Oil Heater System

Oil Heater System

In many industrial sectors, heating oil is used as a heat transfer medium due to its ability to provide stable, high-temperature thermal energy without high system pressure. Oil heater systems are essential in chemical processing, petrochemical refining, food production, and metal treatment—industries where precise temperature control and safety are critical. However, in such systems, the oil flow rate determines both the heating efficiency and equipment safety. When circulation becomes insufficient, it can lead to overheating, coking, or pump damage, posing serious risks to production continuity. To ensure reliability, modern facilities increasingly integrate Explosion-proof Thermal Flow Switches into their oil heater systems. These instruments continuously monitor the flow status of thermal oil, automatically issuing alarms or control signals when abnormalities occur. ZINACA Instruments, a professional manufacturer of industrial automation instruments, provides advanced flow monitoring solutions to help users achieve safer, more efficient, and more intelligent heating control.

What Is an Oil Heater System? 

An oil heater system (also known as a thermal oil circulation system) is designed to heat and circulate thermal oil through a closed-loop pipeline network. This thermal oil transfers heat from the heater to various process equipment such as reactors, dryers, or heat exchangers. Unlike steam systems, oil heater systems can operate at temperatures up to 350°C or higher while maintaining low pressure, making them highly energy-efficient and suitable for processes requiring precise temperature control.

Typical components of an oil heater system include:

Heating unit (oil heater or thermal furnace)

Circulation oil pump

Heat transfer pipelines

Temperature and flow monitoring instruments

Safety control system

The circulation oil pump ensures a continuous flow of hot oil throughout the system. Stable flow is essential to avoid localized overheating or thermal imbalance, which can cause oil degradation or equipment damage.

For this reason, reliable flow detection—especially in explosion-risk environments using combustible thermal oils—is a key aspect of system safety management.

 

How Does the ZINACA Instrument Apply in Oil Heating Systems?

ZINACA Instruments’ Explosion-proof Thermal Flow Switch is specifically engineered for flow monitoring in oil heating and pump circulation systems. It operates based on the thermal dispersion principle, which measures the heat loss from a heated sensor element to the surrounding fluid. As the oil flows past the sensor, it dissipates heat according to its velocity. When the flow rate falls below the preset threshold—indicating blockage, pump malfunction, or system leakage—the sensor detects the temperature change and instantly outputs a switching signal.

This signal can:

Shut off the heater to prevent dry heating or overheating.

Stop the oil pump to avoid mechanical damage.

Trigger an alarm to alert operators to take corrective action.

ZINACA’s explosion-proof flow switch offers several key advantages for oil heating applications:

Explosion-proof design (Ex db IIC T6 Gb) ensures safe operation in areas with flammable vapors or oils.

High temperature resistance, suitable for long-term operation with thermal oils up to 200°C (customizable for higher temperatures).

IP66 enclosure protection, providing durability against dust, oil mist, and high ambient temperatures.

All-stainless-steel construction, ensuring corrosion resistance and extended service life.

No moving parts, meaning the device is maintenance-free and highly reliable for continuous industrial use.

The compact structure allows direct installation on oil pipelines or near the oil pump outlet. When integrated with PLC or DCS systems, it provides real-time flow monitoring and automatic interlock protection—essential for modern oil heater system safety control.

 

How to Choose a Reliable Flow Switch for Oil Heating Systems?

Selecting the right flow switch for an oil heater system is critical to ensure compatibility, accuracy, and safety. The following factors should be carefully evaluated:

① Explosion-proof Certification:

Since oil heating systems often handle flammable or combustible media, choose a switch with internationally certified explosion-proof protection (e.g., Ex db IIC T6 Gb). This ensures safe operation in hazardous environments.

② Temperature and Pressure Tolerance:

Ensure the device can withstand the temperature and viscosity range of the heat transfer oil. Materials such as stainless steel and high-temperature probes are recommended for continuous high-load operation.

③ Sensitivity and Response Time:

A fast response enables the system to react immediately when the flow decreases, preventing potential damage to the heater or pump. ZINACA’s flow switch offers rapid signal feedback for critical safety protection.

④ Installation and Output Compatibility:

Verify that the electrical outputs (relay, PNP/NPN, or analog) match your system’s control circuit. ZINACA provides flexible configurations for seamless integration with control cabinets or PLC interfaces.

⑤ Customization Capability:

Every oil heating system may have unique working conditions. ZINACA Instruments offers custom probe lengths, thread types, and calibration settings to meet specific process requirements.

By considering these aspects, users can ensure stable operation, reduce maintenance costs, and extend the lifespan of both oil pumps and heaters.

 

About ZINACA Instruments

Tianjin ZINACA Intelligent Equipment Co., Ltd. is a professional manufacturer of flow, pressure, temperature, and level measurement instruments serving the global industrial automation market. With a strong commitment to product reliability and innovation, ZINACA Instruments is certified by ISO, CNAS, IAF, SIL, and ACM, ensuring full compliance with international quality and safety standards.

Our Explosion-proof Thermal Flow Switches have been successfully applied in chemical plants, refineries, coating systems, and power generation facilities, providing long-term stable performance under demanding environments. ZINACA also offers OEM and customized solutions, allowing our partners to integrate high-quality sensing technology into their own systems and brands.

With years of experience in fluid control instrumentation, ZINACA Instruments is not only a product supplier but also a technical partner helping customers achieve:

Improved process safety and automation efficiency

Reduced downtime through precise flow monitoring

Reliable protection for pumps, heaters, and pipelines

For more information or to discuss tailored solutions for your oil heating systems, please contact ZINACA Instruments.

We are dedicated to providing professional service, competitive pricing, and dependable instrumentation for every industrial process.