PETRONAS TECHNICAL STANDARDS

Hot Oil System

PTS 16.39.01
June 2017

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© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.

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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 4
SCOPE .............................................................................................................................. 4
GLOSSARY OF TERM ........................................................................................................ 4
SUMMARY OF CHANGES ................................................................................................. 5
2.0 HOT OIL SYSTEM .................................................................................................... 6
GENERAL REQUIREMENTS .............................................................................................. 6
3.0 HEAT TRANSFER EQUIPMENT ................................................................................ 7
HOT OIL HEATER.............................................................................................................. 7
PROCESS USER’S HEAT EXCHANGER ............................................................................... 7
HOT OIL TRIM COOLER .................................................................................................... 8
4.0 HOT OIL EXPANSION VESSEL .................................................................................. 9
DESIGN REQUIREMENTS ................................................................................................. 9
5.0 STORAGE TANK AND SPARE INVENTORY .............................................................. 11
DESIGN REQUIREMENTS FOR STORAGE TANK AND SPARE INVENTORY ...................... 11
6.0 PIPING ................................................................................................................. 12
DESIGN REQUIREMENT FOR PIPING ............................................................................. 12
7.0 PUMPS ................................................................................................................ 13
DESIGN REQUIREMENT FOR PUMPS............................................................................. 13
8.0 INSTRUMENTATION AND CONTROL ..................................................................... 14
DESIGN REQUIREMENTS FOR INSTRUMENTATION AND CONTROL ............................. 14
9.0 STRAINERS AND FILTERS ...................................................................................... 15
DESIGN REQUIREMENTS fOR STRAINERS AND FILTERS ................................................ 15
10.0 DRAIN SYSTEM .................................................................................................... 16
DESIGN REQUIREMENTS FOR DRAIN SYSTEM .......................................................... 16
11.0 BIBLIOGRAPHY .................................................................................................... 17
APPENDIX 1: TYPICAL LAYOUT OF HOT OIL SYSTEM......................................................... 18

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1.0 INTRODUCTION

This PTS provides technical requirements for the design as well as to ensure the safe and
reliable operations of hot oil system. Hot oil system is applied as indirect heating for process
requirement in processing and production of oil, gas and petrochemical facilities.

This PTS also incorporates PETRONAS lesson learnt and best practices.

SCOPE
This PTS specifies design requirement of hot oil system that carries thermal energy which is
used to exchange heat within specific bulk fluid operating temperature range. Hot oil system
is a closed loop system that comprises of heater, expansion vessel, storage tank, pumps and
other associated auxiliaries.

GLOSSARY OF TERM

General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.

Specific Definition of Terms

No Term Definition

1 Expansion vessel A vessel which allows change in fluid volume

upon heating (thermal expansion) & cooling
(surge). The vessel allows for venting of low
boiling point components from the system.

2 Heater Source of heat energy either in the form of a

heat exchanger, an electric heater, a furnace or
a waste heat recovery unit (WHRU).

3 Hot Oil A fluid used for transporting heat energy within

specified temperature range. Also can be
described as Heat Transfer Fluid (HTF) including
synthetic aromatic, silicone-based and specific
mineral oils.

3 Maximum allowable bulk The highest temperature of fluid throughout

temperature (MABT) its flow.

4 Maximum allowable film The highest temperature of outer most layer /

temperature (MAFT) surface of the flowing fluid; or highest
temperature of heater’s inner tube wall.

It is dependent on hot oil’s heat flux and heat

transfer coefficient.

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No Term Definition

5 Maximum operating The highest hot oil operating temperature at

temperature (MOT) which the system is designed which measured
at the outlet of heat source.

6 Minimum operating The lowest hot oil bulk temperature during

temperature start-up and / or shutdown.

7 Return temperature Temperature of returning hot oil to the heater.

8 Supply temperature Battery limit temperature of the hot oil supplied

to users.
Table 1.1: Specific Definition of Terms

Specific Abbreviations

No Abbreviation Description

1 MOV Motor Operated Valve

2 NPSHR Net positive suction head required

3 NPSHA Net positive suction head available

4 WHRU Waste Heat Recovery Unit

Table 1.2: Specific Abbreviations

SUMMARY OF CHANGES
This PTS 16.39.01 (June 2017) replaces PTS 16.39.01 (June 2014).

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2.0 HOT OIL SYSTEM

GENERAL REQUIREMENTS

Hot oil system is an indirect heating system used in many industrial applications operating at
design bulk temperature levels up to 300oC.

Hot oil system consists of storage tank, circulation pumps, heater, expansion vessel, trim
coolers, filters, piping and heat exchangers to users.

Hot oil can be heated up via furnace, waste heat recovery unit (WHRU) and heat exchanger.
Refer to Appendix 1 for typical layout of a hot oil system.

Refer to Standard drawing D16.92.005 for typical design guidance.

Process and control scheme shall be finalized based on process operating condition,
operational requirement, hot oil characteristic and type of heat recovery.

Process Flow Diagram (PFD) for different operating case shall be prepared in accordance to
PTS 16.51.01 and PTS 12.00.02.

Hot oil system control should allow for minimum operator intervention during start up until
minimum stable operating condition. The heater should be designed with minimum fuel
consumption in all operating cases.

The Contractor shall specify the minimum flash point for design and operation; type of hot oil
and MOT, subject to Technical Authority approval.

IPF classification shall (PSR) be conducted (according to PTS 14.12.10) to determine measures
to be taken in the event of tube rupture. This is due to the sudden displacement of fluid from
higher pressure process side into the expansion vessel which can result in hot oil loss into the
flare system.

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3.0 HEAT TRANSFER EQUIPMENT

General heater requirement shall follow as according to PTS 12.41.01 except for amendments
as per listed in Section 3.1.

HOT OIL HEATER

Heaters shall be designed in such a way that the hot oil will not be exposed above MAFT and
MABT.

Maximum operating temperature (MOT) shall be lower than maximum allowable bulk
temperature (MABT).

General requirements for heater design:

i. Selection of fuel shall be based on hot oil properties, characteristics and process
requirement.

ii. 10% margin should be added to duty based on the highest thermal process
demand.

iii. Margin for heat losses from the system shall be specified by Contractor.

iv. For parallel bundles’ manifold, the ratio of lowest to highest flow shall be less than
0.95.

v. The selection of heating coil in WHRU shall consider possibility of tube rupture.
Selecting next higher schedule pipe for such service is recommended.

vi. Relief valves or rupture disks shall be installed outlet of heaters for overpressure
protection.

PROCESS USER’S HEAT EXCHANGER

U-tube type heat exchanger should be considered instead of floating head type heat
exchanger since hot oil system normally can be considered as non-fouling system in order to
reduce the cost and risk of leakage.

Types of hot oil and its trade name and product technical data or MSDS shall be clearly
mentioned in heat exchanger datasheet. Hot oil fouling resistance shall follow PTS 16.12.01.

Strength welded tube-to-tube sheet connection shall be used to avoid leakage. Further
consideration of tube construction shall refer to PTS 12.41.01

Hard piped drains and vents routed into a collection system shall be installed. Location of drain
and vent for single user is recommended at the hot oil supply and return line.

Nitrogen purge connection shall be installed. Location of nitrogen purge connection for single
user is recommended at the hot oil supply and return line.

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HOT OIL TRIM COOLER

Trim cooler is typically Air Cool Heat Exchangers and standard design guideline for Air Cool
Heat Exchangers shall follow PTS 12.21.02.

Trim cooler should be considered as a heat sink and to increase flexibility of hot oil system.

Separate trim cooler is required at outlet of WHRU to maintain constant hot oil supply
temperature to the process consumers.

The sizing of trim cooler should be based on minimum turndown of heater duty with hot oil
flow to the hot oil heater shall be maintained at or above a certain minimum flow to avoid
high film temperatures.

A detailed assessment should be made to determine and optimize the size of the trim cooler
based on the WHRU turndown limitations and minimum flow requirements through the
WHRU.

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4.0 HOT OIL EXPANSION VESSEL

DESIGN REQUIREMENTS

The expansion vessel is required for the following purposes:

i. Allows change in hot oil volume upon heating (thermal expansion) & cooling
(surge), which will then minimize consequences of process upsets;

ii. Venting off low boiling point components generated during normal operation;

iii. Venting off inert and vaporised water during start-up and initial hot oil drying.

Expansion vessel shall be designed to accommodate thermal expansion and contraction of hot
oil during operation due to fluctuation of heat demand considering the following:

i. Expansion vessel shall be designed according to PTS 16.52.09.

ii. Expansion vessel shall be vertical vessel and insulated.

iii. Expansion vessel shall allow degassing of hot oil and fitted (minimum
requirement) with half-open pipe inlet device.

iv. NPSHR to be maintained for all operational scenarios.

a) To provide sufficient NPSHA and facilitate proper venting, vessel shall be
elevated higher than the highest possible hot oil level in the system.
b) Lower elevation may be selected should the requirement is limited (i.e.
space constraint). Vapour lock in the higher parts of the circuit shall be
prevented.

v. To vent off residual water in the system during start-up;

vi. Sufficient to accommodate hot oil inventory which determine by the volume of
largest individual equipment in the system.

vii. Expansion vessel shall be located at system circulation pump suction line. The
vessel shall be elevated so that the normal operating level of the hot oil in then
vessel is higher than the highest possible hot oil level in the system.

viii. Hot oil make up shall be manually initiated as hot oil make up requirement is very
low.

ix. Vessel should be designed for full flow and “double-leg” design which provide
higher flexibility in normal operation.

x. Vessel shall be equipped with safety relief valve that is connected to flare to
protect against over-pressure considering mal operation, overheating or tube
failure scenarios.

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xi. Vessel to be equipped with nitrogen blanketing of minimum 98% purity is to avoid
degradation of hot oil and generation of corrosive acid compounds, vessel’s
vapour space shall be prevented from contact with the atmosphere. Nitrogen
supply to the vessel shall be provided with split-range self-regulating type PRV
and non-return valve to prevent the hot oil vapour back flow into the nitrogen
system in the event of a pressure built up in the vessel. Split range controller and
non-return valve shall be made for larger system.

xii. A positive pressure of approximately minimum 1-2 bar above the hot oil vapour
pressure should be maintained for high temperature operations, especially when
system temperature approaching or exceeding the hot oil boiling point.

xiii. Regular venting should be through the pressure control and generally routed to
flare. In case hot oil collection at the flare knock out drum can lead to potential
contamination issues, the vent line from the expansion vessel should be routed
to a separate collection drum via a condenser prior to venting the non-
condensable to flare.

xiv. Factors that effects the size of the expansion vessel are:
a) Expansion coefficient;
b) Maximum temperature of the hot oil;
c) Quantity of the hot oil in the system.

xv. Preliminary sizing of the vessel shall depend on the estimated quantity of fluid
and shall be adjusted upon completion of the final design stage. The design shall
follow the design rules per PTS 16.52.09 except for amendments made here.
Expansion vessel level setting shall follow below criteria
a) Low Low Level (LL) to Low Level (L)
 Vessel shall be elevated high enough to ensure adequate NPSH at all
operating scenarios.
 Inventory of hot oil between LL to L should be 25% of vessel’s volume.
b) Low Level (L) to High Level (H)
 Volume shall (PSR) be equal to total hot oil expansion volume from
minimum operating temperature to MOT.
 20% additional volume margin should be added to cater for operation
upsets.
c) High Level (H) and above
 As per PTS 16.52.09

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5.0 STORAGE TANK AND SPARE INVENTORY

DESIGN REQUIREMENTS FOR STORAGE TANK AND SPARE INVENTORY

Storage tank shall be designed in according to PTS 12.22.01 and PTS 12.22.02.

Storage tank should be designed to hold full system inventory (including in piping and
equipment) with adequate spare volume to cater for losses due to component venting,
leakage and contamination by process fluid.

Storage tank to be heated and pump suction line should be heat traced and insulated; should
the ambient temperature fall below minimum pumpability temperature.

Storage tank shall (PSR) be equipped with nitrogen blanketing to avoid hot oil oxidation,
degradation, and moisture ingress.

Draining of high temperature hot oil directly to the storage tank shall be avoided. It shall be
cooled prior to sending to the storage tank via a cooler.

Road tanker connection facility should be provided for draining off cooled hot oil out of the
system.

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6.0 PIPING

DESIGN REQUIREMENT FOR PIPING

Hot oil piping shall be designed for 110% of maximum flow and in accordance to PTS 12.30.02
and PTS 12.31.01.

Insulation requirement for hot oil system shall follow PTS 15.13.01.

Flanged connections should be minimized. Leakage may occur due to formation of low boiling
point components from reduction of hot oil flash point at flanged connections. Welded piping
connections are preferred as far as possible.

All low/high points of piping and fittings shall be equipped with hard piped drains and vents
and routed as short as possible to closed drain system. Sight glass shall be made available at
the vent’s down-flow line.

Piping shall be purged free from hydrocarbon and moisture prior to start-up using nitrogen.

Supply header from heater to hot oil consumer shall be as short as possible to reduce
decomposition and degradation of hot oil due to prolong exposure to MOT.

Large hot oil system should consider remotely operated valves for sectionalising during
leakage and emergency cases for inventory management.

The spillover lines and control valves shall be sized for the flow of the largest consumer to
allow for a sudden block-off of the heat user. Manual bypass lines shall be sized for 100% flow.

Sampling connection should be provided to perform sample collection at suction or discharge

hot oil pump as per PTS 12.30.02.

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7.0 PUMPS

DESIGN REQUIREMENT FOR PUMPS

Pump shall be designed according to PTS 12.11.01.

Pump seal shall be designed according to hazard classification in PTS 12.12.03. Dual seal
application shall be applied for hazardous service as per PTS 12.11.01.

Circulation pump should be designed to achieve the specified reliability of the plant. Stand-by
pump shall take over automatically in the event of low system pressure. Stand-by pump shall
be maintained in pre-heated operation to avoid thermal shock. Larger stand-by pump shall
provide bypass across discharge check valve and be routed through pump casing drain to keep
the pump in warm condition.

Type of hot oil, trade name, minimum operating pressure, hot oil physical properties and
characteristic shall be specified in the pump datasheet.

Pump design should consider the lowering of vapour pressure due to degradation of hot oil
during its service. As this may lead to reduction in NPSHA, pump shall be designed with the
assumption that the hot oil vapour pressure is equal to the pressure of expansion vessel during
normal operating temperature.

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8.0 INSTRUMENTATION AND CONTROL

DESIGN REQUIREMENTS FOR INSTRUMENTATION AND CONTROL

Instrumentation and control for hot oil system shall be designed according to PTS 14.10.02
and PTS 14.10.04; covering stable operation from minimum to design heat duty.

Flow controller shall be installed at the feed line to the heater, which will open the spillover
bypass and / or full-flow bypass; to maintain hot oil flow above minimum requirement to avoid
high film temperature. Refer Appendix 1 for detail.

Heater outlet temperature shall be maintained via trim cooler. Heater outlet temperature and
flow controllers will decrease return temperature controller’s set point; which will then
increase the flow thru trim cooler.

If a WHRU is used as hot oil heater, heater outlet temperature is controlled via flow through
WHRU. Should the flow through WHRU at maximum, signal from temperature and flow
controllers will decrease the set point of the return temperature controller, resulting in lower
WHRU inlet temperature. Trim cooler is usually installed at the supply line from WHRU.
Temperature can be maintained by closing the feed to the trim cooler and opening the trim
cooler bypass.

Alarm with trip setting shall (PSR) be provided considering that the flow to the heater can fall
below minimum. Minimum circulation trip flow shall be set at 70% of minimum flow into the
heater.

Other control schemes and strategies may be proposed and subjected to Technical Authority’s
approval.

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9.0 STRAINERS AND FILTERS

DESIGN REQUIREMENTS FOR STRAINERS AND FILTERS

Suction line of circulation pump shall be fitted with temporary wiremesh strainer to prevent
debris from entering the pump during commissioning.

Permanent filter shall only be considered when continuously filtering of hot oil is required and
it is predicted that high formation of high boiling point components persist as advised by the
hot oil manufacturer. In these cases, minimum two filters element size should be advised by
the hot oil manufacturer) should be installed. Differential pressure indicator shall be installed
across the filters to monitor fouling.

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10.0 DRAIN SYSTEM

DESIGN REQUIREMENTS FOR DRAIN SYSTEM

Hard piped (free flowing) closed drain system shall be provided for maintenance purposes.

Hot oil from piping and equipment drains / vents shall be routed back into the system via drain
pump for re-use or controlled disposal once degraded.

Hot oil drain system shall be independent and separated from plant drain system.

Piping drain should be installed underground and is solely for collection and draining of cooled
down hot oil.

The drain header shall be as close as possible to the drain points. This is to reduce the length
of small bore drain piping.

Nitrogen purge shall be supplied for a non-free flow drain system.

Drain collection drum shall be sized to receive the largest hot oil consumer at one time. It shall
be equipped with nitrogen blanketing to avoid moisture and / or air ingress. The collection
vessel shall be provided with a pump for returning the hot oil into the main system, or for the
filling of drums or other means for hot oil disposal. Collection drum to be installed with vent
for safe nitrogen venting to flare and located in a (dry) pit for secondary containment.

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11.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Air-Cooled Heat Exchangers PTS 12.21.02
Standard Vertical Storage Tanks – Selection, Design and PTS 12.22.01
Fabrication Based on BS EN 14015
Vertical Storage Tank Based on API 650 PTS 12.22.02
Fired Heaters Based on ISO 13705 PTS 12.41.01
Symbols and identification system - Mechanical PTS 12.00.02
Pump – Type Selection And Basic Design Requirements PTS 12.11.01
Shaft sealing systems for centrifugal and rotary pumps PTS 12.12.03
(amendments/supplements to ISO 21049:2004)
Piping - general requirements PTS 12.30.02
Pipe supports PTS 12.30.04
Piping classes – Refineries, Chemical And Gas Plants, PTS 12.31.01
Onshore Exploration And Production Facilities
Instruments for measurement and control PTS 14.10.02
Control Valves : Selection, Sizing and Specification PTS 14.10.04
Classification and implementation of instrumented PTS 14.12.10
protective functions
Thermal insulation (amendments/supplements to the CINI PTS 15.13.01
Handbook)
Heat Transfer Equipment Fouling Factor PTS 16.12.01
Design Conditions : Temperature, Pressure & Toxicity PTS 16.50.01
Process Flow Diagram (PFD) and Piping and PTS 16.51.01
Instrumentation Diagram (P&ID)

Two Phase Gas and Liquid Separator PTS 16.52.09

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APPENDIX 1: TYPICAL LAYOUT OF HOT OIL SYSTEM

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