How to Add Thermal Oil to an Electric Thermal Oil Heater?

Elektrische Thermalölerhitzer https://8ruiyan.com/en/all-organic-heat-carrier-boilers/ are vital equipment in many industrial processes. They provide stable and efficient heat for reactors, platens, molds, and more. Thermal oil, the “blood” that transfers heat, makes the filling process the critical first step. Incorrect operation can not only affect performance but also cause serious safety risks.

Today, we will explain how to safely and correctly add thermal oil to your electric heater.

Step 1: Preparation — Safety First

1. Personal Protective Equipment (PPE):

• Safety Goggles: Protect eyes from splashes.
• Chemical-Resistant Gloves (e.g., nitrile): Prevent skin contact with hot oil.
• Long-Sleeved Work Clothes and Safety Shoes: Protect against burns and oil.
• Hard Hat: Essential in workshop environments.

2. Tools & Materials:

• Correct Thermal Oil: Use the type specified by the manufacturer. Avoid mixing new and old oil. If necessary, ensure they are the same brand and type.
• Hand Pump or Gear Pump: The most common tool for transferring oil from the drum into the system.
• Clean Hose: Connects the pump to the system fill port. It must be clean, dry, and free of other oil residues.
• Filter (recommended 100 mesh or finer): Crucial! Installed at the pump outlet or fill port to filter impurities from new oil.
• Tools: Adjustable wrenches, screwdrivers.
• Rags and Drip Pan: For cleanup and containing spills.

3. System Check:

• Power Off: Ensure the heater is completely disconnected from power. Hang a “Do Not Switch On” warning tag.
• System Cooled Down: Ensure the entire system, especially the expansion tank and pipes, is at room temperature to prevent hot oil burns.
• Check Valves: Confirm all system valves are in the correct position for filling.

Step 2: Procedure — Step-by-Step

1. Connect the Filling System
Place the hand pump/gear pump securely on the oil drum. Connect the hose to the pump outlet. Connect the other end of the hose to the system’s fill port (usually on the low point or main pipe) through the filter. Open the vent valve on the expansion tank.

💡 Key Tip: Never skip the filter! Tiny debris can speed up oil degradation, clog pipes, and damage the pump.

2. Start Adding Oil
Pump slowly and steadily. This allows air inside the system to escape through the expansion tank’s vent valve.

3. Watch the Level & Vent

• Watch the expansion tank’s level gauge.
• Stop pumping when the oil reaches 1/4 to 1/2 full.
• Let the system sit. This allows trapped air to rise and escape.

4. Start Circulation, Force Air Out

• Close the vent valve on the expansion tank.
• Start only the circulation pump (keep the heater powered off!). Let the oil circulate without heat.
• This will push remaining air into the expansion tank. The oil may bubble and churn—this is normal.
• After circulating for a while (e.g., 30 minutes), the oil level may drop. Briefly open the vent valve again to release air. Then add more oil until the level is between 1/2 and 2/3 full.

5. Final Check & Finish

• Stop the circulation pump.
• Check the entire system for leaks at all connections, valves, and flanges.
• Disconnect the filling tools. Seal any unused oil drums. Clean up any spills and tools.
• Dispose of used rags and empty drums properly.

Step 3: Important Notes & Common Mistakes

• No Moisture: Water is dangerous. It can turn to steam, cause pressure spikes, and lead to oil eruptions. Keep everything dry.
• Do Not Mix Oils: Mixing different brands or types can cause chemical reactions. This leads to coking, carbon buildup, and clogs.
• Temperature & Pressure: The system must be cool and at atmospheric pressure during filling.
• Go Slow: Pumping slowly helps remove air. Rushing causes air locks.
• Keep Records: Write down the date, oil brand, type, and amount added for future maintenance.

Summary

Adding thermal oil is not just pouring it in. It is a standardized safety procedure. The keys are “Clean, Dry, Slow, and Vent.”

Following these steps ensures a safe and reliable oil fill. This prepares your system for long-term, stable, and efficient operation. If you are unsure about any step, always check the equipment manual and ask a professional.

Safety is paramount. Correct operation protects you and your equipment!

For further consultation, please contact our technical team for expert advice.

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