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FMDS0799 - HTF Loss Prevention
FMDS0799 - HTF Loss Prevention
Table of Contents
Page
List of Figures
Fig. 1. Flow control by three-way control valve and bypass ......................................................................... 7
Fig. 2. Typical vent line details ..................................................................................................................... 12
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7-99 Heat Transfer By Organic and Synthetic Fluids
Page 2 FM Global Property Loss Prevention Data Sheets
List of Tables
Table 1. Sprinkler Protection for Indoor Heat Transfer Equipment ................................................................ 4
Table 2. Properties of Heat Transfer Fluids (HTFs) ................................................................................... 20
1.0 SCOPE
This loss prevention data sheet provides recommendations for the siting, design, operation, maintenance,
inspection, and fire protection of circulating heat transfer systems using flammable heat transfer media.
1.1 Changes
January 2009. Minor editorial change was made in Table 2.
2.1 Introduction
Sprinkler protection alone cannot ensure that a fire involving a heat transfer fluid (HTF) release will not cause
roof collapse. It is critical that the prevention items, and other means of minimizing the incident in all of the
recommendation sections below, also be applied.
2.3 Protection
Install sprinklers on a spacing suitable for extra-hazard occupancies (i.e., maximum 100 ft2 [9.3 m2] per head;
see Data Sheet 2-8N, Installation of Sprinkler Systems (NFPA), for additional installation criteria), and
hydraulically design them as indicated in Table 1. In areas that may be exposed to an HTF spill fire, ensure
sprinkler protection is provided under any obstruction to water distribution that exceeds 3 ft (0.9 m) in width
or diameter and 10 ft2 (0.9 m2) in area (e.g., under large pieces of equipment).
An automatically actuated deluge sprinkler system is an acceptable alternative to an automatic sprinkler
system. Where a deluge system is used, ensure nozzle spacing does not exceed 100 ft2 (9.3 m2). Ensure
detector spacing is as specified in Data Sheet 2-8N.
2.3.1.2 Where the heat transfer system user or heating equipment is located within a multi-level processing
structure with open or incompletely sealed floors, provide fire protection as detailed in Data Sheet 7-14, Fire
and Explosion Protection for Flammable Liquid, Flammable Gas, & Liquefied Flammable Gas Processing
Equipment & Supporting Structures. This applies to buildings with grated floors, or solid floors with numerous
penetrations to the level below, or where heat transfer fluid piping, pumping equipment, heating or user
equipment are on elevated grated mezzanines (i.e., where a three-dimensional fire is a possibility).
2.3.1.3 Automatic sprinkler protection may be omitted in building areas that contain no combustibles other
than the heat transfer fluid in the pipeline, if:
a) the piping is all welded, with no flanged joints;
b) there are no valves, pumps, or other accessories that are known to be potential leakage points; and
c) the piping system consists solely of ferrous piping installed as recommended, including either automatic
or manual remote shutoff.
Use an inert gas, such as carbon dioxide or nitrogen. Steam is acceptable only when there is an independent,
reliable source of it. For carbon dioxide or nitrogen inerting systems, refer to Data Sheets 4-0, Special
Protection Systems, 4-11N, Carbon Dioxide Extinguishing Systems (NFPA), and 7-59, Inerting and Purging
of Tanks, Process Vessels, and Equipment, for additional design criteria. See also NFPA 12, Carbon Dioxide
Extinguishing Systems, for further information.
For steam inerting systems, provide steam at a rate of 4 to 8 lb/min per 100 ft3 (0.64 to 1.3 kg/min/m3) of
enclosure volume (The enclosure is defined as the entire volume being protected. This would normally include
the entire interior volume of the heater or vaporizer, but would not normally include the exhaust stack.). The
lower figure can be used for relatively tight enclosures if steam is introduced at or below the level of a
possible fire. Use the higher figure if there is unavoidable leakage of up to one air change per minute, or if
steam is introduced above the level of the fire. Adequate steam condensate trapping must be provided for
steam inerting systems.
The inerting concentration needs to be maintained until hot surface parts, especially refractory, cool below
the ignition temperature of the HTF.
Extended-discharge systems are preferred over one-shot discharge systems due to the increased reliability
and added cooling capability.
2.3.2.2 Ensure the fixed inerting system is automatically actuated by detection of any two of the following
conditions. Provide an alarm when any one of these conditions is detected.
a) High values from a differential flow detector comparing HTF flowing into and out of the heater. On
very large units (i.e., where heat exchange tubes or coils have a diameter of 4 in. 100 mm or more) with
multiple tubes or coils, provide a differential flow detector for each tube or coil.
b) Low HTF level in the expansion tank. (Note: This function can be used only if the expansion tank level
is not automatically corrected with a pumped re-supply of HTF from the storage tank.)
c) High values from flue gas combustibles analyzer
d) Increase in opacity of smoke exiting the heater or vaporizer
e) High flue gas temperature
f) Increase in carbon monoxide in flue gas
g) Decrease in oxygen in flue gas
The inerting system should also be provided with a remotely located manual actuator.
2.3.2.3 If an HTF fire occurs in the combustion chamber of a heater or vaporizer, ensure the following actions
are taken:
a) Shut off the fuel supply.
b) Stop combustion air fans and shut any combustion air inlet dampers.
Outlet dampers should preferably remain open to prevent overpressure of the firebox due to the inert-gas
smothering system discharge as well as to help purge any combustible vapors. However, isolation
dampers may be provided on flue gas ducts where it is determined that lack of these would possibly prevent
adequate inert gas concentrations from being achieved and held, such as with systems that only provide
a one-shot inert gas discharge, as opposed to extended discharge systems.
Ensure dampers fail-safe in the desired position since power may be lost or shut off in the event of a
fire.
c) Open steam or inert-gas smothering systems or use portable extinguishers at openings to the fire box.
d) With a heater or vaporizer provided with a fixed inert-gas smothering system, do not drain the HTF
until after the fire is extinguished. HTF pumps may also be kept running to continue fluid circulation through
the unit, if desired.
e) On units that are not provided with an inert-gas smothering system, drain the heat transfer fluid within
the heater or vaporizer as soon as possible and as quickly as possible, regardless of residual heat damage
considerations. This is justified by the overriding consideration that the flow of leaking HTF must be
stopped to extinguish the fire. Rapid draining is best accomplished by isolating the unit from the remainder
of the system with valves and then draining only the liquid in the heater or vaporizer itself back to the
storage tank. Use oversized emergency drain piping to help provide short drain times. If a storage tank
is not available, drain to a safe location. Where damage to empty tubes from hot refractory heat holdup
is a concern, air dampers may be re-opened and fans re-started after the fire is out.
Exceptions:
i) Where the HTF is at a temperature above its atmospheric boiling point, ensure the heater or vaporizer
is subjected to a rapid drain only if an emergency cooler is provided that can cool the HTF to below
its atmospheric boiling point prior to discharge into the storage tank(s). Otherwise, ensure the HTF is
drained slowly, and only in cases of extreme emergency.
ii) Where the leakage rate is visually verified to be small enough to allow the combustion of HTF
immediately after issuance from the leaking tube(s), without a constant size or growing pool of HTF
at the bottom of the firebox chamber, then manual fire extinguishment may be attempted without
draining the HTF from the tubes. Perform a manually controlled heat transfer system shutdown. Shut
off fuel to the heater or vaporizer. Ensure the tubes are depressurized (e.g., throttled back on valves
upstream of the heater or vaporizer) while continuing minimal circulation to prevent fouling. If the fire
cannot be extinguished after this has been done, then drain the tubes.
iii) Drainage is not possible with certain tube configurations, such as horizontally oriented helical coils
or vertical pendent tubes, due to the lack of a single low point.
f) Where an inert gas extinguishing system is provided and is automatically actuated, then ensure steps
a. to c. above are all automatic. Step d. may be manually initiated. Where the inert gas extinguishing
system is manually actuated due to the lack of appropriate instrumentation as enumerated in 2.3.2.2, then
steps a. through d. may all be manually initiated. If the inert gas extinguishing system is ever converted
to automatic actuation, then convertall of steps a. through c. to automatic at that time as well.
g) Where a fixed inert gas extinguishing system is not provided, but heat transfer system instrumentation
is already present that can detect at least two of the conditions enumerated in 2.5.2.2 (i.e., conditions
indicative of a firebox fire), ensure steps a. and b.) above are automatic upon detection of any two of these
conditions. Where appropriate system instrumentation is not present, steps a. and
b. above may be manually initiated.
2.3.2.4 Perform a full discharge test after installation of an inert gas extinguishing system. Where possible,
do this during normal operation of the heat transfer system to ensure all extinguishing system components
and process interlocks will operate and that inert gas design concentrations are being achieved and
maintained. Ensured the unit is not being used for production purposes during the test.
Note: Where an inert gas discharge nozzle is unusually close to a hot component inside the protected volume,
there may be a possibility of thermal shock damage to that component. In such a case, discharge the system
running, but cold.
Verify isolation dampers that are intended to actuate in the event of a fire to help maintain inert gas
concentrations on a regular basis to ensure they are operational. Ensure a minimum yearly test frequency.
a) 75 ft (23 m) away from important buildings, or 25 ft (7.6 m) if the total system HTF capacity does not
exceed 1500 gal (5.7 m3). Where this space separation cannot be provided, ensure the exposed wall(s)
has a minimum 1-hour fire resistance.
b) 100 ft (30 m) away from outdoor flammable liquid or gas processing equipment. The space separation
may be less than this if either the process area or the HTF heater or vaporizer is protected by an
automatically actuated deluge sprinkler system. Where the loss expectancy does not justify the cost of
deluge sprinkler protection, and space separation is less than 100 ft (30 m), then provide manual protection
(e.g., hydrants, monitor nozzles). Regardless of the protection provided, do not locate the HTF heater
or vaporizer in any area requiring hazardous location electrical equipment as defined by the National
Electrical Code Article 500 (or national/international equivalent). See Data Sheet 5-1, Electrical Equipment
in Hazardous (Classified) Locations and NFPA 497A to determine the extent of the hazardous (classified)
area.
c) 75 ft (22.9 m) away from important outdoor processing equipment that does not handle any flammable
liquids or gases, or 25 ft (7.6 m) away if the total heat transfer system fluid capacity does not exceed
1500 gal (5.7 m3). Where this separation cannot be provided, ensure manual protection (e.g., hydrants,
monitors) is provided to prevent heat damage to the exposed equipment.
2.3.3.4 If outdoor piping has potential leakage points (e.g., valves, flanged joints, fittings, pumps, etc.) and
a leak and subsequent fire could cause significant damage to buildings or important structures, provide
suitable fire protection.
2.4.1.2 Ensure the flow velocity through the heat exchange tubes in the heater is sufficient to result in fully
turbulent flow in the tubes. Heat transfer calculations should be provided by the system installer to ensure
the HTF manufacturer’s maximum recommended film temperature will not be exceeded during any
foreseeable operating conditions.
2.4.1.3 Provide an emergency drain line at the system low point(s), piped to one or more vented storage
tanks, or to a safe area capable of accommodating the total fluid contents of the system or that part that can
be isolated. Drainage may be by gravity flow or by pumps as long as power to the pumps is ensured in the
event of an emergency. The same drain lines may be used for both routine and emergency drainage. Arrange
the tank(s) as indicated in 2.4.1.8.
2.4.1.4 Do not pumpHTF throughout a facility to provide building heat via local heat exchangers. When HTF
is used for building heat, provide a central heat exchanger to generate hot water, hot glycol, or steam, which
can then be piped throughout the facility.
2.4.1.5 Provide control equipment to permit operation of key equipment and valving from both the control
room and from close to the location of the equipment.
2.4.1.6 In designing and building a heat transfer system, consult the manufacturer of the HTF for advice
on the choice of gasketing material (for joints) and packing material (for valves and pumps) that will provide
the best leak-free service for their fluid at the intended operating temperatures and pressures, and considering
the operating environment, both internal and external. (See also general recommendations in Section 2.4.2
below.)
2.4.1.7 Locate piping and equipment containing HTF so they will not be exposed to temperatures below
the pour point of the fluid. (See Table 2 in Appendix D for pour points of various fluids.) Provide a combination
of insulation and electric or steam heat tracing on critical system piping and equipment where it is impractical
to reliably guarantee that temperatures will not go below the pour point for any extended period of time (e.g.,
outdoor equipment where the ambient temperature occasionally reaches values below the pour point;
equipment indoors in unheated buildings where the only source of heat is the heat transfer system itself and
outdoor temperatures regularly or seasonally reach values below the pour point).
Refer to Data Sheet 9-18/17-18, Prevention of Freeze-Ups, for additional recommendations to prevent freeze
damage and for information on heat tracing systems.
Freeze protection may be omitted for system segments that may be drained to the storage tank(s) through
valved system low points.
2.4.1.8 Where possible, locate the storage tank(s) below the lowest system drain opening to permit gravity
flow when emptying. Due to the fact that the fluid does not circulate through the storage tank, make provisions
for freeze protection where necessary. Provide adequate breather vents based on the maximum emptying or
filling rates.
2.4.1.9 Do not convert steam boilers to HTF operation except under the guidance of the equipment
manufacturer.
2.4.2.4 Do not use mixtures of HTFs in a system, unless such mixtures are in accordance with
recommendations of the manufacturer of the fluids and heat transfer equipment.
2.4.2.5 Prior to changing an existing system from one heat transfer fluid type to another, ensure a full
engineering review is done to determine that all aspects of the system are appropriate for the new fluid (e.g.,
system materials, flow rates, temperatures, pressures, vented vs. closed/inerted system, etc.).
2.4.2.6 Avoid gauge glasses if possible. Where used, ensure gauge glasses are of a high pressure rated
type consisting of a steel body with a special tempered glass window secured between bolted flanges.
2.4.2.7 Do not use trycocks for checking liquid levels in vaporizers. It would be undesirable to release the
substance in the vaporizer room.
2.4.2.8 Provide FM Approved combustion safeguards and fuel safety shutoff valves on gas and oil burners.
(See Data Sheet 6-4/12-69, Oil- and Gas-Fired Single-Burner Boilers, Data Sheet 6-5/12-70, Oil- or
Gas-Fired Multiple Burner Boilers, and Data Sheet 6-10, Process Furnaces, as applicable.) Consult Data
Sheet 6-2/12-63, Pulverized Coal-Fired Boilers, Data Sheet 6-13/12-13, Waste Fuel-Fired Boilers, or Data
Sheet 6-7/12-7, Fluidized Bed Combustors and Boilers, as applicable, for recommendations where the heat
transfer fluid is heated by burning solid or waste fuels.
2.4.2.9 If stack gas from the HTF heater or vaporizer is recovered to provide auxiliary base load heat for
other equipment (e.g., rotary dryers), provide suitable dampers, isolation gates, burner control logic, etc., to
ensure that all equipment is properly purged and will operate in a safe manner. Ensure the control logic is
able to anticipate all possible operating modes of the individual pieces of equipment, whether operating singly
or together, to ensure safe startup and shutdown under normal or upset conditions.
2.4.2.10 Tightly seal ny openings in pipes or equipment, such as manholes, instrument ports, inspection
ports, etc., to ensure they will not allow HTF leakage in the event of a system upset.
2.4.3 Tanks
2.4.3.1 If located indoors and above ground, ensure the expansion tank and storage tank are located within
diked areas capable of containing the total volume of the tanks. Where storage tanks are located below grade
in a pit, ensure the pit is capable of containing the total volume of the tank.
The following can provide acceptable alternatives to secondary containment where a full capacity dike is
economically impractical or physically difficult:
a) If the tanks are located in dedicated rooms cut off from manufacturing or storage areas, ensure curbs
at the door(s) are sufficiently high to contain the total spill volume of the tank within the room.
b) Provide minimum 4 in. (100 mm) high curbing around the tank, with adequate drainage provided within
the curbed area capable of draining away fire protection water (sprinkler flow plus hose stream flow)
discharged in the event of a fire. See Data Sheet 7-83 for required drainage capacity and other drainage
system installation details.
c) Where an expansion tank includes an internal overflow line that is piped to a low-level storage tank,
secondary containment is not required as long as the overflow line is unvalved, or has shutoff valves that
are locked in the fully open position. Ensure there are no other openings or weak fittings on the expansion
tank that could allow fluid escape into the immediate environment in the event of overflow line blockage.
However, where the expansion tank is located directly above high-value or critical process equipment, at
least provide a drained drip pan below the tank to catch and remove to a safe location any minor (i.e.,
non-catastrophic) leakage that might occur.
d) An emergency drain is provided on the expansion tank as detailed in 2.4.3.2.
2.4.3.2 Where the expansion tank is located above floor level and has a capacity of over 250 gal (1000 l),
provide it with a low-point drain line that can allow it to be drained to the low-lying drain tank (storage tank).
Ensure the drain line valve is remotely operable from a safe place. Provide a low-point drain for expansion
tanks with a capacity of less than 250 gal (1000 l).
2.4.3.3 For systems that approach or exceed the atmospheric boiling point of the HTF, provide the expansion
tank with an inert gas (e.g., nitrogen) blanket under a positive pressure of at least 15–25 psi (1–1.7 bar)
above the fluid’s vapor pressure. Provide an interlock that will shut down the fuel source to the heater or
vaporizer if the inert gas pressure falls below the minimum required. Always provide a pressure relief device
in conjunction with inert gas pressurization. Refer to Section 2.4.9, as well as to Data Sheet 12-43, Pressure
Relief Devices, for additional guidance on pressure relief devices.
2.4.3.4 If an HTF expansion tank is provided with a breather vent, ensure the discharge outlet from this
vent terminates at a safe location so if burning vapor or liquid is discharged it will not expose buildings,
equipment, combustibles, or personnel.
2.4.3.5 Ensure any above-ground HTF storage tanks (indoors or outdoors) are constructed, located, and
arranged as detailed in Data Sheet 7-88, Storage Tanks for Flammable and Combustible Liquids.
2.4.4 Piping
2.4.4.1 Ensure piping is securely supported and protected against mechanical injury. Provide adequate
clearance between HTF piping and wood or other combustible construction materials, as follows: insulated
piping with surface temperature below 200°F (93°C): 1 in. (2.5 cm) minimum; uninsulated pipe: 18 in. (0.45
m) minimum.
For insulated pipe whose surface temperature exceeds 200°F (93°C), provide suitable clearance to keep
the surface temperature of nearby combustible construction materials below 160°F (71°C). Keep piping well
away from any combustible storage.
2.4.4.2 In and around process equipment where combustible materials will unavoidably settle on HTF piping
or heated surfaces, provide sufficient insulation on the piping or equipment to prevent ignition of the deposited
material. Where hot surfaces must be kept uninsulated due to process considerations, remove any
combustible accumulations on a daily to weekly frequency, depending upon the rate of accumulation.
2.4.4.3 Minimize overhead routing of HTF piping. Run piping underground, outside, or in floor trenches where
possible.
2.4.4.4 Welded pipe connections are preferred throughout an HTF piping system. Use of mechanical joints
should be limited to pump, valve, and equipment connections if possible. For systems operating above
15 psig (1.03 barg), ensure pipe materials and types are in accordance with ANSI/ASME B31.1, Power Piping,
or ANSI/ASME B31.3, Chemical Plant and Petroleum Refinery Piping, (or national/international equivalent)
as applicable. For systems operating at or below 15 psig (1.03 barg), refer to Data Sheet 7-32 for
recommendations regarding acceptable pipe materials and types. The ANSI/ASME standards can also be
used as a guide. For systems operating at any pressure, do not use copper or cast iron piping.
2.4.4.5 Incorporate a Hartford loop into the condensate line of vapor-phase heating equipment having a
gravity return whenever the condensate is returned to a point in the vaporizer below the lowest safe liquid
level.
2.4.4.6 Where HTF system piping is connected to heated rolls with rotary joints, use flexible connections
(e.g., flexible metal hose) at the joint so it is free to follow any movement of the roll.
2.4.4.7 Design piping from safety valves to the point of safe discharge to withstand the anticipated
backpressure and mechanical stresses. Weld all joints. Ensure changes in direction of the discharge line
are adequately braced to resist anticipated thrust loads caused by fluid flow.
2.4.4.8 Do not use threaded pipe fittings used with HTF temperature above 350°F (177°C), or at temperatures
above 220°F (104°C) where the pressure exceeds 100 psig (6.9 barg). (Note: Flanged joints are the preferred
mechanical connection at all temperatures.)
2.4.5 Valves
2.4.5.1 Install valves with stems in the horizontal position so any leaking fluid will drip away from the
insulation.
2.4.5.2 Use double-seal valves in order to minimize leakage.
2.4.6 Joints
2.4.6.1 Weld all joints to minimize the potential for leakage.
Where flanged fittings are used, use the following gasket materials, which have been shown to provide
acceptable reliability:
2.4.7 Pumps
2.4.7.1 Use sealless pumps of cast steel construction to minimize leakage.
2.4.8 Insulation
2.4.8.1 Ensure the insulation used to cover HTF piping and equipment is nonabsorbent.
Any type of insulation may be used where the pipe is all welded (i.e., without flanged fittings) and where
there are no other sites prone to leakage, such as valves or pumps. Commonly used insulating materials
are grouped as follows:
NONABSORBENT ABSORBENT
closed cell cellular glass calcium silicate
(foamed glass) 85% magnesia
reflective aluminum foil glass fiber batts
or sheets ceramic wool
mineral wool
asbestos fibers,
silicate bonded
2.4.8.2 Apply insulation to system piping and equipment only after a leakage or pressure test of the plant
has been conducted. Allow a full heating cycle before applying insulation.
2.4.8.3 In existing installations where equipment and piping is covered with open cell (HTF absorbing)
insulation, remove the insulation from system components that are prone to leakage and cover only with a
spray shield. Where insulation must be provided, the components may be re-covered with nonabsorbing
insulation. Alternatively, cover the existing open cell insulation with hydraulic-setting oil-resistant cement in
areas of potential leaks.
2.4.9.5 Ensure outdoor discharge piping from pressure relief devices for media having high pour point
temperatures is heated by steam tracing or other means, so that during cold weather, leakage or emergency
discharge of such media will not solidify and obstruct piping.
2.4.9.6 Ensure outdoor vent pipe outlets are either hooded or terminated in a U-bend to keep out rain.
2.4.9.7 Ensure discharge piping is supported and arranged according to the recommendations of pressure
relief device manufacturers to avoid strain on the valve, which could cause leakage.
2.4.9.8 Where allowed by codes, a non-fragmenting rupture disk may be installed upstream of the safety
relief valve. Where this is done, provide a pressure gauge, bleed line, or vent between the rupture disk and
the safety valve, to test the rupture disk for leakage. Refer to Data Sheet 12-43 for additional guidance.
2.4.9.9 Ensure afety relief valves have tapered or streamlined inlets and externally guided disks to avoid
sticking of valves, which might result from carbon formation on internal guides.
2.4.9.10 Ensure safety relief valves have enclosed springs to prevent vapor from escaping around the valve
spindle. Use special steels to withstand the high temperatures. Cap adjustment screws to avoid tampering
with the setting of the valves. Ensure all safety relief valves comply with applicable pressure vessel codes.
j) High value from a differential flow meter measuring HTF heater or vaporizer inlet and outlet flows.
(optional)
Note: Provide an alarm set point at levels below or above the auto shutoff levels to monitor the above-
mentioned variables and provide an opportunity for operators to correct the problem before conditions reach
an unsafe level.
2.4.10.2 Interlock the heat transfer system to stop the circulation of fluid throughout the system and to isolate
major piping segments in the event of a fire. To accomplish this, provide the following, arranged to actuate
either in the event of sprinkler system operation or abnormally low pressure in the heat transfer system, or
upon operation of a heat detection system using FM Approved (see Appendix A for definition) detectors
installed according to the limitations indicated in the Approval Guide, a publication of FM Approvals.
a) Provide safety shutoff valves or 3-way divert valves of fail-safe design to isolate all secondary circulating
loops from the primary loop running into and out of the vaporizer or heater. A positive displacement pump
arranged to stop operating is an adequate substitute for a safety shutoff valve located in the same place.
b) In primary or secondary loops that have sizeable HTF hold-ups (greater than approximately 500 gal
2000 l), provide additional safety shutoff valves along the length of piping within the loop to minimize the
volume of a potential release. The following are some factors to consider in deciding the need for and
location of additional safety shutoff valves:
i) Attempt to prevent released HTF from flowing at or near equipment that is particularly valuable,
has long repair/replace times (e.g., foreign and/or very specialized), or is a production bottleneck.
ii) Attempt to prevent any significant gravity flow from occurring, such as at low points of loops that
have much piping or equipment at higher levels.
c) If safe to do so, arrange all system pumps to stop.
d) Exceptions/modifications to a–c. The refractory inside some heaters or vaporizers can retain enough
heat to cause HTF breakdown and tube fouling if fluid circulation through the unit is stopped, even with
the fuel supply shut off. Where this is the case, or with solid waste-fuel fired units, the HTF may continue
to be pumped until the heater or vaporizers is deemed to have cooled sufficiently under any of the following
conditions:
i) If the fire is within the heater or vaporizer and a fixed inert gas extinguishing system is provided,
then circulation may be continued, through the entire system if desired.
ii) If the leak or fire is somewhere other than within the heater or vaporizer room, the HTF flow can
be diverted from the secondary equipment loops and most of the primary loop to an emergency cooling
loop connected local to the heater. All piping through which the HTF is flowing during the diversion
to the emergency cooling loop should be located in an area(s) not involved in the fire. The acceptability
of this arrangement is based on the provision of zoned automatic sprinkler system flow detection and
zoned low pressure interlock switches to ensure the HTF fire or leak is not in the heater/vaporizer room
or other areas where the emergency cooling loop piping is located.
iii) If the leak or fire can be pinpointed to a specific secondary loop, and a fire involving the one leaking
loop or system cannot involve other secondary HTF loops or another primary loop due to space
separation or physical barriers, then flow may be continued through the primary loop and other
secondary loops if needed. Safety shutoff valves should be provided as explained in 2.4.10.2a and
2.4.10.2b above to isolate the loop involved in the leak or fire. Acceptable means of pinpointing the leak
or fire to a specific secondary loop include zoned sprinkler system flow detection, differential flow
detectors located on secondary equipment loops, or zoned low pressure interlock switches.
2.4.10.3 Where safety shutoff valves or other valves are provided to isolate a length of piping or a piece
of equipment, provide either an automatically opening drain line or a pressure relief device for the trapped
volume if there is the potential for fire exposure or other condition leading to overpressurization. A pressure
relief device may, in some cases, be required by applicable jurisdictional codes.
2.4.10.4 Provide a well-marked remote emergency shutoff switch capable of safely shutting down the entire
heat transfer system. Locate it either in a constantly attended control room or at a location that would be
accessible in the event of an HTF leak and/or fire.
2.4.10.5 Where leakage from a secondary HTF loop can result in a fire with a particularly high loss
expectancy, such as at critical and/or very high value production equipment, provide differential flow detection
for any such loops (i.e., measure and compare flow to and from the loop), interlocked to shut the safety shutoff
valves that isolate that loop. Ensure the flow differential set point is as low as possible (a function of the
sensitivity of the flow measuring devices) so isolation of small leaks will occur without inadvertent shutdown
due to instrument sensitivity.
Additionally, acoustic leak detection can be provided. Arrange acoustic leak detection to only provide an alarm,
with the operator responding by shutting the safety shutoff valves that isolate that loop. Acoustic leak
detection will detect smaller leaks than can be detected by differential flow monitoring.
2.4.10.6 Ensure safety shutoff valves used to isolate portions of the HTF piping system are of the pneumatic
type, or other type that can be arranged for fail-safe operation. Where pneumatic type valves are provided,
provide a fusible plug on the pressure line used to operate the valve so it will automatically close in the event
of a nearby fire exposure. Plastic air lines may also be used to accomplish the same effect.
2.4.10.7 If there are any flammable gas lines running in or through rooms (areas) containing parts of the
HTF system, such as to feed gas-fired HTF heaters, provide an emergency shutoff valve on the gas line,
located such that it would be readily accessible in the event of a fire inside the building. Train employees or
the Emergency Response Team in the location and operation of the shutoff valve.
2.4.10.8 To prevent overheating of tubes due to faulty firing or heating operation, or due to an internal HTF
leakage fire, provide a thermocouple located at the bridge wall (transition from radiant section to convection
section of firebox) interlocked to shut off the fuel supply when the recorded temperature exceeds the normal
maximum temperature by approximately 100°F (56°C).
2.4.10.9 Where the level in the expansion tank is prevented from going below a pre-set level by an
automatically actuated low-level supply pump fed from the storage tank, provide an interlock to shut down
the supply pump when a high level indicator is actuated, regardless of whether the pump is in automatic or
manual mode.
2.4.11.4 Provide appropriate hardware and set automated control logic and/or manual operating procedures
prevent the accumulation of explosive concentrations of combustible gases in the combustion chamber,
exhaust ducting, or any stack gas utilization equipment, following a shutdown with unburned fuel in the
combustion chamber.
2.4.11.5 Provide additional safeguards that are not directly linked to the heat transfer system per Data Sheet
6-13/12-13, Waste Fuel-Fired Boilers.
available and accepted by the authority having jurisdiction. Never compromise the safety factors and design
contingencies. Also consult the HTF manufacturer so an alternative fluid can be selected if the new process
conditions exceed the existing fluid’s limitations.
2.5.2.2 Ensure system vaporizers and heaters are under automatic control and regulated by a temperature
or pressure element in the outlet.
2.5.2.3 If it is suspected that the material being heated is infiltrating into the HTF loop, shut down the system
and find the internal leakage point as soon as possible.
2.5.5 Maintenance
2.5.5.1 Ensure any and all system leaks are corrected promptly, regardless of how small they may be. Make
corrections of a permanent nature, such as repacking valve stems, replacing leaky gaskets, etc., as
applicable. Ensure any fluid spilled from a leak or from safety valve operation is cleaned up immediately if
it is or can come into contact with a hot or warm surface. Clean up other spills at the first available opportunity.
Ensure any pipe or equipment insulation that is discovered to be oil-soaked is promptly removed and replaced
with clean, oil-free insulation, and the cause of the leak is corrected.
2.5.5.2 Ensure systems are shut down and allowed to cool before being opened to the atmosphere. Where
freezing of cooled HTF is a concern, drain piping and/or equipment.
2.5.5.3 Use a permit system to control cutting and welding. Drain and clean (or inert) equipment or piping
that is to be worked on. Blank off any pipes left disconnected during the work.
2.5.5.4 Ensure any openings in pipes or equipment, such as manholes, instrument ports, inspection ports,
etc., are on the same inspection and maintenance schedule as all system flanges, equipment, seals, and
other known potential leak points.
2.5.5.5 Disconnect safety valves at least once yearly, and inspect, repair or replace as necessary. Test them
at the same time to be sure they open below the design pressure of the equipment. Refer to Data Sheet
7-49/12-65, Emergency Venting of Vessels, and Data Sheet 12-43, Pressure Relief Devices, for additional
maintenance recommendations and details of acceptable test procedures. (Note: Safety valve inspection and
testing is a requirement of the National Board Inspection Code, which has been adopted by all Canadian
and most United States jurisdictions.)
2.5.5.6 Use extreme care when cleaning the outside of the tubes within the heater or vaporizer, to prevent
doing any damage that could eventually result in tube leakage or rupture.
2.6 Training
2.6.1 Provide all operators involved with heat transfer systems with formal training detailing the proper
operation of the heat transfer system along with emergency procedures to be taken in the event of all
conceivable process control upsets and emergency conditions. Ensure operators are aware of hazards
relating to heat transfer system misoperation and leakage. Ensure training should includes recognition of
upset conditions that could lead to dangerous situations. Give refresher training to all operators at least
annually.
2.6.2 Make complete operating manuals available where system operators are stationed, detailing normal
and emergency procedures. Ensure emergency procedures include scenarios such as system leak or fire.
Also ensure an emergency procedure is available for an orderly shutdown in the event that a small HTF
leak is detected within the heater or vaporizer firebox.
2.6.3 Ensure operator training and the operating manual establishes the relationship between percentage
of full firing rate, HTF temperature increase through the heater, and HTF flow rate through the heater, so that
when a high HTF exit temperature condition is first detected, it can immediately be verified whether the
overtemperature condition is due to HTF leakage within the firebox or a ‘‘normal’’ process upset. Have the
operating manual specify a visual verification of the inside of the heater or vaporizer upon receipt of a high
temperature alarm (flue gas or HTF exit temperature) or on observation of heavy (dark) smoke exhaust.
2.6.4 Make the Emergency Response Team (ERT) and fire service aware of the location of HTF piping and
shutoff valves and proper fire fighting methods. Ensure the ERT is also aware of the freeze-up potential of
the HTF.
2.6.5 Use a written permit system to ensure equipment shutdown and lockout during system maintenance
and to control ignition sources during repairs to oil piping.
2.6.6 Ensure operating procedures specify shutdown of the heater or vaporizer fuel supply as soon as the
HTF temperature anywhere in the system exceeds the fluid manufacturer’s recommended maximum bulk
fluid temperature (Table 2). Any actions taken to correct a high temperature condition must be done with the
heat source shut completely off.
2.6.7 Establish a written policy to indicate to operators that safety controls and interlocks must not at any
time be bypassed, even at the expense of a system shutdown that might curtail production activities.
2.6.8 Do not use direct flame heating to thaw HTF that has frozen (i.e., temperature below the pour point)
in system piping or equipment. Use general area heating, steam heating, or temporarily installed heat tracing.
4.0 REFERENCES
4.1 FM Global
Data Sheet 1-19, Fire Walls, Subdivisions and Draft Curtains
Data Sheet 1-44, Damage-Limiting Construction
Data Sheet 2-8N, Installation of Sprinkler Systems (NFPA)
Data Sheet 3-26, Fire Protection Water Demand for Nonstorage Sprinklered Properties
Data Sheet 4-0, Special Protection Systems
Data Sheet 4-11N, Carbon Dioxide Extinguishing Systems (NFPA)
Data Sheet 5-1, Electrical Equipment in Hazardous (Classified) Locations
Data Sheet 6-2, Pulverized Coal-Fired Boilers
Data Sheet 6-4, Oil-and Gas-Fired Single Burner Boilers
Data Sheet 6-5, Oil-or Gas-Fired Multiple Burner Boilers
Data Sheet 6-7, Fluidized Bed Combustors and Boilers
Data Sheet 6-10, Process Furnaces
Data Sheet 6-13, Waste Fuel-Fired Boilers
Data Sheet 7-14, Fire & Explosion Protection for Flammable Liquid, Flammable Gas & Liquefied Flammable
Gas Processing Equipment & Supporting Structures
Data Sheet 7-32, Flammable Liquid Operations
Data Sheet 7-49, Emergency Venting Of Vessels
Data Sheet 7-59, Inerting and Purging of Tanks, Process Vessels and Equipment
Data Sheet 7-83, Drainage Systems for Flammable Liquids
Data Sheet 7-88, Storage Tanks for Flammable and Combustible Liquids
Data Sheet 9-18/17-18, Prevention of Freeze-Ups
Data Sheet 12-43, Pressure Relief Devices
4.2 Others
ANSI/ASME B31.1, Power Piping
ANSI/ASME B31.3, Chemical Plant and Petroleum Refinery Piping
ASME Boiler and Pressure Vessel Code
NFPA 12, Carbon Dioxide Extinguishing Systems
NFPA 497A Classification of Class I Hazardous (Classified) Locations for Electrical Installations and Chemical
Process Areas
National Electrical Code Article 500
APPENDIX E BIBLIOGRAPHY
Dow Chemical Co. Engineering Manual for DOWTHERM Heat Transfer Fluids. Form No. 176-1334-591 AMA,
1991.
Dow Chemical Co. Health, Environmental, and Safety Considerations in High Temperature Heat Transfer
Fluid Systems. Form No. 176-1336-87, 1987.
Green, R. L., and A. H. Larsen, et. al. “Get Fluent About Heat Transfer Fluids.” Chemical Engineering Vol.
96, No. 2 (February 1989).
Green, R. L. and D. E. Dressel. Heat Transfer Fluid Fires and Their Prevention in Vapor Thermal Liquid
Systems. Paper No. 9d, presented at the 1989 Spring National Meeting of the American Institute of Chemical
Engineers.
Mobil Oil Company. Heating with Mobiltherm Heat-Transfer Oils. Mobil Technical Bulletin.
Paratherm Corp. Fire Prevention in Thermal Oil Heat Transfer Systems. Paratherm Technical Data publication,
Rev. 500.
Wagner, Walter. Heat Transfer Practice with Organic Media. 2nd ed. New York: Begell House, 1997.