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A Step-By-Step Guide To Starting Up Your New Heat Transfer System

In this post, we present a step-by-step guide on how to start up your new heat transfer system. Some of the steps may not apply to smaller systems without expansion tanks, so feel free to skip. It is important to consult your equipment manufacturer’s instructions/manual for additional guidance. Here are the steps that you need to get your new system up and running.

  1. Tighten all fittings, valves, and flanges on your heat transfer equipment as well as on associated piping and pumps. Check to make sure all seals (gaskets and O-Rings) are in place. Make sure all switches and valves are in the proper startup positions.
  2. Open all drains and blow dry air or Nitrogen into the system to remove any residual water left over from hydrotests or other factory testing procedures. Check to make sure that there is no moisture in your system.
  3. Close all drains after you confirm that the system is completely dry. Open up valves to points where the heat transfer fluid is to be used. Open the relief valves on the expansion tank as well.
  4. Connect the pump inlet to the drum, tote or tank holding the thermal fluid. Connect the pump outlet to the lowest intake valve on the system. Set the pump to a low flowrate and charge in the virgin heat transfer fluid slowly.
  5. Set the low-level switch (if available) to match a quarter of the total expansion tank volume.
  6. As pumping continues, shut-off each bleed vent in the system as the fluid level rises to that point.
  7. Continue the fill until the low-level alarm goes off or until the heat transfer fluid reaches quarter level on the expansion tank level indicators.
  8. If available, inject Nitrogen continuously into the headspace above the fluid in the expansion tank. A low-pressure Nitrogen pad is typically sufficient for a premium quality fluid like Relatherm.
  9. Start the burner/heater on the low fire setting and continue to circulate the heat transfer fluid at full flow as you slowly raise the temperature
  10. Ensure that burner flame impingement is well distributed across boiler tube cross section.
  11. Once there is circulation through the burner/heater, increase the temperature of the bulk fluid in increments of 20 o to 25o until the fluid reaches a viscosity of 10 cP. The temperature-viscosity data that you need at this point can be found on the Technical Data Sheets of all Relatherm Heat Transfer Fluids.
  12. Above 104°C / 220°F, check the pump to make sure it is operating smoothly without cavitation.
  13. Follow the manufacturer’s recommendation for a full fire heat up. 
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