EPCOR successfully performs upgrade to the thermal heater

Within EPCOR, the necessary components are tested with warm (hot) air during maintenance work. This is necessary to approximate the operation of the component in the aircraft as closely as possible. To heat the test air, EPCOR uses a thermal installation in which oil is heated and the heat energy is transferred to the passing air through a heat exchanger. The installation is gas fired and the oil used must be kept at 150ºC to be effective. The installation is the second largest consumer of gas within EPCOR. In its quest to reduce gas consumption, a project team started looking for alternatives. The project team’s goal was to reduce gas consumption or use electric heating where possible.

The first step was taken by Engineering. They questioned the need for hot air testing with the OEMs with the result that the largest hot air consumers, the Starters, no longer need to be tested with hot air and the Air Cycle Machines can also function with less hot test air.

This information was then used to examine how we could meet the heat demand. Should the existing installation be modified or is electric heating an option? Although the Thermal Heater is old, it was found to be still in excellent technical condition and replacement was not necessary.

Switching to electric heating required a major investment. As a result, we started looking for a solution that was cheaper yet sustainable. The solution was found in replacing the thermal oil. EPCOR was forced to keep the old oil at a minimum of 150ºC while the new oil can be kept at room temperature if there is no testing demand.

After the necessary preparation work, the redundant pipes were disconnected and removed in the week of 16 September and 3,000 litres of old silicone oil was replaced by 2,000 litres of new synthetic oil. A timer programme has also been set up that switches the installation off after working hours and during the weekend and switches it on early in the morning on working days so that it is ready for use.

The final step in the drive for efficiency involves the smart planning of hot air testing to minimise the need to start up the plant. How much does EPCOR save with this action? Annual gas consumption will be reduced by 13,000 m3. In addition, EPCOR will also save 100 litres of oil per year.

All in all, a great cost saving that is also good for the environment. A prime example of a win-win situation.