HOT OIL SYSTEM DESIGN GUIDE

FIRST EDITION, June. 2004

Guide Book Vendor data

Hot oil System System check
.
Vendor Hot oil data
Hot oil system
Project
, Update ..
Guide Book Hot oil system ,
.

2004 11 19

-1-

Content
1. INTRODUCTION
General
Definition
2. HOT OIL SELECTION GUIDE
General consideration to hot oil selection
Hot oil system and application of hot oil
3. COMMERCIAL HOT OIL DATA
Commercial hot oil evaluation
Typical hot oil selection
Detailed commercial hot oil data (refer to attachment)
4. HOT OIL SYSTEM DESIGN GUIDE
Heater
Expansion Drum (Surge drum)
Circuit
HTF storage
Trim Cooler, Rundown Cooler
Heat Consumer
Pumps
Instrumentation and control
Material Selection
5. OPERATIONAL REQUIREMENTS AND PRECAUTION
Starting the Plant
Supervision of Operation
Maintenance of Plant
6. REFERENCE HOT OIL SYSTEMS
Hot oil system summary of GSP-5 project
Hot oil system summary of Songkhla GSP-1 project
Hot oil system summary of LAB project
Hot oil system summary of project

-2-

Hot oil system summary of TA/PTA project

7.

REFERENCE

-3-

8. ATTACHMENT: VENDOR INFORMATION

DOW
Dow Product Guide
Equipment for Systems using dowtherm
Dowtherm, Syltherm Data
Dowtherm for Low Temperature Transfer
Dowtherm A, G, HT, J, MX, Q, RP, T, XLT
Dowtherm Q, RP Product Technical Data
Syltherm 800, HF

DYNALENE
Dynalene 600, HT, SF

IMPERIAL OIL
Thermoil and Essotherm

MOBIL
Mobiltherm

MULTITHERM
Safety Issues for Thermal Fluid Systems
Multitherm Products
Multitherm 503, IG-1, IG-4, OG-1, PG-1

PARATHERM
A Comparison, Thermal Fluid vs. Steam
Fluid Degradation Problems with Improper Shutdown
Fluid Fouling Problems in Closed-Loop Temperature Control
How to Track the Performance of Heat Transfer System
Oxidation in Heat Transfer Fluids
Problems With Multi-Purpose Oils in Heat Transfer Service
Recommended Hot Oil System Components
Significance of Flash and Fire Points in Heat Transfer Fluids
Analyzing Your Fluid

-4-

Heat Transfer Fluid Tips

Draining, Flushing and Charging Your Thermal Oil System
Fire Prevention in Thermal Oil Heat Transfer Systems
Paratherm CR, HE, LR, MR, NF, OR

RADCO INDUSTRY
Technical Tip 1: Proper Maintenance can extend the life
2: Selecting High temp HTF, synthetic or hot oil
3: Saving system downtime
4: Expansion tank design
5: HTF service can extend fluid life
6: Starting HTF selection process
Xceltherm 445, 500, 550, 600, HT, LV series, MK1, XT

SHELL
Thermia Oil B

SOLUTIA
Therminol HTF Design Seminar
Therminol Selection Guide
Bulletin 1: Cleaning organic HTF system
2: In-use testing
3: HTF filtration How and Why
4: Heat transfer system expansion tank design
5: Moisture Removal
Liquid Phase Design Guide
Vapor Phase Design Guide
System Design Data

Therminol 55, 59, 66, 72, 75, D12, FF, LT, VP-1, XP

-5-

1. INTRODUCTION
1.1 General
The most common heat transfer fluids are steam and water, and if the
temperature is above the freezing point of water (0C) and below about
175C, the choice is usually between these two fluids. On the other hand,
if the temperature of application is below the freezing point of water or above
about 175C, it is necessary, or at least desirable, to consider other fluids.
For temperature below the freezing point of water the most common heat
transfer fluids are air, refrigerants such as halogenated hydrocarbons,
ammonia, brines and/or solutions of glycol and water.
As temperature increase above 175C, the vapor pressure of water increase
rapidly, and the problems of structural strength for processing equipment
becomes more and more severe. Thus with high temperature systems it
becomes increasingly important to consider fluids with vapor pressures
lower than water. That is a reason hot oil is required.
Hot oil system is high temperature heating system, used for industrial
processes most often instead of steam, because of much higher operating
temperatures at low operation pressure and because of significant less
overall operation costs.
In the design of a high temperature organic heat transfer system, the
engineer has two key problem areas to evaluate. These are:
1) The selection of the heat transfer media; and
2) The system design and selection of process equipment.
Comparison with steam boiler and hot oil heater
Hot oil
Operating pressure
(based on 250)
Water treatement
Winterizing
Life cycle
Temp. Control range
Loss of heating medium
Blow down
Cost of invest

Steam boiler

0 bar or a little higher (safe)

Over than 100 bar (danger)

No need (cheap)
No need (pour point -30)
Over than 15 years
No corrosion
0.5 (sensitive)
No
No
Relatively low

Need (expensive)
Need
Short
Corrosive
Wider than 0.5
Vaporizing and trapping
Continuous loss
Expensive

-6-

1.2 Definition
Heat-transfer fluid (HTF),
Fluid capable of transporting heat energy within a specified temperature
range in a closed circuit to heat or cool the system. In this design guide,
the Heat Transfer Fluid is Hot Oil (Synthetic or Mineral Oil).
Liquid Phase System
Heat transfer fluid is used in the circuit without phase change, thus heat
transferred by sensible heat of the fluid
Vapor-Liquid Phase System
Heat transfer fluid is used in the circuit with phase change, thus heat
transferred by latent heat of the fluid.
Expansion drum (or Surge drum)
The drum to buffer the HTF volume difference between each conditions.
Drop tank (or dump tank)
A tank capable of holding the HTF inventory, in case of an emergency
and/or maintenance drain of the circuit.
HTF system
All heaters, piping, pump, vessels, heat exchangers and auxiliaries that
make up the closed circuit containing the HTF.
Heater
Heat energy producer in the system. Applications include furnaces and
(waste) heat recovery units(HRU), both fired and unfired.
Maximum allowable bulk temperature (MABT)
The maximum bulk temperature of the HTF allowed anywhere in the circuit.
Maximum film temperature
The maximum temperature to which the HTF may be subjected anywhere in
the system. The highest temperature is usually found at tube inner wall of
the heater, the level being determined by the fluid bulk temperature and the
heat flux impinging on the tube.
Minimum application temperature
The lowest bulk temperature at which the HTF can be used; i.e., pumpability
limit, pour or crystallization point.
Return temperature
The temperature that the HTF returns on the return header after heat
transferred to the system.

-7-

Supply temperature
The temperature that the HTF supplies on supply header before heat
transferred to the system.

-8-

2. HOT OIL SELECTION GUIDE

2.1 General consideration to hot oil selection
Thermal fluids have been developed which can offer some advantages over
the alternative carriers. The properties of an ideal thermal fluid are:
1) Not-toxic, non-flammable and non-corrosive
2) Low pour point or freezing point

3) Low vapor pressure (liquid system), high boiling point

4) No thermal decomposition in the working temperature range
Some hot oils, if those are contacted with water, humid or oxygen,
become degrade to shorten life. Especially silicone based heat transfer
fluid could decompose into light volatile components.
Hot oil
composed of Nitrite could explode when it reacts with organic
compounds.
5) High film heat transfer coefficient (high thermal conductivity and specific
heat capacity, low viscosity index)
6) High latent heat of vaporization (vapor systems)
7) High maximum working temperature

The engineer needs to select the thermal fluid that will perform satisfactorily
and safely at the process temperature required. To do this, the engineer
can draw on his past experience or make the comparisons between the
well-known fluid manufacturers. The important factors he must consider in
selecting a high temperature heat transfer fluid can be categorized into the
following four areas.
Toxicity and Environmental Ecology
Toxicity and ecology are, of course, extremely important from both an
operating and a process standpoint. There is always a chance that a heat
transfer fluid may find its way through packing glands on valves, pumps,
heat exchangers, etc., hence, operators, maintenance men, and
surroundings will be exposed to the fluid. More ecological information for
evaluating this subject is being made available from many fluid
manufacturers today.
Corrosiveness to Materials of Construction
In general, a heat transfer fluid should be non-corrosive to mild steel.
Otherwise, the equipment cost will be prohibitively high. It should be noted
that all of the chlorinated compounds recognized as heat transfer fluids, are

-9-

essentially non-corrosive to mild steel as long as all traces of water are kept
out of the system and the fluid is not overheated.
If halogenated materials are overheated either by bulk temperature higher
than the recommended maximum temperature or by localized hot spots in
furnace, hydrogen chlorides gas will be evolved. The hydrogen chloride
gas will remain relatively non-corrosive to mild steel as long as the system
kept absolutely dry, but if traces of water are present, the hydrochloric acid
will be formed extremely corrosive, particularly at elevated temperatures.
Chlorides can also cause a stress corrosion cracking of stainless steels if
water is present.
Flammability
Lack of flammability is always vital whenever there is a chance that a fluid
may not be completely separated from all sources of ignition. Some of the
chlorinated compounds such as chlorinated biphenyls are fire resistant
because they will not support combustion due to the chlorination. However,
if they are heated to a sufficient high temperature they exhibit a flash point
and an explosive range. They will burn if subjected to the ignition
conditions encountered in the fire box of a fired heater. Thus, organic fluids
must not be exposed to a source of ignition.
While non-chlorinated heat transfer fluids will burn, this factor presents no
problems if they are contained properly.
If, due to some unusual
occurrence, they leak from the system into a space other than the fire box of
a furnace, they will almost invariably, if not always, be below their auto
ignition temperatures before they come in contact with air. Thus there must
be a source of ignition before leak outside a fire box can be serious.
Moreover, combustion requires a mixture of air and vapors having a
concentration within the flammability limits of the fluid. For continued burning,
the liquid must be at temperatures higher than its fire point.
Thermal Stability and Engineering Properties
Several generalizations can be made about thermal stability and
degradation of organic heat transfer media.
1) In comparing classes of compounds, aromatics materials have thermal
stability generally superior to aliphatic compounds.
2) For commercial products, the recommended maximum operating
temperature is a rough measure of relative thermal stability.
3) Polymer formation is detrimental particularly if the polymerization is
exothermic. Polymers increase the viscosity of a fluid and promote
carbonization leading to inefficient and potential failure of the heater.
4) Fluid degradation should produce a minimum of volatile materials such as

- 10 -

hydrocarbons. These decomposition products will increase operating

losses and they are a safety hazard (fire and toxicity) in a vented heating
loop.
5) Degradation should not produce reactive or corrosive, toxic, and they
accelerate fluid breakdown at high temperatures. Cracking products such
as olefins will polymerize under operating conditions.
6) Oxidative stability can be an important factor if air is present at high
temperatures.

- 11 -

2.2 Hot oil system and application of hot oil

2.2.1 Hot oil system
Liquid Phase System
Liquid phase heat transfer fluids operate over the broad temperature range
of -85 C to 385 C and are designed to be used in non-pressurized
systems. A major advantage of liquid heat transfer is lower cost
installation and operation. Capital cost is reduced by elimination of largediameter piping, safety valves, steam traps and water treatment facilities.
Operating cost is reduced by low maintenance requirements and reduced
makeup.
(1) No phase change, so that the temperature is controlled easily.
(2) No temperature difference from pressure change
(3) Heat transfer evenly distributed and suitable for multiple users through
the main header to branches.
(4) Minimize vent loss against thermal degradation when operation in the
temperature range selected.
(5) Liquid phase system gives small investment cost because of low
design pressure and small size equipment required.
Liquid/Vapor System
Liquid/vapor phase heat transfer fluids offer a broad operating temperature
range and uniform heat transfer. Other major benefits include precise
temperature control and low mechanical maintenance costs. Also, a heat
transfer system that utilizes a vapor phase medium requires less fluid than
a comparable liquid phase system because the equipment fills with vapor
instead of liquid.
(1) Large heat transfer capacity by using latent heat
(2) Less hot oil inventory within the system.

2.2.2 Types and application of heat transfer fluid

Quoted maximum fluid temperatures vary, but most are around 350 ,
allowing them to be used for process temperatures up to 300 . The
atmospheric boiling points of theses fluids are in the range 260 340 ,
so the system must be pressurized, but vapor pressures are generally only
1 2 barg at working temperatures.
The system is pressurized by a nitrogen blanket in the expansion tank,
which also prevents air from coming into contact with the fluid; dissolved
oxygen is more of a problem with the synthetic aromatic fluids than with

- 12 -

the mineral oils, and is made worse by the higher operating temperatures.
The synthetic aromatics generally have better low temperature
performance than mineral oils. These fluids cost between two and two
and a half times as much as the mineral oils.
For temperatures up to 1000 liquid metals like mercury, sodium and
sodium potassium alloys have been used. Nuclear power plant designers
may have no alternatives, but for ordinary process industry applications
the disadvantages of liquid metals are obvious.
Type
Mineral oils:

Synthetic aromatics:

Diphenyl-diphenyl oxide:

Silicones:

Brand name

Manufacturers

Mobiltherm 605

Mobil

Essotherm

Esso

Transcal 65

BP

Diphyl DT

Bayer

Dowtherm Q

Dow

Syntrel 350

Exxon

Marlotherm L

Huls

Santotherm 66

Monsanto

Gilotherm

Rhone-Poulenc

Transcal SA

BP

Diphyl

Bayer

Dowtherm A

Dow

Thermex

ICI

Santotherm VP-1

Monsanto

Syltherm 800

Dow

General liquid phase heat transfer fluid

(1) General range of application is 150300
(2) Mostly refined MINERAL OIL
(3) Example: Calcium chloride solution, Methanol, Glycol solution,
Dowtherm J, Syltherm
Heat transfer fluid for low temperature service
In general they use glycol mixture for low temperature service but in this
design guide it is not included.
Heat transfer fluid for vapor / liquid system

- 13 -

Mixtures of alkylated aromatics, diphenyl and diphenyl oxide are used for
condensing heat transfer services.
Heat transfer fluid for high temperature service
(1) Application temperature range is 275375.
(2) Types of the fluids for high temperature application: Synthetic paraffin,
Diaryl alkanes, Poly-phenyl derivatives, Aryl ether, Di-methyl siloxane
polymer
(3) Inorganic compounds also are used and are non flammable, thermally
stable, non volatile but corrosive; sodium nitrate(), sodium
nitrite(), potassium nitrite()
Inorganic slat mixtures are also an option. Process temperatures
much higher than 350 are difficult to achieve with organic fluids but
can be handled easily with molten salts, notably the eutectic mixture of
53% KNO3, 40% NaNO2 and 7% NaNO3. This can be used at
temperatures up to 500 and has a very low operating vapor
pressure, although it has a disadvantage that it freezes at 143 . The
only way to obtain this is by using a water dilution system; adding water
to make a 60% solution will lower the freezing point to 20 . Careful
heating allows the water to boil off so that it can be removed by a
condenser, and when the system is cooled down the water is sprayed
back into the storage tank. Although this slat mixture is an oxidizing
agent and will support combustion, it is not flammable like organic
fluids. In addition, its very low vapor pressure and low toxicity can be
advantageous.
These fluids are thermally stable in correctly designed fluid heating
systems. The efficiency of the plant is retained as the fluids are noncorrosive hence heat transfer surfaces remain clean without the need
for any treatment of the fluid. Nor annual shutdown is required for
insurance inspection, and the problems associated with freezing of the
system on shutdown during cold weather are eliminated. The fluids,
however, do slowly degrade.

- 14 -

3. COMMERCIAL HOT OIL DATA

3.1 Commercial hot oil evaluation
(-1 project )

()

Thermia B
(Shell)
P-68
(LG-Caltex)
68
(S-Oil)

Dowtherm RP
(Dow)
Therminol 66
(Monsanto)

Syltherm800
(Dow)

15~320

0~350

-40~400

340

375

300 oC

5~10

10

degradation

- 15 -

,


(70% )

3.2 Typical hot oil selection

(Vapor pressure shown on this table is at the maximum temperature)
Hot Oil

Maker

Temp()

Base

Min

Max

Vap.
Pres
kg/cm
2A

Pour
Point
()

Flash
Point
()

Ignition
Point
()

Chemtherm
550
Dowtherm G
Dowtherm HT

Coastal

Paraffin Oil

40

320

0.14

-10

200

350

Dow
Dow

Aryl ether
Hydro Polyphenyl

-5
-5

370
340

3.0
1.1

-35
-25

140
180

580
350

Dowtherm LF

Dow

Alkyl
Aromatics

-40

340

3.3

110

470

Hitec

Coastal

260

530

140

Mobiltherm 603
Multitherm IG-2
Multitherm PG1
Syltherm 800

Mobil
Multitherm
Multitherm

Nitrate,
Nitrite
Paraffin Oil
Paraffin Oil
Paraffin Oil

40
65
65

320
320
280

0.07
1.1

-5
-30
-40

170
230
170

350
370
530

-30

400

14.0

-40

180

380

Syltherm XLT

Dow

-70

260

5.6

-100

55

350

Syntrol 350

Exxon

Diaryl
Alkane

-30

370

1.3

-35

190

410

Thermalane
550
Thermalane
600
Thermalane
800
Thermalane
FG-1
Thermalane L

Coastal

Synthetic
Paraffin
Synthetic
Paraffin
Synthetic
Paraffin
Paraffin Oil

-30

280

0.07

-40

220

380

-30

300

0.07

-70

240

380

-30

330

1.5

-75

230

380

40

280

0.6

-40

170

530

Synthetic
Paraffin
Alkyl
Aromatics
Alkyl
Aromatics

-45

260

0.9

-85

165

330

-30

320

0.5

-40

180

360

-45

320

1.1

-70

150

410

Dow

Coastal
Coastal
Coastal
Coastal

Therminol 55
Therminol 59

Solutia

- 16 -

- 17 -

Hot Oil

Maker

Base

Temp()
Min

Max

Vap.
Pres
kg/cm
2A

Pour
Point
()

Flash
Point
()

Ignition
Point
()

Therminol 60

Solutia

Alkyl Polyphenyl

-45

320

1.6

-70

155

450

Therminol 66

Solutia

Hydro
Polyphenyl

-10

340

1.1

-25

180

370

Therminol 75

Solutia

Alkyl Polyphenyl

70

400

1.3

50

200

540

Vapor / Liquid System Purpose

Dowtherm A

Dow

Dowtherm J

Dow

Thermex

Coastal

Therminol Lt

Solutia

Therminol VP1

Solutia

Diphenyldiphenyl
oxide
Alkyl
Aromatics
Diphenyldiphenyl
oxide
Alkyl
Aromatics
Diphenyldiphenyl
oxide

40

400

10.7

10

120

620

-70

320

12.3

-75

55

420

40

400

11.0

10

120

640

-70

320

14.5

-75

55

430

-70

400

11.0

10

120

620

- 18 -

3.3 Detailed commercial hot oil data (refer to attachment)

Name
Manufacturer
Property
Appearance
Composistion
Flash Point ()
Fire Point ()
Auto. Ignition Point
()
Min. Pumping
Temp. ()
Boiling Range ()
Viscosity (cP)

Density (kg/m3)

Heat Capacity
(kJ/kg-K)

Thermal
Conductivity
(W/m-K)

Vapor Pressure
(kPa)

Other Products

Home Page
Address

THERMINOL 66

DOWTHERM A

DYNALENE SF

SOLUTIA

DOW

DYNALENE

Clear, Pale Yellow

Liquid
Modified Terphenyl
min. 184
212

Clear, Light Brown Oily

Liquid
Diphenyl Oxide/
Biphenyl Blend
113

Alkylated Aromatics
180
210

374

615

330

-3~11
348 ~ 392
1320 @ 0
3.6 @ 100
0.86 @ 200
0.25 @ 325
1021 @ 0
955 @ 100
885 @ 200
788 @ 325

12
257~400
5.0@ 15

-10
> 330
160 @ 0
2.8 @ 100
0.66 @ 200
0.26 @ 300
890 @ 0
823 @ 100
755 @ 200
688 @ 300

0.13@ 400
1062.3@ 15

679.5@ 400

1.49 @ 0
1.84 @ 100
2.19 @ 200
2.67 @ 325

1.556@ 15

2.702@ 400

0.118 @ 0
0.114 @ 100
0.106 @ 200
0.091 @ 325

0.139@ 15

0.078@ 400

1.89 @ 0
2.26 @ 100
2.62 @ 200
2.99 @ 300
0.136 @ 0
0.129 @ 100
0.121 @ 200
0.112 @ 300

0.048 @ 100
0.138 @ 160
2.2 @ 200
0.897 @ 200
52 @ 325
1060 @ 400
23.52 @ 325
THERMINOLLT/DDOWTHEM12/XP/55/59/72/75/VP- G/J/HT/Q/RP/MX/T/800
DYNALENE1
/XLT/HF
600/HT
www.therminol.com
www.dowtherm.com
www.dynalene.com

- 19 -

Name
Manufacturer
Property

THERMOIL 100

MULTITHERM FF-1

PARATHERM-CR

IMPERIAL OIL

MULTITHERM

PARATHERM
Clear, Brine Water
White
Synthetic
Hydrocarbon
43

Appearance
Composistion
Flash Point ()
Fire Point ()
Auto. Ignition Point
()
Min. Pumping Temp.
()
Boiling Range ()
Viscosity (cP)

Density (kg/m3)

Heat Capacity (kJ/kgK)

Thermal Conductivity
(W/m-K)

252

221
5
349
86.3 @ 38
8.9 @ 100

142

866.5 @ 38
822.1 @ 100
749.4 @ 200
664.6 @ 316

101.2 @ 10
3.53 @ 93
0.73 @ 204
0.46 @ 260
914 @ 10
861 @ 93
789 @ 204
752 @ 260

850 @ 0
800@ 100
700 @ 150
650 @ 200

1.93 @ 38
2.15 @ 100
2.52 @ 200
2.93 @ 316

1.76 @ 10
2.14 @ 93
2.64 @ 204
2.81 @ 260

1.85 @ 0
2.23@ 100
2.44 @ 150
2.65 @ 200

0.13 @ 38
0.126 @ 100
0.118 @ 200
0.11 @ 316
0.074 @ 200
1.04 @ 260
5.21 @ 316

0.1284 @ 10
0.142 @ 0
0.1223 @ 93
0.134@ 100
0.1142 @ 204
0.130 @ 150
0.1104 @ 260
0.126 @ 200
0.0004 @ 93
126.8 @ 204
Vapor Pressure (kPa)
0.092 @ 204
0.59 @ 260
Other Products
MULTITHERM- PGTHERMOIL- 32/46
1/IG-1/IG-4/
ESSOTHERM Light/N OG-1/503/ULT-170/LTPARATHERM100
112/WB
HE/LR/MR/NF/OR
Home Page Address www.imperialoil.com
www.multitherm.com
www.paratherm.co
m

- 20 -

Name
Manufacturer
Property
Appearance
Composistion
Flash Point ()
Fire Point ()
Auto. Ignition Point ()
Min. Pumping Temp. ()
Boiling Range ()
Viscosity (cP)

Density (kg/m3)

Thermia Oil B

XCELTHERM 550

MOBILTHERM 600

SHELL

RADCO INDUSTRY

MOBIL

Pale Yellow Liquid

220 ~ 232
255
375

165
193
338
-23
293 ~ 446

230

> 355
199 @ 0
4.04 @ 100
1.04 @ 200
0.43 @ 300
868 @ 15

892 @ 25

857 @ 15

www.shell.com

XCELTHERM445/500/550
www.radcoind.com

www.mobil.com

26 @ 40
4.6 @ 100

Heat Capacity (kJ/kg-K)

Thermal Conductivity
(W/m-K)

Vapor Pressure (kPa)

Other Products
Home Page Address

- 21 -

4. HOT OIL SYSTEM DESIGN GUIDE

Typical hot oil system with full option is composed of:
-

Fired heater or Waste Heat Recovery Unit

Circulation pumps
Makeup pumps
Expansion Drum (Surge drum)
Vapor condenser with separator
Trim cooler
Rundown cooler
Storage tank
Filters
Drain tank and pump (not shown in the figure below)
Hot oil temperature control, N2 blanket with pressure control

- 22 -

4.1 Heater
The heat energy producer may be a furnace or a (fired or unfired) waste
heat recovery unit (WHRU), linked to a gas turbine or other hot flue-gas
producers. The heater design shall ensure that the HTF will not be
subjected to temperatures in excess of the maximum allowable film
temperature.
To provide sufficient operational flexibility and, in the case of organic fluids,
allow for an acceptable degree of fluid ageing, the location of maximum HTF
film temperature and the peak heat flux should not coincide.
The heater design shall comply with the relevant sections of the followings:
DEM-9422 Fired Heater
API std.560 Fired heaters for general refinery service

- 23 -

4.2 Expansion Drum (Surge drum)

The expansion drum allows for the thermal expansion of the HTF, the
venting of low boiling components generated in the HTF ageing process,
and is also used to minimize the consequences of upsets in the HTF system
operation, Where applicable the design shall take into account the following:

- Provision of adequate volume to accommodate the fluid thermal

expansion when heated from ambient to normal working temperature;
- Provision of adequate Net Positive Suction Head (NPSH) of the HTF
circulating pumps;

- 24 -

- Prevention of HTF spillover into the flare system in case of a sudden

vapor release into the circuit due, for example, to a tube rupture inside
heat-transfer equipment operating at a process pressure above that of
the HTF circuit;
- The displacement of HTF as a result of the steaming out of a heater coil
(following a tube burst);
- The presence of residual quantities of water in the circuit during startup;
- Prevention of loss of HTF circulation in the case of a sudden loss of fluid
due to e.g. a tube rupture inside heat transfer equipment operating at
process pressures below that of HTF circuit;
-

Provision of sufficient HTF inventory to allow the filling of individual heat

consumers during pre-commissioning after shutdown for maintenance.

When a separate HTF storage tank with standby facilities for HTF makeup/draw off is provided, it will tank account of some of the volume
requirements listed above, thereby allowing a smaller size expansion drum.

4.2.1 Expansion drum location and arrangement

The expansion drum shall be located upstream of the HTF circulation
pumps. The drum should be located at an elevation such that the normal
operating HTF level in the drum will be located above the elevation of the
highest component in the HTF-system. This elevated arrangement will
ensure a positive venting capability for the circuit and facilitate the provision
of sufficient NPSH for the pumps.
If this requirement would be difficult to accommodate, a lower elevation may
be selected but provisions shall be make to prevent vapor being locked in
the higher parts of the circuit and to evacuate such a vapor lock if it occurs.
The drum shall be designed for full flow of the HTF through the vessel
(double-leg design, see above figure). The application of a simple
expansion vessel layout (single-leg design) requires approval.
The expansion drum shall be provided with a dry inert gas blanket to
prevent the HTF from coming into contact with oxygen or picking up
moisture. Oxygen will accelerate fluid degradation; some HTFs may
produce acidic compounds in the presence of oxygen, such reactions being
accelerated by the fluid return temperature which will be significantly above
ambient conditions. Moisture ingress may lead to sudden pressure surges
in the circuit upon vaporization of the water; moisture picked up by silicone
polymer based HTFs will deactivate the fluids stabilizing additive, whereby
deposits will be formed and fluid degradation will accelerate.

- 25 -

The preferred inert gas is dry nitrogen, but in some cases other dry, oxygenfree gases (CO2 or sweet fuel gas) may be used; the HTF manufacturer
shall be contacted for confirmation of the compatibility of such blanket
gases with the selected fluid. The inert-gas supply shall be provided with a
split range controller. This controller can import inert gas (N2) or export to
flare. To avoid unnecessary consumption of inert gas, the controller output
shall have a gap between import and export. A non-return valve shall be
installed in the inert gas supply line to prevent backflow in case of overfilling
of the expansion drum.
The drum vent line shall be provided with a back pressure regulator set
sufficiently above the HTF working pressure level to minimize venting of
low-boiling compounds (low boilers) and consequential loss of HTF
inventory. The back pressure regulator setting may be increased further to
satisfy the MPSH requirements of the circulation pumps, but then the
system design shall account for the increased working pressure. In cases
where regular venting of vapors is unavoidable, a vapor cooler condenser
should be installed downstream of the regulator to recover the low boiling
compounds. This reduces emissions and also allows indication of the
amount of low boilers being produced, thereby providing an indication of the
progress of HTF degradation. The recovered low boiling compounds shall
not be returned to the HTF system, but shall be disposed of properly. In
general the vent line shall be routed to flare; only in cases where the vapors
meet the criteria of being non-toxic, non-flammable and odorless, may
venting to a safe location be considered.
The vessel shall be provided with safety relief facilities capable of protecting
the complete circuit against over pressurization, including that caused by
excessive formation of low boiling point compounds resulting from
degradation of the HTF or inadvertent vapor releases into the system due to
tube ruptures inside equipment that operate with elevated pressure at the
process side. To be able to stream purge out the furnace coils, the sizing
of the surge drum relief valve shall also be capable of relieving the flow of
purging medium (e.g. stream, nitrogen) which is equivalent to a vapor
velocity in the furnace coils of 15 m/s. If necessary the purge flow can be
limited by installing a restriction orifice in the common supply line. The
relief line shall be routed to flare.
Consideration shall be given to provide tracing to the inert gas supply, vent
and relief lines up to the relief header to prevent accumulation of any high
boiling condensate or crystallizing compounds leading to possible line
obstruction.
In climates where the ambient temperature can fall below the HTF minimum
application temperature, the expansion drum should be provided with a

- 26 -

heating coil to improve the suction conditions form the circulation pumps
during startup. To prevent foaming/overflow of HTF in the event of a coil
leak, electrical heating internally or externally is preferred.
The vessel shall be designed for the upper design temperature and
pressure of the HTF system.

4.2.2 Expansion drum sizing

This section discussed the sizing criteria for typical HTF expansion drums.
As the sizing depends upon the fluid properties as well as its inventory
inside the circuit, an expansion drum design based upon estimated line and
equipment sizing and preliminary plot plans shall be adjusted in accordance
with the finalized project design situation. It is the responsibility of the
designer to review and, if necessary, revise the vessel design when line
sizes, plot plans and piping layouts are finalized.
Care shall be taken to base the relief calculations for the expansion drum
sizing on the working pressure differential between the HTF and consumer
process sides. If the design pressure of the HTF side of the system is
lower than the process sides, process fluid will enter the HTF side in the
case of a tube leak.
A distinction is made between systems that are provided with stand-by HTF
makeup / draw-off facilities and those without. Next figure shows the levels
distinguished in a typical expansion vessel arrangement.

- 27 -

4.2.2.1 Systems without stand-by HTF make-up / draw-off facilities

In these systems the expansion drum has the combined functionality of an
expansion, knock-out and storage vessel, capable of handling the fluid
inventory during normal operation and foreseeable upsets.
The vessel diameter shall be calculated and the maximum level set to
prevent entrainment of HTF liquid into the flare line in case of a sudden
vapor ingress into the system caused either by a tube rupture inside heat
transfer equipment or by the streaming out of furnace coils.
The minimum level setting shall be established to ensure the provision of
adequate NPSH for the HTF circulation pumps taking into account the fluid
viscosity at minimum temperature (start up conditions).
The volume between the minimum level and the minimum working level
shall be at least the larger of the following:

- 28 -

* The volume of HTF lost in 15 minutes via a ruptured tube in a heat

exchanger operating with a process pressure lower than the HTF
system pressure;
*

The volume required to allow the filling of an individual HTF

consumer after a maintenance shutdown assuming interruption of
make up for any reason.

The volume between the minimum working level and the normal working
level shall be at least the larger of the following:
** The volume increase of the total HTF inventory when the
temperature is raised from operational to normal working level;
** The volume of HTF lost via a ruptured tube in 15 minutes in a heat
consumer operating with a process pressure below the HTF
system pressure.
The volume between the normal working level and the maximum
working level shall be at least:
*** The volume increase of the total HTF inventory when the
temperature is raised from normal to maximum working level.
In case a drop tank is included in the circuit, the volume between the
minimum working and maximum working levels shall be equal to the
maximum volume of HTF supplied to the system in 15 minutes. As the
drop tank will be atmospheric, a rundown cooler shall be installed to avoid
to hot fluid entering the tank (See 4.4 HTF storage also).
The volume between maximum working level and maximum level shall be
at least the larger of the following:
**** Volume of HTF displaced if the furnace coils are steamed out via
the full flow bypass of the spill over control valve;
**** Volume of HTF displaced from any consumer (including associated
piping) in case residual quantities of water are inadvertently
present at start up the system;
**** The volume of HTF displaced from a heat consumer and
downstream piping as the result of a tube rupture in a consumer
operating with a process pressure in excess of the HTF system
pressure.

- 29 -

4.2.2.2. Systems with stand-by HTF make-up/draw-off facilities

In these systems a separate HTF(operational) storage is provided, linked
to the expansion vessel by means of a level-controlled supply/spill-back
piping arrangement(as shown in the scheme of Fig. 1). There facilities
provide for a smaller size surge vessel.
The diameter and the minimum/maximum level settings shall be subject to
the same criteria as for systems without continuous make-up facilities (see
4.2.2.1. second and third paragraphs).
* The volume between the minimum level and the minimum working
level shall be equal to the volume of HTF lost in 15 minutes via a tube
rupture in a heat consumer operating with a process pressure below
the HTF system pressure.
**/*** The volume between the minimum working and maximum working
levels shall be equal to the maximum volume of HTF supplied to the
system in 15 minutes via the make-up line.
The volume between maximum working level and maximum level shall be
at least the larger of the following:
**** The volume of HTF displaced from any consumer (including
associated piping) in case residual quantities of water are
inadvertently present at start-up of the system;
**** The volume of HTF displaced from a heat consumer and
downstream piping as the result of a tube rupture in a consumer
operating with a process pressure in excess of the HTF pressure.

- 30 -

4.3 Circuit
All low points in the circuit shall be supplied with drain connections to enable
residual water to be drained prior to commissioning of the system.
Facilities for blowing out the circuit with dry hot air or, preferably, dry
nitrogen shall be provided to ensure a thorough system dry-out. The latter
is particularly important for silicone HTF systems.
Heat consumer equipment that may need to be evacuated (e.g. for
temporary decommissioning) whilst the circuit is kept in operation shall be
provided with dedicated drainage facilities enabling the HTF to be run down
to the storage or drop tank via the rundown cooler.
For systems with heaters arranged in parallel, sampling facilities shall be
provided to allow evaluation of HTF degradation in the parallel loops.
For systems with heat consumers operating at pressures above the HTF
system pressure, measures shall be taken to prevent over-pressurization of
the HTF system as the result of a tube rupture inside the heat-consumer
equipment.
As the application of a high supply temperature leads to smaller size heatconsumer equipment, it is expected that HTF system designs will be driven
to the application of a supply temperature close to the MABT of the HTF.
Particularly in the case where the selection of the HTF would provide only a
small temperature approach between the HTF and the process fluid,
allowance shall be made for the heat loss over the transfer line from the
heater to the heat consumers, causing the HTF supply temperature to fall
below the heater exit temperature. Failure to do so will result in either the
heat-consumer performance falling below expectations, or the overheating
of the HTF, with an ensuing increase in the degradation rate.
4.3.1 Piping
The system shall be designed for a total flow of 110% of the cumulative
flows through the consumers.
The spill-over control valve shall be designed for a maximum flow of 30% to
accommodate a sudden closure of the consumers. The valve in the (full
flow) bypass shall be designed for a flow of 100% for start-up purposes.
To minimize pressure drop over the distribution system, HTF flow velocities
in the circuit piping should not exceed 2 m/s.

- 31 -

4.3.2 Insulation
Because of their low viscosities at operating temperatures, most HTFs have
a tendency to penetrate joints and seals, resulting in small leaks that can
lead to accumulation of fluid inside the insulation at pipe joints. Insulation
materials such as magnesia, silicate-bonded asbestos or calcium silicate
when saturated by organic HTFs may promote a slow oxidation reaction at
temperatures above 250-260.
The large internal surface area, poor heat-dissipation conditions and the
possible catalytic activity of the insulation material may cause significant
temperature build-up within the insulation mass. Such slow combustion
may progress undetected but may lead to sudden fires when the cladding is
damaged, or opened for maintenance. Non-absorbent (closed cell)
insulation (e.g. cellular glass of foam-glass) that will not soak up the fluid
shall therefore be sued at potential fluid creepage locations (instrument
connection, valve stems, flanges and joints).
4.3.3 Auxiliaries
The circulation pump suction line shall be provided with a wire-mesh strainer
during system start-up to prevent millscale, weld spatter of other
construction debris from entering the pumps. The fine mesh should be
removed as soon as there foreign materials have been removed from the
circuit, to avoid unforeseen obstruction of the suction line.
In system with organic type HTFs operating close to the MABT, installation
of permanent filters shall be considered. As the fouling of such filters when
installed in the main suction line could adversely influence the NPSH of the
circulation pumps, they should be installed in a bypass over there pumps,
allowing the filtering out of a small amount of fluid that is returned to the
pump suction (refer Fig. 1). The provision of a flow indicator in this bypass
allows monitoring of the onset of fouling.

- 32 -

4.4 HTF storage

The HTF storage tank shall be capable of containing the full inventory of the
HTF circuit. Additional capacity shall be included to hold the fluid volume
for making up the loss due to ageing(10% of the inventory) and the amount
of fluid lost in 15 minutes as a result of a tube rupture inside heat-exchange
equipment.
The minimum level shall be set to ensure sufficient NPSH for the make-up
pump, taking into account the viscosity at the minimum fluid storage
temperature. In climates where the ambient temperature can fall below the
HTF minimum application temperature, the tank shall be supplied with a
heating coil to improve the suction conditions for the make-up pump. To
avoid moisture ingress, electric heating is preferred and the storage tank
should be supplied with a dry inert gas blanket.
The provision of stand-by make-up/draw-off facilities not only results in a
smaller size expansion drum, but also limits the amount of HTF being
subjected to elevated temperature levels, i.e. minimization of fluid ageing.
In the latter case, the operation of the make-up pump and the rundown
control valve shall be controlled by a level controller on the expansion drum.
The storage tank now also functions as a drop-tank and a rundown cooler
shall be provided to prevent too hot fluid entering the tank. In case a
rundown cooler is installed, it may be given a reverse function (heating the
HTF inventory in the storage tank) by the provision of a simple heating
bypass. This arrangement obviates the need to install a heating coil inside
the tank.
The function of the rundown cooler can also be taken up by a sufficiently
large inventory of cold HTF inside the drop tank. Provided this cold heel
and the drop-tank ullage are sized adequately, this option will ensure a failsafe and fast disposal route for the full system inventory in a case of an
emergency. It will also obviate the requirement for a large (and expensive)
rundown cooler, which normally will have to be used only infrequently and
therefore might present operational problems when its proper functioning is
essential.

- 33 -

4.5 Trim Cooler, Rundown Cooler

To facilitate the start-up and increase the flexibility of the system, a trim
cooler should be installed in the circuit, capable of replacing the heat duty of
the biggest consumer or the minimum heater duty whichever is the larger.
A rundown cooler is required in order to allow hot HTF to be run down from
the circuit in case a heat consumer is taken out of service and the HTF
liberated by emptying the equipment cannot be contained in the expansion
drum, To mitigate adverse effects of moisture ingress into the expansion
drum, the make-up supply shall be fed not directly into the expansion drum
but to the HTF return line close to the expansion drum instead.
To prevent the formation of scale inside the tubes, the cooling medium for
the vapor condenser, trim cooler and rundown cooler shall not be cooling
water. For these cooling services properly treated water(e.g. condensate
or boiler feed water) should be used, of alternatively, air cooling may be
applied.

- 34 -

4.6 Heat Consumer

When designed and operated properly, HTF systems can considered a
clean(non-fouling) service so that U-tube type heat exchangers can be
applied on the heat consumer side when the HTF flows inside the tubes.
This saves in cost (U-tube types being roughly 30% less expensive than
floating-head type exchangers), but also significantly reduces the risk of
leakage and contamination of the HTF of process fluid.
To enable proper engineering design of the heat exchangers, the requisition
sheet shall clearly mention the type of HTF of the trade name of the fluid to
be used. For the design specification of HTF systems a fouling resistance
of 0.00017K/W shall be used.
For systems operating at moderate temperature levels(below 275) the
application of the (simple) hot-oil type fluid may still be considered. Being
derived as straight-run mineral oil distillates, such hot oils will be cheaper
and easier to source than the comparable synthetic organic HTFs.
However, unlike the latter HTFs, the hot-oil types have not been developed
to sustain long-term operation at specified temperature levels and have
significantly lower temperature stability. Hot oil systems therefore are
susceptible to fouling even when operating at moderate temperatures.
As a consequence, the hot-oil system design shall take into account the
appropriate fouling resistances. Equipment in hot-oil service shall have
provisions to enable proper cleaning of the heat-transfer surfaces; this would
mean e.g. the application of floating-head type heat exchangers.
For applications where leakage of HTF into process fluid could lead to
hazardous situations(e.g. in the case of HTF air pre-heaters), the equipment
design pressure shall be at least twice the highest pressure that can occur in
the system(e.g. pump shut-off pressure of relief valve set pressure), and the
use of flanged connection shall be minimized.

- 35 -

4.7 Pumps
Circulation pumps provide with different drives. Depending on local
conditions (e.g. energy balance or reliability requirements) both pumps can
be either electric motor or turbine driven.
The pumps shall be designed for the maximum furnace outlet temperature
at design conditions.
In case of low HTF pressure, the spare pump shall take over automatically.
This shall be indicated in the control room by an alarm and indicating lights.
In case the HTF is operated at or above the auto-ignition temperature, the
pump suction valves shall be remotely operated.

- 36 -

4.8 Instrumentation and control

The instrumentation for an HTF system shall be engineered in accordance
with the specifications selected.
All instruments shall be able to withstand the maximum HTF pressure and
temperature. Special care shall be taken that, when heat-traced lines can
be blocked in, the instruments on these lines are not damaged due to
excess pressure.
System turn down should enable, with minimum operator intervention, stable
operation from the condition of full heat consumption to that of zero heat
consumption. The preferred control set-up combines the provision of
adequate turn down with the conservation of energy by controlling the flow
through the spill-over bypass with a flow controller upstream of the heater.
This controller should prevent the flow in the circuit from falling below the
heater minimum coil flow. The maximum return temperature shall be
controlled by the trim cooler, which should be sized for at least the minimum
heater duty. The maximum return temperature level is fixed by the minimum
pass flow, maximum heater outlet temperature and heat input at minimum
stop of the burners.
For large systems (> 50 MW thermal duty), coil balancing of the heater
outlet temperature should be applied. This standard algorithm shall adjust
the coil flows to equalize the coil-outlet temperatures whilst maintaining
maximum valve opening for the individual passes.

- 37 -

4.9 Material Selection

Material should be selected base on the following consideration:
(1) In general, carbon steel is used in most case.
(2) Aluminum, brass and bronze will not be used.
(3) Cupper and cupper alloy can be adopted in the place of no air contact.
(4) Austenite stainless steel will not be used if chlorinated contamination is
concerned.

- 38 -

5. OPERATIONAL REQUIREMENTS AND PRECAUTION

Although the physical advantage of hot oil, such as a high thermal stability, a
low operating pressure at high temperature, and a low viscosity, make its
use as a heat transfer medium highly attractive, there are several points to
which attention should be drawn to ensure trouble-free operation.

5.1 Starting the Plant

It should be ascertained that all parts of the plant are correctly assembled,
and that all special requirements for venting, safety valves, expansion
vessel, etc., have been included. All new equipment should be cleaned
and free from loose rust, scale, dirt or pieces of weld metal. Water should be
circulated through the system; afterward, pump strainers should be cleaned
and the system thoroughly dried out. All pipelines and other parts of the
equipment should be pressure tested before use, preferably with hot oil
rather than water.
Filling with Hot Oil
Before the initial filling of a plant, it is necessary to ensure that the correct
operating level is clearly marked. Hot oil expands on heating and
allowance must be made for the expansion of liquid between the filling and
operating temperatures.
The hot oil is normally at room temperature when the plant is being charged;
if the ambient temperature is below 12, the hot oil will require heating in
order to liquefy it, and special precautions will be necessary to ensure that
subsequent solidification does not take place in the pipelines and other parts
of the system during filling. When filling under very cold conditions, it is
advisable to warm the plant with hot air, and to fill the heater first.
Circulation of hot oil through the heater and its by-pass is then started and
the hot oil is gradually fed to other parts of the system, the addition of liquid
hot oil being continued until the plant is filled to the necessary level. If it is
necessary to warm the hot oil before filling the plant, particular care should
be taken that there are no open flames near the filling point.
Initial Heating
The first heating of a plant, after commissioning or after a prolonged shut
down, should be carried out very slowly. Although plants should be
provided with a storage and discharge vessel for hot oil in some cases this
may not have been included, or the plant may have been incompletely
drained, so that some lines are blocked by solid hot oil.

- 39 -

If the presence of solid material is suspected, testing must be extremely

cautious and the temperature of the heater should be kept to a minimum
until circulation is established.
If gentle heating is not successful in establishing circulation(say 50 at
heater coils), heating should be discontinued and the blockage located and
cleared by applying gentle external heat to the affected portion of line.
Extreme heat is not required for clearing blockages; raising the room
temperature will usually be sufficient to clear lines inside a building, while
low-pressure steam is normally adequate for thawing external lines.
Once circulation has been established, heating can be continued slowly up
to the operating temperature, all flanges and joints being checked for leaks
after every 50 rise. All vents and the by-pass to the safety valve, if fitted,
should be open until all air pockets have been removed from the system.
Plants operating at atmospheric pressure should not be heated to such an
extent that hot oil is discharged from the vent pipes or from the condenser.
Plants operating under pressure should never be heated beyond the hot oil
temperature corresponding to the test pressure of the plant, or in any case
higher than 400. Most plants operating under pressure are fitted with
automatic controls limiting the maximum obtainable.
Removal of Extraneous Water
The presence of extraneous water in a hot oil system can be dangerous,
owing to the high vapor pressure of water at temperatures above 100. It
is therefore recommended that, after a hydraulic test with water, new plant
should be thoroughly dried by compressed air before being filled with hot oil.
Alternatively, the water can be vaporized and vented to atmosphere before
the plant system is brought up to its full working temperature.

- 40 -

5.2 Supervision of Operation

The level of hot oil charge in the system should be checked at regular
intervals. Changes in hot oil composition arising from prolonged operation
or extraneous causes should be periodically checked. The changes due to
polymer formation are best checked by physical measurements of the
distillation range, crystallization point or viscosity. Where contamination
with process materials is suspected, tests should be made immediately for
the chemicals concerned, as most organic chemicals are much more liable
to carbonize than hot oil is, and if left in the system will impair heat transfer
and may even choke pipelines.
Analysis and Replacement Service
When the polymer content, that is the amount distilling at temperatures
above 260 under atmospheric pressure, is in the range 10 ~ 15%, the hot
oil should be replaced. This can be done either by regenerating the
degraded material locally or by using the replacement service operated by
vendor. It should be noted that it may not be possible to regenerate hot oil
that has been contaminated by large quantities of material of low thermal
stability, such as greases or tars.
When HTF is decomposed due to thermal degradation, flash point, ignition
point and auto-ignition temperatures are lower than its original properties
that need to check the following properties.
(1) Viscosity
Viscosity effects fluidity and heat transfer efficient. If it is lower viscosity,
than it gives better heat transfer and fluidity but changing viscosity
reveals thermal degradation of hot oil. Along with time, viscosity
increases in poly-phenyl derivatives and in mineral oils but decreases in
synthetic paraffin.
(2) Acid Number
Hydrolysis or oxidation degree can be checked via acid number.
Maximum is 4.0KOH/g-oil in paraffinic compounds, 1.0 KOH/g-oil in
poly phenyl compound.
(3) Non acetone soluble
Carbon and solids scale is measured.
erosion.

Maximum is 50/-oil to avoid

(4) Water
Water is the source of increasing light volatile compounds and acidic
compounds. Maximum allowable should be 2000ppm for synthetic
paraffin, 400ppm for aromatic compound.

- 41 -

(5) Light volatile materials

This content shows the degree of thermal degradation. If it exceeds
10%, then flash point and ignition point should be checked.
(6) High boilers (Heavy components)
This content shows the degree of thermal degradation.
10%, then coke will form.

- 42 -

If it exceeds

5.3 Maintenance of Plant

Before performing any maintenance work involving the breaking of joints, all
the hot oil should be drained from the plant into the storage tank. Where
welding is required on a plant item, the part should be thoroughly steamed
out to remove traces of hot oil before welding is started. Where the work
involved is small, it may be possible to do the operation without danger by
filling the section of pipe or plant with nitrogen and maintaining a continuous
flow of nitrogen while welding is proceeding. After any maintenance
operation the plant should be tested to ensure freedom leaks before being
put back into operation.

- 43 -

6. REFERENCE HOT OIL SYSTEMS

Previous experience data for the hot oil system design are presented
here. Hot oil system design even if there are some standard design
method, actual application is also important reference when they start
the design for new system.

6.1 Hot oil system summary of GSP-5 project

Design summary
Hot Oil: PTT

SERVICE

NO.
REQ.

TYPE

3508 P01

Hot Oil Transfer Pump

CEN

120

3.142

37.0

3508 P02A,B,R

Hot Oil Circulation

Pump

2+1

CEN

3549.8

11.636

3508 P03

Hot Oil Sump Pump

VERT

12

3508 P04,R

Hot Oil Drainage

Pump

CEN

36

ITEM NO.

ITEM NO.

3508 F01

SERVICE

In-plant Power
Generator WHRU

Sales Gas
3508 F02 Compressor Turbine
WHRU

ITEM NO.

SERVICE

NO.
REQ.

DESIGN CONDITION
MAT'L
CAPA.
HEAD CASING/
P
(m3/h)
(bar)
(m) IMPELLER

DIMENSION
IDxT.L
()

Sp.Gr

OPER.
TEMP.
(Deg'C)

CS

0.866

15

150.0

CS

0.791

130

0.615

6.3

CS

996.000

28

3.033

37.0

CS

0.836/
0.701

60/
270

CAPACITY

OTHER SPECIFICATION

32250~86000 kW
(Absorbed)

846466kg/h at 130 Deg.C (Max Case)

Density 791.1 kg/m3 at 130 Deg.C
Temp. In = 130, Temp. Out = 270 deg.C

32250~86000 kW
(Absorbed)

846466kg/h at 130 Deg.C(Max Case)

Density 791.1 kg/m3 at 130 Deg.C
Temp. In = 130, Temp. Out = 270 deg.C

NO.
REQ.

3508 D01

Hot Oil Storage

Tank

3508 D02

Hot Oil Expansion

Tank

3508 D03

Hot Oil Drainage

Tank

TYPE

TYPE

DIMENSION
IDxT.L
()

Cone
Roof

10100X12000 CS+3.0mm

MAT'L

DESIGN CONDITION
PRESS.
TEMP.
barG
Deg'C

OPR. CONDITION
PRESS. TEMP.
barG
Deg'C

0.02/-0.006

85

0.0

60

Horizontal 4750X15000 CS+3.0mm

295

0.1

130

Horizontal 2000X4000

295

0.1

270

- 44 -

CS+3.0mm

ITEM NO. SERVICE

3508 E01

ITEM NO.

3508S01,R

Hot Oil
Trim Air
Cooler

SERVICE

Hot Oil
Recycle Filter

3508S02,R Hot Oil Filter

3508S03

Hot Oil
Transfer Filter

NO.
Req'd
(Bay)

TYPE

Forced

NO.
REQ.

DIMENSION

TYPE

NORMAL
SURFACE AREA
HEAT DUTY
(m2)
(WxL, mm)
(MW)
Bare
Fin
18.0x1.05

CAPACITY

Cartridge 355m3/h

Cartridge 36m3/h

Cartridge 120m3h

1,045

DESIGN COND
PRESS
TEMP
barG
Deg'C

20.0

8.0

6.0

- 45 -

295

295

85

22,147

MAT'L
TUBE &
TUBESHT
CS
+3.0mm

OPR. COND
PRESS TEMP
barG
Deg'C

12.4

1.8

1.917

130

DESIGN COND
PRESS
TEMP
bar g
'C
20.0

295

OTHER SPECIFICATION
Efficiency : 99.5%(>3
Micron:100%)
Removed Particle Size :
0.5 ~ 3.0Micron
Material: CS (+3.0mmCA)

Efficiency : 99.5%(>3
Micron:100%)
60/270 Removed Particle Size :
0.5 ~ 3.0Micron
Material: CS (+3.0mmCA)

15/60

Efficiency : 99.5%(>3
Micron:100%)
Removed Particle Size :
0.5 ~ 3.0Micron
Material: CS (+3.0mmCA)

Hot oil control system of GSP-5 project

HTHOC: High Temperature Hot Oil Circuit (270 supply)

LTHOC: Low temperature Hot Oil Circuit (170 supply)

- 46 -

Hot oil schematic diagram of GSP-5 project

Trim cooler
Expansion Drum

WHRU F-01

Hot Oil Pump

WHRU F-02

HT Users
LT Users
To Expansion
drum

Filling conn.
Gravity drain
from users

Make-up
pump

Storage
Tank

- 47 -

Drain Tank and

Pump

6.2 Hot oil system summary of Songkhla GSP-1 project

Design summary

Songkhla
Hot Oil

Shell, Thermia Oil B (Mineral Oil)

cf. Thermia B : up to 320 centigrade

Oper. Temp

System Vol

Low Temp.:

170 oC (-> 140 oC)

High Temp.:

220 oC (-> 200 oC)

About 550 m3
Equipment volume Plot plan Line volume
15% margin

Equipment
Tag No.

Service Name

Quantity Type
Oper. S'by

Duty

Driver

kW

Elec
power
kW

Oper
speed
rpm

Design condition
Press.
Temp.
barg max/min

1108

-D- 01 A/B

Hot Oil Surge

Drum

Hori.

3.5

190/19

1108

-D- 02

Hot Oil Sump

Hori.

3.5

240/19

1108

-D- 03

Hot Oil Storage

Tank

Cone

0.10/
-0.0025

220/19

1108

-E- 01

Hot oil cooler

AC

4337

11.0

Motor
(2 sets)

21

250/19

1108

-P- 01 A/B/C/D

Hot oil circulation

pumps

Cent.

400

Motor

2970

21

190/19

1108

-P- 02

Hot oil make up

pumps

Cent.

5.5

Motor

2925

4.4

190/19

1108

-P- 03 A/B

Hot oil sump

pumps

Cent.

5.5

Motor

2950

5.6

240

1108

-P- 04

Hot oil filling pump

Cent.

3.7

Motor

2925

3.8

65

1108

-S- 01

Hot oil filter

Catr.

21

190/19

1108

-S- 02

Hot oil sump filter

Catr.

5.6

240/19

1108

-U- 01

Hot Oil Heater

Package

22530

21
min.

250
min.

1108

-U- 02 A-D

Waste heat
recovery units

6915

- 48 -

Equipment
Tag No.

Service Name

P. in
barg

Operating condition Dimensions

Rated
P. out T. in T.out
ID
L.
Cap. Head
mm mm m3/hr m
barg

Materials

1108

01 A/B
D-

Hot Oil Surge

Drum

0.5

149

3200 8600

SA516Gr70

1108

02
D-

Hot Oil Sump

0.05

AMB ~
220

1800 5000

SA516Gr70

1108

03
D-

Hot Oil Storage

Tank

0.05

AMB ~
160

11000 8500

SA516Gr70

1108

01
E-

Hot oil cooler

4.1

3.6

220

200

HeaderSA516Gr60 TubeSA179

1108

Hot oil circulation

01 A/B/C/D
Ppumps

1.84

14.7

147

781.2 168

API610
Class S-6

1108

02
P-

Hot oil make up

pumps

2.9

AMB

10.0

34.4

API610
Class S-6

1108

03 A/B
P-

Hot oil sump

pumps

-0.3

1.43

AMB
~160

20.0

22.5

API610
Class S-1

1108

04
P-

Hot oil filling pump

-0.1

2.5

AMB

6.0

30.9

API610
Class S-6

1108

01
S-

Hot oil filter

147

592

1450

SA516Gr70

1108

02
S-

Hot oil sump filter

220

547

1350

1108

01
U-

Hot Oil Heater

Package

11.5

10

162 ~
167

220

Header:CS
T:SA106Gr B

1108

02 A-D
U-

Waste heat
recovery units

11.1

10.1

149

167

By Vendor

- 49 -

SA516Gr70

Hot oil schematic diagram of songkhla GSP-1 Project

Expansion Drum

HT User: 220 supply

LT User: 170 supply

Fired
Heater

WHRU

FC
FC

HT Users
FC

PD

Hot Oil Pump

TC

LT Users

To Expansion
drum

FC

Gravity drain
from users

Make-up
pump

Storage
Tank

- 50 -

Filling pump

Drain Tank and

Pump

6.3 Hot oil system summary of LAB project

Design summary
System volume: 834 m3, Hot Oil: Therminol 66
Supply temperature to users: 320 deg.C
NO.
ITEM NO.

SERVICE

2063Hot Oil Pumpout

1+1
E-001-1/-2 Cooler

AES

600*4000

NO.
ITEM NO.

SURFACE

MATERIAL

AREA
()

SHELL TUBE

HEAT
TYPE DIMENSION DUTY
IDxT.L () MM /H
REQ.
0.83

REQ.
Hot Oil Pumps

2+1

2063-P002ABC-P1

Auxiliary Lube Oil

Pump

2+1

2063-P002ABC-E1 Lube Oil Heater

90-10/
Cu-Ni

CS

S.S

T.S

S.S

T.S

7.0

6.5

288

65

DESIGN
CONDITION
CASE/ RATED
RATED CAPA. DIFF.PRES HEAD NPSHA IMPELLER POWER
(m3/H)
(KG/Cm2) (m)
(m)
MAT'L
(KW)

TYPE

SERVICE

2063-P-002 A/B/C

81.1

DESIGN CONDITION
PRESS
TEMP
(/G)
()

Cent.
(Between
Bearing)

2114.3

13.2

161.3

77

Steel/
11-13%Cr

907.8

2+1

2063-P-003

Pumpout Pump

Cent.

4.4

3.8

38.5

3.4

Steel/
Steel

4.58

2063-P-004

Hot Oil Transfer

pump

Cent.

11

3.5

34.7

3.4

Steel/
Steel

4.27

ITEM NO.

SERVICE
REQ.

TYPE
(CAPA.)
()

DIMENSION
Dia.xT.L
()

SHELL
MAT'L

Vert.

5000OD*180
00

SA 515
GR.70

NO.

2063-V-001 Hot Oil Surge Drum

NO.
ITEM NO.

SERVICE

TYPE

DIMENSION
IDxT.L

REQ
.

CAPACITY

DESIGN CONDITION
PRESS.
TEMP.
(/G)
()
3.5/FV

360

OTHER SPECIFICATION

()

2063-F-001 Hot Oil Heater

Radiant
Convective
(Vetical Box
Type)

2063-G-001 Hot Oil Filter

Cartridge

390 X 1650

- 51 -

3,470,110
Kg/Hr

Heat Duty: 94.67 MMKcal/Hr

<Coil Specification>
Coil Design Pressure: 24.0 /G
Design Temp.: 425
Tube Material: C.S.(ASTM A-106
Gr.B)

Max.
28,250 Kg/Hr

Design Pressure: 15.0 /G

Design Temp.: 320
Material: C.S.

Hot oil schematic diagram of LAB Project

F
C

Hot Oil Heater

2063-F-001

Process
Bulk Hot Oil
Container

P
C

Nitrogen
connection

Hot Oil Surge Drum

2063-V-001

Make-up
Pump

Drum

Export to a certain
container
Hot Oil Pump-out
Cooler

Hot Oil Pumps

2063-P-002 A/B/C

N2 connection
for drain

Supply header
Return header

Connected to the Hot oil user:

All users have low point drain connection to pump-out by a Potable pump

- 52 -

6.4 Hot oil system summary of project

Design summary

Hot Oil
Oper. Temp

280 oC

Heat Duty

Eq. Short spec

System Vol
Eq. Short Spec

Hot Oil Fired Heater Package (SA-A-5801A/B)

7812 kW per each unit (240 oC -> 280 oC)
about 251 t/h
Hot Oil Rundown Cooler (SA-E-5801)
13 t/h,

280 oC -> 60 oC

Hot Oil Circulation Pumps (SA-P-5801A/B)

1 operationg, 1 standby
Nor.: 372 m3/h,

Rated: 440 m3/h

Hot Oil Slim Stream Filter (SA-S-5801)

37.24 m3/h

(10% of Circ. Pump normal capacity)

Hot Oil Tank (SA-T-5801)

4500 mmID x 6000 mm H

(about 84 m3 - HLL)

Hot Oil Expansion Vessel (SA-V-5801)

Vertical,

2200 mmID x 7100 mm H

- 53 -

Hot oil schematic diagram of Project

N2

ATM
PD
C

Stabilizer
Reboiler A, B

PC
V-5801
S-5801
FC

Gylcol Regen
Pkg 1, 2
A-5801A/B
P-5801A/B

ATM

N2
PC

E-5801

T-5801

P-5802

- 54 -

6.5 Hot oil system summary of TA/PTA () project

Design summary

Equipment
Tag No.

Service Name

Quantity
Oper. S'by

Type

Design

- Heat duty: 25 MMKcal/h

- Size: 7030ID*40968H
- Material: (BODY)A36 GRADE STEEL
(COIL):A106Gr.B
- Heat Transfer Medium
ThermS-600 (290 316 )
Flowrate (max. / nor.):
1,600/1,544.5 ton/h
Press. Drop (max. / nor.):
2.0/1.8 kg/cm2
- Integrated with steam recovery system

BA

8101

Hot Oil Heater

EA

8102

Hot Oil Cooler

BEU

FA- 8101

Hot Oil Expansion

Drum

FA

8102

Hot Oil Blow Down

Drum

FB

8101

Hot oil Storage

Drum

FD

8101 A/B

GA

GA

Design condition
Press.
Temp.
Kg/cm2g

12

360

- Size: 500ID x 4880L

- Surface area: 42 m2

12 / 8

360 / 80

Vert.

- Size: 3800ID x 5000H

3.0/FV

360

Vert.

- Size: 3800ID x 5000H

FW

360

Vert..

- Size: 2200ID x 5000H

3.0/FV

360

GA-8101A/B
Suction Filter

- Flowrate: 1800 kg/h

5.0/FV

360

8101 A/B

Hot oil Circulation

pump

Cent.

12

360

8102

Hot Oil Charge

Pump

-Cent.

12

360

- 55 -

Flowrate: 1800 m3/h

Differential head: 65 m
Power:, 450 kW (motor)
Flowrate: 10 m3/h
Differential head: 34 m
Power: 3.7 kW (motor)

Hot oil schematic diagram of TA/PTA Project

FA-8102

FA-8101

FB-8101

PC

FD-8101A/B

FC

GA-8101A/B

GA-8102

BA-8101

HC
EA-8102

- 56 -

7. REFERENCE

Project Operator training

Shell HTF

Process Utility Systems, by Jack Broughton
Vendor Design Guide

- 57 -