Keep Your System Safe: Common Safety Device Failures in Thermal Oil Heaters

Thermal oil heaters https://8ruiyan.com/en/all-organic-heat-carrier-boilers/are reliable workhorses in many industries. But like any equipment, their safety systems need attention. When protection devices fail, risks arise. Let’s look at some common failures, their consequences, and what to do.

1. Low Oil Level Switch Failure

• The Problem: If this switch fails, the heater might not stop when oil is low. This can cause overheating. The remaining oil can degrade or even crack, leading to system blockages and heater damage.
• What to Do: Check the level switch and probe regularly for buildup or damage. Test its function often. Always maintain the proper oil level. If it fails, shut down the heater immediately and repair or replace the switch.

2. Pressure Relief Valve (PRV) Malfunction

• The Problem: A stuck or sealed PRV cannot release excess pressure. This creates a major risk of rupture or explosion in the system.
• What to Do: Test the PRV manually as scheduled. Never lock or seal it shut. If it fails to operate, shut down the system at once. Let it cool completely. Then, replace the valve before restarting.

3. Flow Switch/Sensor Failure

• The Problem: This device monitors oil circulation. If it fails, the heater may not detect low or no flow. This leads to rapid overheating and oil degradation.
• What to Do: Inspect the flow sensor regularly. Check for deposits or obstructions. Verify its signal matches the pump’s actual operation. If faulty, stop the heater. Find and fix the root cause (e.g., pump issue, blockage). Then replace the sensor.

4. High-Temperature Cut-Out Failure

• The Problem: This is a critical safety limit. If it fails, there is nothing to stop the heater from reaching dangerous temperatures. This can cause severe oil breakdown and system damage.
• What to Do: Test this cut-out frequently. Calibrate it according to the manual. If it does not activate during testing, take the heater offline immediately. Do not use it until the cut-out is repaired and tested.

5. Pump or Power Failure

• The Problem: A sudden stop in circulation causes intense heat buildup in the heater coil. This is very dangerous and can damage the system quickly.
• What to Do: Ensure backup power systems (like emergency generators) are ready. Use pumps with reliable seals and monitors. Have a clear emergency procedure. This should include activating a backup pump or initiating a controlled cool-down process.

General Best Practices:

• Routine is Key: Follow a strict schedule for inspection and testing of all safety devices.
• Training Matters: Make sure operators know the warning signs and emergency steps.
• Act Immediately: Never ignore a fault alarm or bypass a safety device. Always investigate and resolve.
• Keep Records: Log all tests, maintenance, and any faults.

Závěr

The safety systems on your thermal oil heater are its most important parts. They are the last line of defense. Regular care and prompt action for any faults are not just recommendations—they are essentials for safe operation. Protect your equipment, your process, and your people by making safety system checks a top priority.

For further problems about organic thermal fluid heaters, please contact our technical team for expert advice.

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