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Fire risk in thermal oil systems is exceptionally low due to decades of optimized safety measures and protocols. Both manufacturers and users understand the critical role of proper design, operation, and maintenance in ensuring the safety of personnel and equipment. At Pirobloc, we prioritize safety as the core of every thermal oil installation, offering highly efficient, safe, and reliable solutions.
**Causes of Fire in Industrial Hot Oil Heating Systems**
The primary causes of fire in thermal fluid installations include:
**Leaks**
Poorly designed or maintained systems are prone to leaks, often caused by failures in seals, gaskets, or hoses. When a large volume of hot thermal fluid comes into contact with an ignition source—such as bearings, electrical panels, or motors—it can lead to fire. Even small leaks on flanges can pose risks if not properly managed using materials like graphite or fiber-reinforced Teflon.
**Insulation Fires**
Though rare, insulation fires can occur if thermal fluid seeps into porous materials like mineral wool or fibreglass. The open structure allows the fluid to spread, increasing the risk of spontaneous ignition. Using closed-cell foam glass insulation at potential leak points is the most effective prevention method.
**Undetected Loss of Flow**
A loss of flow in the thermal fluid circuit, combined with safety system failure, can lead to overheating and subsequent fire. Modern systems like Pirobloc’s tri-redundant SIL systems help eliminate such risks.
**Cracked Tubes**
While rare, cracked tubes made from unsuitable materials can cause serious fires. Using ASME ASTM A106 Gr. B Sch. 40 piping and regular maintenance helps prevent this issue.
**Assessing Fire Risk**
Key parameters for assessing fire risk include flash point, ignition point, and autoignition temperature. However, the real risk often lies in system design and maintenance rather than the fluid itself.
**Fire Prevention Measures**
Proper design, regular maintenance, and adherence to safety guidelines significantly reduce fire risk. This includes using closed-cell insulation, replacing faulty seals, installing low-flow shutdown systems, and ensuring adequate ventilation.
**Importance of Thermal Insulation**
Thermal insulation plays a vital role in fire prevention by limiting heat transfer and preventing flammable liquids from being absorbed. Closed-cell cellular glass insulation, such as FOAMGLAS®, is the safest option, though more expensive. Combining it with cheaper alternatives in low-risk areas can optimize costs.
In conclusion, while fire risk in thermal oil systems is minimal, proactive measures, proper maintenance, and high-quality materials are essential to ensure long-term safety and efficiency. Always consult with experts and follow manufacturer guidelines to maintain optimal performance and safety.
June 27, 2025