Chemical Engineering August 2021 - 17

Facts At Your Fingertips
Digitalization of Heat Transfer Fluid Systems
Department Editor: Scott Jenkins
he spread of COVID-19 opened the world's eyes to
the weakness of much of its infrastructure and drove
home the important role operators and engineers
play in keeping manufacturing plants running. These unsung
heroes were challenged with the difficult logistics of
meeting production schedules and maintenance requirements
while mitigating the spread of the coronavirus.
The pandemic also highlighted the need for digitally
connected plants and operations. By digitally enhancing
heat transfer fluid (HTF) systems, operation managers and
engineers can be equipped with richer data to manage
their production and maintenance more effectively and
safely. In this way, they can monitor and forecast fluid testing
issues related to acid number, moisture, viscosity and
other parameters -- all of which can impact production
schedules and maintenance operations.
Despite the challenges of COVID-19, strict quarantine
practices and modified work schedules allowed plants to
continue normal operation by having essential workers
on-site. But plants would have benefited from technology
platforms that enabled productivity from afar. Not only
are digitally enabled tools more convenient to monitor and
track systems, they also give plant managers the ability
to look across systems at various locations, fluids and
applications to gain more insights. They enable managers
to answer key questions like: " Are we operating most
efficiently? " and " Are we maximizing the life of our fluid? "
The functions listed below are among the expectations
plant managers and engineers struggled with when monitoring
and tracking heat transfer systems during the unconventional
operating conditions of the pandemic.
Production schedules. Digital tools that gather data and
compile a dashboard of metrics and alerts for any subsystem
within the plant help ensure production schedules
are met, even when daily routines are disrupted.
Maintenance schedules. Ensuring efficient maintenance
and having a view of future performance trends is
also critical to productivity. Organized knowledge of past
actions and results is important to understand how to
resolve future challenges more efficiently.
Plant and system efficiency. Regardless of markets
and global conditions, driving efficiency is critical to remaining
competitive. Digital tools can allow operators to
easily understand systems' conditions at a glance.
Training. Teams have experienced various shifts in roles
and responsibilities to maintain operations. For this reason,
there is a need for in-depth training materials to
quickly bring your team up to speed.
Safety. Safety in manufacturing is critical to ensure an engaged
workforce but also allows for the best overall productivity.
Insights that proactively highlight potential safety
challenges are invaluable.
HTF maintenance
When it comes to digitally connected HTF systems, the
lessons learned from operating during the pandemic can
16a
T
be applied as normal operations resume to further improve
day-to-day operations. Furthermore, all critical decisions
involving heat transfer fluids have daily consequences for
operators and engineers. The items listed below are some
key best practices and recommendations to help ensure
optimal performance of your HTF systems.
Improvements to digital monitoring capabilities. Production
operations are likely already digitally enabled with
programmable logic controllers (PLCs), distributed control
systems (DCSs) and so on. To remain competitive, all
companies should continue to explore and deploy more
advanced digital tools to drive continued efficiency when
it comes to monitoring viscosity, acid numbers, moisture
content, flash point and more.
Annual fluid testing. Performing yearly fluid analysis offers
a baseline for your system's performance. Digitally
prompted or scheduled reminders facilitate compliance.
Actionable recommendations. Test results are valuable,
but recommendations based on the results from experienced
partners are even more valuable. Artificial intelligence
and machine learning supported by vendor partners
can help facilities receive the best recommendations
for optimal fluid performance. For example, by analyzing
moisture content trends, facilities can identify potential issues,
such as heat exchanger pinhole leaks, that could
result in an unplanned shutdown.
Easy-to-read sample analysis reports. Adopting a digitally
enabled platform that provides easier-to-read sample
analysis reports allows users to quickly scan key system
performance metrics and know if action is required.
Sample analysis historical data. Data and digital trends
can help quickly identify systematic or recurring issues
based on current system performance compared to past
performance. This includes trend recognition of viscosity
and moisture content, inconsistent temperature or accelerated
degradation.
Maintenance tracking and troubleshooting. Along with
historical data, access to past maintenance activities allows
engineers and operators to repeat actions, correct
issues, or spot new issues. Also, tagging maintenance activities
with the personnel who took action provides new
employees with a network to discuss current activities.
Preventive maintenance systems can begin to do this,
but inclusive digital HTF maintenance systems that couple
data and maintenance history with actionable recommendations
are also available. ■
Sponsored by
Editor's note: Content authored by Kapil Bathla, technical
service and application development representative,
Eastman Heat Transfer Fluids..
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