Sustainability is no longer just a buzzword but an essential strategy for facilities managers looking to reduce operational costs and improve their environmental impact. According to the International Energy Agency, industrial heat accounts for two-thirds of industrial energy demand and nearly one-fifth of global energy consumption, making it a key area for improvement. By improving heat transfer system efficiency, facilities managers can reduce energy usage while supporting sustainability. Here, Dave Dyer, technical sales engineer at thermal fluid specialist Global Heat Transfer, outlines practical steps to achieve this.
Thermal fluid systems face multiple operational challenges beyond energy efficiency. One critical concern is the degradation of the fluid itself, which can occur when it is exposed to high temperatures or poorly maintained systems. Without proper preventative measures, this degradation can escalate into serious safety and environmental hazards.
Improving heat transfer system efficiency through insulation
Uninsulated equipment in heat transfer fluid systems can waste substantial amounts of energy, leading to higher costs. For instance, if pipes carrying heated fluids are not properly insulated, they lose heat to the surrounding air. As a result, the system must work harder to maintain the desired temperature, increasing both energy use and the likelihood of thermal fluid degradation.
In a heat transfer system, certain areas are particularly prone to energy loss, such as piping and flanges. For example, flanges are joints connecting two pipes, which can allow heat to escape or even fluid to leak. Insulating these critical points prevents unnecessary heat loss, helping systems maintain consistent temperatures and reducing energy consumption.
Research from the US Department of Energy estimates that adding insulation to pipes can cut heat loss by up to 90 per cent, yielding significant cost savings over time. For maximum efficiency, non-porous sprayed glass insulation is recommended, particularly for areas within 600 millimetres of flanges. Beyond this, standard materials such as a rock-based mineral fibre product can complete the insulation.
After addressing these critical areas, additional measures such as valve and strainer jackets should be considered. These removable covers are designed to fit over specific components, helping further reduce heat loss and protect equipment in high-temperature environments. Once insulation is in place, how can you confirm it is performing as expected?
This is where thermal imaging comes in. Using infrared technology, thermal imaging cameras visualise heat retention and loss across a system, offering clear comparisons before and after insulation. This confirms insulation effectiveness and can guide adjustments to boiler temperatures, improving overall heat transfer system efficiency.
By addressing heat loss through targeted insulation and using tools such as thermal imaging, facilities managers can achieve significant savings while moving towards sustainability. However, energy efficiency must go hand in hand with system safety.
Preparing for the unexpected
While insulation helps reduce energy loss, facilities must also be prepared for the unexpected, such as oil spills. These incidents can pose environmental hazards and disrupt operations, so basic containment measures remain essential. Regular inspection of bunded areas and ensuring spill kits are accessible, with staff trained in proper response protocols, can help minimise risk and maintain safe working conditions.
One sometimes overlooked safety measure is the use of spray guards on flanges and valves. In the event of a leak or seal failure, even a minor release can cause high-pressure fluid to spray, creating hazardous conditions for personnel and increasing the risk of fire or equipment damage. Spray guards act as a vital containment solution, preventing this spray from escaping.
Modern spray guards are designed for both durability and performance, offering reliable protection while supporting compliance with international safety standards such as SOLAS regulations and the Model Code of Safe Practice IP15. These standards acknowledge that even fluids typically regarded as non-hazardous can become dangerous when released under pressure as mist or spray.
In systems using thermal fluids, where pressure and temperature are often high, spray guards offer essential protection against sudden gasket failure or unexpected leaks, helping facilities meet compliance requirements while protecting people, equipment and the environment.
Supporting heat transfer system efficiency with proper ventilation
Energy efficiency is not just about retaining heat; it is also about ensuring systems operate optimally. Ventilation plays a critical role in keeping thermal fluid systems running efficiently and safely.
Expansion tanks accommodate changes in the volume of thermal fluid as it heats and cools, but without proper ventilation the expansion tank gets too hot, which oxidises the fluid. The expansion tank vent should be piped to the ground floor into a vented dump tank. This set-up adds an extra layer of safety, along with clear signage and restricted access to reduce fire risks. The dump tank should be located away from drains and watercourses.
Inside heater rooms, airflow is essential. Installing louvre panels at different heights on walls, doors or windows ensures natural air circulation, preventing heat build-up. Where structural modifications are not possible, electric fans or ducting can provide effective alternatives. For indoor expansion tanks, maintaining at least a two-metre clearance around the tank ensures sufficient airflow and prevents overheating.
Each of these improvements – insulation, bunding and ventilation – contributes to more sustainable operations. Together, they form a comprehensive approach that balances energy efficiency and environmental responsibility.
Maintaining heat transfer system efficiency
Implementing these measures is only the beginning. Maintenance plans such as Thermocare provide facilities managers with the tools and expertise they need to maintain heat transfer system efficiency. By regularly sampling fluids to tailor system audits, equipment lifespan can be extended, downtime reduced and overall sustainability improved.
Sustainability is not achieved overnight, but small, strategic changes can lead to transformative results. Facilities managers who focus on retaining energy, preparing for the unexpected and optimising airflow improve their environmental impact while supporting operational efficiency and safety. By taking these steps and partnering with thermal fluid experts, facilities managers can build a system that is both sustainable and cost-effective.
Visit Global Heat Transfer’s website for more insights into improving heat transfer system efficiency.
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