubes

as it is heated. The fire is outside the

tubes. In fire tube heaters, Therminol

flows through the heater “shell” around

the outside of the fire tubes.

Liquid tube heaters are preferred

at all temperatures. At Temperatures

below 260°C (500°F), fire tube heaters

with a special baffle design to eliminate

hot spots can be used. Most Therminol

fluids are liquid when transferring heat.

To avoid hot spots in the heater,

therefore, the fluid should be pumped

10 | P a g e
over the heating surfaces at sufficient velocity so that no area of fluid stagnation occurs. Since

heating is not uniform in fired heaters, the maximum heat stress conditions must be used to

determine what film temperatures will be encountered.

Fluid velocities over

the heat transfer surfaces

must be relatively high to

develop turbulent flow. This

helps avoid excessive film

temperatures that may be

detrimental to heat transfer

surfaces and to the fluid. The

heater manufacturer should

be consulted for the required

flow velocities.

11 | P a g e
EFFECT OF LIQUID VELOCITY ON FILM TEMPERATURE DURING HEATINGS

The illustration below shows the effect of fluid velocity on film temperature and

indicates the importance of this heater design requirement.

12 | P a g e
 In electrical heaters, all the heat delivered by the elements passes into the fluid. The

maximum heat flux at the surface of the heat source and the fluid velocity over it should be in

proper balance to avoid excessive film temperature. As with fired heaters, careful attention

must be paid to achieving turbulent flow (without stagnation zones) around the heat transfer

surfaces to eliminate hot spots and localized fluid boiling. In general, Therminol heat transfer

fluids can give long service life if the maximum bulk and the maximum film temperatures of the

system do not exceed the recommended maximum limits for the particular fluid and if no

contamination or exposure to oxygen occurs.

HEAT TRANSFER COEFFICIENTS

To determine overall heat transfer coefficients for the heating system, individual

coefficients have to be calculated for the heat source side and the fluid service side at each user

station. For fully developed turbulent flow through a circular tube with a constant wall

temperature, the average film coefficients for Therminol fluids can be estimated by using a

Seider & Tate* type equation:

13 | P a g e
PUMPS

Pumps must have sufficient capacity and pressure head to circulate the fluid at the rate

required by the particular installation. For large flow rates, the pump should generally be of the

centrifugal type. Pumps conforming to ANSI B73.1 or to API Standard 610, for high-temperature

service, will usually be suitable. Fluid-cooled bearings and seals are recommended to extend

pump service life.

For most systems, cast steel pumps are preferred. Pump manufacturers usually specify

that above 230°C (450°F) a cooled, jacketed stuffing box or a cooled mechanical seal should be

used. Mechanical seals are widely used.

Secondary sealing with vent and drain glands is recommended to collect fluid leakage

and to provide space for inerting the outside of the seal. Inert blanketing of the seal with steam

or nitrogen eliminates oxidation deposit formation which can lead to seal leakage. This

secondary sealing provides additional safety in the case of sudden seal failure.

Sealless pumps (magnetically driven and canned motor) are regularly employed in

Therminol fluid systems. Because of the operating temperatures and range of viscosities often

encountered in Therminol systems, the pump manufacturer should be consulted. On pumps

with a stuffing box, at least five rings of packing should be provided, i.e., laminar graphite rings

such as Grafoil.

14 | P a g e
. When a new system is first put into operation, a slight leakage may be noticed at the

pump packing. The pump gland should not be tightened, however, until the system has heated

to near the temperature of operation.

Regardless of the type of pump selected, the flow rate should be checked regularly

against the pump’s performance when new. To prevent alignment problems and seal leakage, it

is important to avoid pipe support stresses on the body of the pump. Each pump should be

fitted with a control device to switch off the heat source in case of pump failure. If expansion

loops are used in the pump suction piping, they should be installed horizontally.

FILTERS

Before starting up a new system, install a wire mesh strainer in the pump section. These

strainer baskets may be removed after debris removal from start-up is completed.

Piping systems should be designed with provisions for the installation of a side-stream

filter. Filters that have generally been employed for these applications are glass fiber string-

wound cartridges or cleanable sintered metal filters in the 1-30 micron range.

Clean fluids prolong the life of system components, i.e., pump shaft seals and valve

stems. Filtration also reduces fouling and plugging.

15 | P a g e
MATERIALS OF CONSTRUCTION (EXCLUDING HEATER COILS)

Process chemistry is normally used to determine materials of construction. The majority

of metals and alloys normally encountered in high-temperature heating systems can be used

with Therminol heat transfer fluids.

Materials of construction are generally selected on the basis of their suitability for

operation throughout the system’s temperature range. Mild steel is widely used, but it must be

qualified for low-temperature use (brittle/ductile transition temperature). While Therminol

heat transfer fluids are compatible with aluminum, bronze and brass alloys, etc., the use of

these metals should be kept to a minimum because of their loss of mechanical strength at

higher temperatures.

Due to their temperature limitations, non-metallics (plastics and elastomers) are not

recommended for materials of construction in heat transfer systems.

Trademark of Union Carbide

THE EXPANSION TANK AND VENTING ARRANGEMENTS

Usually, the expansion tank is installed at the highest point in the system and is

connected to the suction side of the pumps. It should serve as the main venting point of the

system, as well as provide for system fluid expansion, which can be 25% or more depending on

fluid Choice and on the operating temperature range. All vent lines should be routed to a safe

16 | P a g e
location. The double drop leg expansion tank (see Figures A and B on page 10) provides greater

flexibility of operation than a single leg tank. From a single leg expansion tank, venting of non-

condensibles (water, etc.) is often difficult in heating systems as is purging of air/water on start-

up. A double leg expansion tank provides uninterrupted flow on start-up and significantly

improves the venting capability of the system.

Experience indicates that systems with expansion tanks open to the atmosphere have

fluid contamination problems related to oxidation and excessive moisture. Therefore, open

expansion tanks should not be employed in systems using Therminol heat transfer fluids.

An effective way of minimizing fluid oxidation is to blanket the system with an inert gas

(e.g., nitrogen) as shown in Figure A. When using a nitrogen blanket, moisture should be driven

off from the fluid before the gas pressure is set. If this is not practical, air contact can be

minimized by a cold seal trap arrangement as shown in Figure B. Low boilers and moisture can

collect in the cold seal trap, so the fluid in the trap should be discarded periodically.

The expansion tank should be sized so that it is one-fourth full when the system is at

ambient temperature and three-fourths full when the system is at operating Temperature. It

should be fitted with a high-pressure sight glass at the full range and with a minimum level

Switch to shut off the heater and the pump in the event of accidental fluid loss.

As is good design practice with all large components in a heat transfer system, the

expansion tank should be fitted with a pressure relief device, such as a relief valve, rupture disk

17 | P a g e
or vent traps. These can relieve excessive pressures to prevent damage or rupture of the

expansion tank. These devices should be sized to vent the expansion tank vapor space in

anticipation of the

most severe venting condition. Industrial standards for relief devices and sizing are covered in

API Standards 520-527.

PIPEWORK

The piping layout for systems utilizing Therminol heat transfer fluids should be sized to

provide the normal required flow rate at an economical pressure drop. Because the system will

undergo temperature changes, adequate flexibility to relieve thermal expansion and

contraction stresses is essential. Schedule 40 carbon steel pipe (ASTM A53 for welded and

seamless or ASTM A106 for seamless) should be used throughout the system.

The tendency to leak through joints and fittings is characteristic of most organic heat

transfer fluids (including Therminol fluids) unless these fittings are very tight. Control of piping

leaks is especially important since fluid-soaked insulation poses a more serious hazard than the

leaking fluid itself (see section on insulation). The best way to prevent piping leakage is to weld

all connections. Use of threaded fittings is strongly discouraged due to their tendency to leak.

Where access is necessary, raised-face flanges with weldneck joint (ANSI B16.5 Class 300) or

equivalent raised-face flanges are recommended. Recommended flange gasketing for high-

temperature heat transfer fluid systems is the spiral-wound type conforming to ANSI B16.20.

18 | P a g e
Standard materials for spiral-wound flange gaskets are Type 304 stainless steel and flexible

graphite filler.

For leak-free performance of spiral-wound gaskets, the following points are important:

use of raised-face flanges (125 RMS finish) and alloy steel bolting with copper-or nickel-based

thread lubricants, uniform compression of the gasket during bolt pull-up, and flange faces clear

of imperfections and parallel. Other requirements for safe design of piping are found in the

Chemical Plant and Petroleum Refining Piping Code, ANSI B31.3.

EXPANSION TANK AND COLD SEAL TRAP

19 | P a g e
 For start-up or venting operations, valves B, C, D and F are opened. Valve A can be

throttled to assure fluid flow through the expansion tank. Valve E should be throttled to limit

the inert gas flow through the expansion tank.

For normal operation, valves B, C, and F are closed, and Valves A, D and E are open. This

arrangement provides normal return flow to pump suction with an open static head line from

tank to pump. By-pass line through valve D minimizes thermal siphon to expansion tank.

20 | P a g e
INSULATION

Normal high-temperature insulation, such as calcium silicate, mineral wool and cellular

glass, can be used in Therminol fluid service. However, fluid-saturated insulation is a potential

fire hazard at the temperatures often encountered while operating a heat transfer fluid

system.

Heat transfer fluids can exhibit a slow oxidation reaction with air in the presence of

porous insulating materials. This phenomenon can be minimized through the use of cellular

glass insulation which resists saturation by the heat transfer fluid due to its closed cell nature.

The following additional suggestions may help minimize the fire hazard potential in insulation

systems:

• Install and maintain a leak-free piping system.

• Reduce the number of flanges and other mechanical joints in initial system design.

• Use suggested piping specifications.

• If a leak develops, remove the insulation, and contain and control the fluid until the leak can

be repaired.

• On vertical runs of pipe where occasional leaks can develop at flanges, install protective tight-

fitting caps to divert any fluid leakage outside the insulation.

• Install valve stems horizontally or in a downward position so that any stem leakage does not

enter the insulation.

• Always consult your insulation supplier and insurance company for additional suggestions

on reducing fire hazards in insulation.

21 | P a g e
VALVES

Cast or forged steel valves with 13-chrome trim are satisfactory for systems utilizing

Therminol fluids. Globe valves with an outside screw (as a protection against high

temperatures) should be used throughout the system when tight sealing of Therminol fluids is

desired. Gate valves are acceptable for Therminol fluid service; however, they should not be

relied upon to provide reliable positive shut-off.

The use of metal bellows valve stem seals is increasing and should minimize leakage.

PACKING

Various types of high-temperature packing have been used to seal valve stems and

pump shafts in high temperature Therminol fluid service. Excellent service life has been

achieved through the use of graphite-based packing (as long as said packing contains no soluble

organic binders). Generally, a minimum of five rings of packing is specified on valve stems to

assure a reasonable seal. Mechanical seals or ring-shaped flexible graphite packing gives the

best service for pumps.

CONTROLS

Controls for heating systems using Therminol heat transfer fluids should be installed

both on the heater itself and on the energy-using units. Install heater controls to regulate the

firing mechanism

22 | P a g e
in direct proportion to the required output. These controls should increase or decrease the heat

input to maintain Therminol fluid at the operating temperature required by the energy

demand. Small units may be operated satisfactorily by relatively simple “on-off” or“high-low”

controllers. However, units of all sizes will operate more uniformly if equipped with modulating

temperature controls.

Install user controls to regulate the flow of the heat transfer fluid in proportion to the

energy consumption of the equipment. In a multiple-user system, separate controls should be

installed on each consuming unit to assure the proper energy delivery.

FIRE PROTECTION

Where fire protection is concerned, it is best to consult your insurance company for

guidance and counsel. Likewise, you will want to discuss your fire safety requirements with

qualified suppliers of fire protection equipment, as selection and sizing of this equipment is

important to safeguard the installation.

Guidelines that may be followed to improve the overall safety of the installation include

the following:

1. The fired heater and other equipment should adhereto the spacing guidelines noted

in the NFPA 30. This document gives guidelines for spacing from property lines and important

buildings.

2. Where possible, heat transfer systems should be installed in open structures. Closed

structures should have explosion relief construction and adequate ventilation to prevent vapor

concentration.

23 | P a g e
 3. The design should consider the benefits of a primary and secondary heating loop to

isolate the heat transfer fluid.

4. Automatic, remotely operated (fail safe) valves and automatic pump shut-down

should be incorporated to prevent the possibility of the system feeding the fire in the event of a

tube rupture. This shut-down could be triggered by a low-flow interlock, a low expansion tank

level interlock, a high stack temperature interlock, or other acceptable means. Provisions

should be provided for pressure relief as required.

5. Automatic sprinklering is recommended. Considerations should include the burner

front, relief device discharges, control rooms, furnace openings, heat transfer fluid piping

systems and vessels, pump locations, escape routes, and operating areas. Suggested guidelines

for fire protection of new fired heater installations are as follows:

A. Automatic deluge protection on an area basis (0.3gpm/ft).

B. Areas requiring the automatic deluge protection to include grade level, burner

firing level, the three external vaporizer walls (where vaporizers are closely spaced), and

subsequent levels above the burner level.

C. Manual fire extinguishers available – Class B.

D. Slope grade so runoff is routed away from equipment.

E. Supplement automatic systems with 500 gpm (single fired unit) – 1,000 gpm

(multiple furnace) available capacity for hoses.

6. Snuffing steam (or other acceptable media) should be provided on the fire box side of

any fired heater. A commonly used method of preventing fire in the event of tube rupture in

fired heaters is to supply steam or CO2 as a snuffer into the combustion chamber of the heater.

24 | P a g e
Steam snuffer systems should employ a trap to avoid slugging the combustion chamber with

water when the system activates or is activated manually. This snuffer system can be

automated by the use of an exhaust stack temperature switch, which would energize a solenoid

valve and an alarm upon excessive temperature rise, thus automatically flooding the chamber

with a fire extinguishing agent.

7. Consider remote operation of key equipment/valving with manual back-up of

automated controls.

8. Electrical equipment should be designed to preventingress of heat transfer mists.

9. Insulation (in areas prone to leakage) should be of a type that cannot become

saturated with heat transfer fluid. One example would be cellular glass. Caremust be taken to

verify the insulation material is rated for the system temperature. The piping system should be

designed for combustible fluid service at the rated temperature.

10. Discharge lines on all heat transfer fluid relief devices should be:

A. Routed to a safe discharge to atmosphere (not inside a heater room) or

routed to an adequate collection system.

B. If necessary, protected with additional fire protection so that the fire hazard is

minimized at the discharge point.

SAFETY CONTROLS

In addition to activating controls, the system also must be fitted with the proper safety devices

to meet local code requirements. Knowledgeable equipment manufacturers should be able to

25 | P a g e
provide guidance on proper safety controls. Safety controls should include, but not be limited

to:

1. High-temperature cut-off at the heater outlet: to shut off the burner in the event of

an excessive temperature rise.

2. Heater low-flow cut-off: to shut down the burner should flow rate drop below design

rates or should a loss of flow occur due to pump malfunction or failure. Regular automatic

ignition controls and flame-failure controls should be included on all burners. In wide-ranging

firing, an over-fire draft control will save heat losses.

3. Expansion tank low-level shut-down: to shut off the heater and the pump(s) in the

event of accidental fluid loss.

4. Expansion tank high-level alarm: to alert plant operations of system leakage into the

fluid.

5. Safety relief valves: All safety relief devices in thermal liquid heat transfer systems

should discharge at a point remote from possible ignition sources and away from areas where

danger to personnel exists. Pressure relief devices should be placed on the heater outlet, on the

expansion tank, and (where appropriate) on system users.

6. Other safety controls: Electric power failure and instrument air failure safety controls

also are desirable. In general, a policy of “fail-safe” instrumentation and control in the designing

is essential, using quality indicating and recording gauges, with accurate-reading scales

calibrated for the specific limits of operation.

26 | P a g e
Typical Liquid Phase Heat Systems
SYSTEM 1 –THE BASIC SYSTEM

The transfer of process heat as a liquid offers these benefits to the installation:

• Precise heating levels

• Closer temperature control at each user station

• Minimum cost installations

• Greater operating safety

• Low maintenance costs

Systems utilizing Therminol heat transfer fluids are characterized by their extreme

flexibility. A single heater can serve multiple “users” operating at the same or different

temperature levels. The systems can be designed to deliver and to remove heat.

With thermal liquid heat transfer systems there are few problems of condensation, pressure

drop and large heat surges associated with vapor systems. The four system diagrams on pages

14-17 illustrate a few of the many arrangements of heat users that can be operated with

Therminol fluids.

System 1 is the basic system configuration with a single user operating at heater outlet

temperature. The temperature control valve regulates flow of the hot Therminol to meet the

user’s temperature requirements. The pressure control valve assures that a minimum flow will

be maintained through the heater at all times. This system has maximum temperature

flexibility. Note also the heater and the pump safety controls and their connection to the heater

flow, the heater outlet temperature and the expansion tank low-liquid level sensors.

27 | P a g e
 User temperature also may be controlled by regulating the fuel supply to the heater.

This method sometimes has a very limited turndown and should only be used with a continuous

process with small load changes. An adequate flow of Therminol fluid must be maintained in

the heater at all times to satisfy the energy balance and to prevent exceeding the maximum

bulk and maximum film temperatures of the Therminol heat transfer fluid.

SYSTEM 2 – HEATING MULTIPLE USERS

This is the same system as Number 1 except several heat users are connected to the

heater, all operating at the same temperature. To control temperature, each user has a

28 | P a g e
modulating control valve. A single minimum flow by-pass valve is used at the end of the piping

loop.

Note: Refer to System 1 diagram (page 14) for placement of safety controls and fluid

relief devices.

SYSTEM 3 – HEATING SEVERAL USERS AT DIFFERENT TEMPERATURES

With this arrangement, several heat-users at different temperatures may be operated at

one time. Each temperature zone has its own recirculating pump located at the user inlet with

the temperature control valve located downstream of the user. A by-pass from the zone pump

29 | P a g e
inlet is connected to the user outlet. When the temperature control valve is opened, fresh high

temperature Therminol heat transfer fluid is admitted to the zone where it is mixed and

recirculated.

This blending of hot and cold Therminol fluids gives precise temperature control at

some temperature below heater outlet temperature.

This same principle can be used with System Number 1 when the user has a very large

fluid volume and a small heat load. The main recirculating pump is sized for the heat load

through the heaters while the zone pump is sized to recirculate a larger volume of blended

Therminol

fluid through the user.

Both of these arrangements will give excellent temperature control, as well as a fast

response to system change.

Note: Refer to System 1 diagram (page 14) for placement of safety controls and fluid

relief devices.

30 | P a g e
SYSTEM 4 – HEATING AND COOLING OF A SINGLE USER

This is a dual system for heating and cooling, using two separate circulating systems for

a common user. The temperature controller output is connected in a split range manner to the

cold and hot Therminol fluid control valves. As the output increases from 0%-55%, the cold

valve closes (with a minimum stop to prevent deadheading the cooling zone pump). As the

output increases from 45%-100%, the hot valve opens. The pressure control valve maintains a

minimum flow through the heater under all conditions. Even with the slight overlap in the cold

31 | P a g e
and hot valve ranges, this design operates with a minimum of interchange between the two

circulating systems.

Note: Refer to System 1 diagram (page 14) for placement of safety controls and fluid relief

devices.

Start-Up
SUGGESTED START-UP PROCEDURE FOR NEW SYSTEMS

32 | P a g e
 For a new system or one that returns to service after draining, the following checkpoints

are recommended as guides. They are supplemental to those of the heater manufacturers and

the recommendations of heat transfer equipment makers, and are not intended to supersede

or preclude those recommendations. Generally, they apply to the care of the fluid in all sizes

and types of systems.

1. Check safety and control devices:

For proper installation and functioning, be certain that the range settings are proper for

the operation. Manually activate the instruments and apply all tests necessary to assure proper

functioning. For protection of the system and for the expected long service life of the fluid, it is

vitally important that all instruments and controls function properly.

2. Check for leakage.

3. Remove moisture from the system, using dry compressed air or other suitable means.

4. Fill the system with Therminol heat transfer fluid.

A. Fill the system with Therminol fluid, with all vents to the expansion tank or

atmosphere open for air removal. Fill the expansion tank to the desired low level. Where

needed, have the steam tracing system operable.

B. Open all valves, then start the main circulating pump in accordance with the

manufacturer’s recommendations. Observe the liquid level in the expansion tank, refilling as

necessary until the system has been filled. Allow for thermal expansion of Therminol fluid in

determining the cold charge level. The expansion tank should be adjusted to 70%-75% full

when the hot operating temperature is reached.

33 | P a g e
 C. Circulate the Therminol heat transfer fluid through the system for about three to four

hours to eliminate air pockets and to assure complete system fill. Before firing the heater, be

sure that the Therminol fluid is circulating freely through the entire system.

5. Start the heater.

A. Bring the system up to temperature slowly – about 35°C (63°F) per hour. This should

prevent thermal shock to heater tubes, tube/heater joints, refractory materials, etc., and will

allow operators to check the functioning of instruments and controls. The slow heat-up also will

allow moisture trapped in all sections of the system to escape as a vapor. Inert gas should

sweep the expansion tank to remove non-condensibles and residual moisture. Hold the

temperature above 100°C (212°F) until no signs of moisture remain (eg. knocking or rattling of

pipes, moisture from vents, etc.).

B. Bring the system to operating temperature, put the “users” on the line, and place the

expansion tank inerting system into operation.

C. The fluid should generally be analyzed with 24 hours of plant start-up and annually

thereafter. Consult your Therminol Fluid Specialist for specific recommendations for your

system.

D. Check the start-up strainers. If foreign material collects, the strainer should be

periodically removed and cleaned. After several days of operation with no foreign material on

the strainer, it may be permanently removed. If the start-up strainer is to remain permanently

installed, it should be tagged for easy identification.

Note: The system should be heated and cooled for at least two cycles with the screen in

place since the resulting expansion and contraction will loosen mill scale.

34 | P a g e
OPERATING INSTRUCTIONS
SUGGESTED OPERATING INSTRUCTIONS FOR LIQUID PHASE HEATING SYSTEMS USING THERMINOL® FLUIDS

The following operating suggestions are not intended to supersede or preclude those

operating instructions provided by a heater or a system supplier.

1. Check safety controls:

In addition to activating controls, the heater also should be fitted with the proper safety

controls to meet local code requirements.

2. Start-up temperature precautions:

A. Temperature of fluid at start-up is important; consult your heater and pump supplier

for the maximum recommended start-up viscosity. This should correspond with the minimum

permitted fluid temperature. Failure to comply with supplier recommendations may lead to

equipment damage.

B. If start-up must be made at temperatures below the fluid pump ability limit, the fluid

should be heated in a safe way, i.e., with steam or electrical tracing.

C. One way of avoiding start-up temperature problems in cold weather is to keep the

system idling at 105°C (221°F)- especially for those fluids which can solidify or become too thick

to pump.

3. Procedure for start-up (cold fluid):

35 | P a g e
 A. When the start-up temperature is correct, start the circulating pump and check the

expansion tank level to see that the Therminol heat transfer fluid is at the proper cold-start

level (usually 25% full). Activate the inert gas sweeping system at the expansion tank.

B. Start burner at the “low” flame setting and continue full circulation until the bulk

temperature of Therminol fluid reaches 105°C (221°F).

C. Turn heater to full or proceed with the heater manufacturer’s heat-up schedule.

4. Procedure for start-up (hot fluid):

After an automatic shut-down by the safety controls, fluid should still be above 105 °C

(221°F).

A. Determine the cause of the shut-down and rectify the conditions that caused the

shut-down.

B. Run the circulating pump to turn the system volume over a number of times to

eliminate any vapor pockets formed while the fluid has remained static in the heater.

C. Start the burner at the low flame setting. When the flame is stabilized, the heater can

be turned to full fire.

5. Procedure for shut-down:

A. Shut off burner completely with the circulating pump still operating. Continue to run

the pump at full capacity to dissipate residual heat in the heater.

B. When the heater has cooled to the manufacturer’s recommended low temperature,

shut off the circulating pump and switch off all heater electrical controls.

36 | P a g e
 C. Caution must be exercised during shut-down to ensure that no area in the system is

totally and completely isolated. This will prevent a vacuum from forming, which could damage

(implode) equipment.

37 | P a g e
Operating Instructions

6. Planned maintenance:

Regular maintenance inspection schedules should include the manufacturer’s

recommendations for the heater and the components, as well as inspection of the Therminol

heat transfer fluid. The following maintenance suggestions are not meant to supersede or

preclude those maintenance instructions provided by the system designs or equipment

manufacturers:

A. Lubricate moving parts.

B. Check operating fidelity and the accuracy of the readings of safety controls and temperature

limit controls.

C. Inspect heater tubes, burner and refractory linings.

D. Periodically service the heater.

E. Inspect the fluid cooling at the circulating pump.

F. Repack stuffing boxes according to the manufacturer’s specification.

G. Inspect all sealed surfaces, i.e., flanges, valve packings, etc., for evidence of leakage. Repair

leaking areas to prevent more serious fluid loss and to reduce safety hazards.

H. Fluid samples for analysis should be taken within 24 hours of plant start-up and annually

thereafter.

Consult your Therminol Fluid Specialist for specific recommendations for your system.

Solutia will provide free sample analysis and will then indicate the necessary corrective action

required should results be outside the acceptable values for used fluid. Special heat transfer

fluid sampling kits can be requested through your Solutia Therminol Fluid Specialist by calling

38 | P a g e
Therminol technical service at (800) 433-6997, or from our website at

http://www.therminol.com.

SAFE HANDLING AND DISPOSAL

Animal toxicity studies and manufacturing experience indicate that no special

precautions are required in the handling of these products at ambient temperatures. Acute

toxicity studies indicate that most of the Therminol heat transfer fluids are practically non-toxic

by ingestion of single doses. Although tests suggest that these materials are probably not

irritating to skin, it is good practice to avoid repeated and prolonged skin contact with any

industrial chemical, heat transfer fluid or petroleum product. Vapors or spray mists of the

material, on the other hand, while not dangerously toxic, can give rise to discomfort, and

thermal decomposition caused by excessive heating may generate more irritating fumes.

Systems should be made as leak tight as possible and any spillage absorbed and/or

removed. Repairs to leaks of hot fluid should be carried out under well-ventilated conditions. Of

course, extra care is necessary when the system is at high temperature. Most repairs and

maintenance activities should be performed at low temperatures. More data are available for

each product in the Material.

Safety Data Sheets, which are available upon request or directly from the Therminol

website. While it is believed that Therminol heat transfer fluids pose no serious problems with

respect to the environment, as a concerned supplier to industry, Solutia urges the user to

39 | P a g e
maintain a tight system, to correct leakage promptly, and to exercise care in the handling and

the disposal of this and all other such products. A consistent maintenance program not only

protects the environment but keeps employees comfortable, the working area clean, and the

system running smoothly.

IMPORTANT WARNING

Heat transfer fluids are intended only for indirect heating purposes. Under no

circumstances should Therminol heat transfer fluids contact or in any way contaminate food,

animal feed, food products, food packaging materials, pharmaceuticals or any items which

many directly or indirectly be ultimately ingested by humans. Any fluid contact may

contaminate these items or products to the extent that their destruction may be required.

Precautions against ignitions and fires also should be taken with these fluids.

Resistance of Valves and Fittings

A simple way to account for the resistance offered to flow by valves and fittings is to add
to the length of pipe in the line a length which will give a pressure drop equal to that which
occurs in the valves and fittings in the line.
Example: The dotted line shows that the resistance of a 6inch Standard Elbow is equivalent to

approximately 16 feet of 6-inch Standard Steel Pipe.

40 | P a g e
41 | P a g e
Steel Pipe Dimensions
CAPACITIES AND WEIGHTS*

42 | P a g e
Engineering Conversion Factors
Average Properties of Tube

43 | P a g e