Avoiding a Full Oil Change Through Root Cause Identification
System Type
Thermal fluid system (110,000 litres)
The Challenge
The site had been advised to replace the thermal fluid due to flashpoints falling below recommended minimum levels.
Test data showed a clear step change in thermal degradation.
The Solution
TFS reviewed previous audit data and requested a new oil sample for a full OPC® test suite. Changes in acidity, viscosity and flashpoints indicated a likely refractory issue within the combustion chamber.
An internal inspection confirmed that the back refractory wall had collapsed, allowing combustion gases to impinge on coil surfaces.
After refractory repair (2 days downtime), TFS:
- Recovered the fluid online (no additional downtime)
- Removed acid and degradation products
- Restored stable operating condition
- Degradation products removed: 160 litres
The Result
- Root cause identified and repaired
- Full oil change avoided
- Fluid recovered and stabilised
- System returned to safe, consistent operation
- Significant cost savings achieved
