PETRONAS TECHNICAL STANDARDS

Hot Oil System

PTS 16.39.01
June 2014

© 2014 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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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.

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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

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specific requirements are not covered in the PTS, it is the responsibility of the

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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.

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In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
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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
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requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.
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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
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otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.
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The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
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kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
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PETRONAS that this requirement is met.

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ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 - 2015 which includes revision to numbering system, format and content. As part of this change,
the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition
to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required
make reference to other PTS in its revised numbering to ensure consistency. Users are requested to
refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For
further inquiries, contact PTS administrator at [email protected]

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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
SCOPE .............................................................................................................................. 5
GLOSSARY OF TERM ........................................................................................................ 5
SUMMARY OF CHANGES ................................................................................................. 6
2.0 HOT OIL SYSTEM .................................................................................................... 7
GENERAL REQUIREMENTS .............................................................................................. 7
3.0 HEAT EXCHANGER ................................................................................................. 8

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HOT OIL HEATER.............................................................................................................. 8

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PROCESS USER’S HEAT EXCHANGER ............................................................................... 8
HOT OIL TRIM COOLER .................................................................................................... 8

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4.0 HOT OIL EXPANSION VESSEL ................................................................................ 10

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DESIGN REQUIREMENTS ............................................................................................... 10
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5.0 STORAGE TANK AND SPARE INVENTORY .............................................................. 12
DESIGN REQUIREMENTS FOR STORAGE TANK AND SPARE INVENTORY ...................... 12
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6.0 PIPING ................................................................................................................. 13

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DESIGN REQUIREMENT FOR PIPING ............................................................................. 13

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7.0 PUMPS ................................................................................................................ 14

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DESIGN REQUIREMENT FOR PUMPS............................................................................. 14

8.0 INSTRUMENTATION AND CONTROL ..................................................................... 15
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DESIGN REQUIREMENTS FOR INSTRUMENTATION AND CONTROL ............................. 15

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9.0 INSULATION ........................................................................................................ 16

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DESIGN REQUIREMENTS FOR INSULATION................................................................... 16

10.0 STRAINERS AND FILTERS ...................................................................................... 17
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DESIGN REQUIREMENTS fOR STRAINERS AND FILTERS ............................................ 17

11.0 DRAIN SYSTEM .................................................................................................... 18
DESIGN REQUIREMENTS FOR DRAIN SYSTEM .......................................................... 18
12.0 BIBLIOGRAPHY .................................................................................................... 19
APPENDIX 1: TYPICAL LAYOUT OF HOT OIL SYSTEM......................................................... 20
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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.

SCOPE
This PTS specifies design requirement of hot oil system that carries thermal energy 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.

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GLOSSARY OF TERM

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1.2.1 General Definition of Terms & Abbreviations

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

1.2.2 Specific Definition of Terms lU

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No Term Definition
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1 Expansion vessel A vessel which allows change in fluid volume

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upon heating (thermal expansion) & cooling

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(surge).
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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).
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The highest temperature of fluid throughout its

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3 Maximum allowable bulk flow.

temperature (MABT)
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(MOT > MABT; for MOT < MABT, subject to Technical Authority’s
approval.)
The highest temperature of outer most layer /
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4 Maximum allowable film surface of the flowing fluid; or highest

temperature (MAFT) temperature of heater’s inner tube wall.

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

transfer coefficient.

5 Maximum operating The highest operating temperature at which the

temperature (MOT) 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.

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No Term Definition

8 Supply temperature Battery limit temperature of the hot oil supplied

to user.
Table 1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviation Description

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1 PFD Process Flow Diagram

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2 MSDS Material Safety Data Sheet

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3 NPSHR Net positive suction head required

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4 NPSHA Net positive suction head available

5 MOV Motor Operated Valve

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6 WHRU Waste Heat Recovery Unit
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Table 2: Specific Abbreviations

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SUMMARY OF CHANGES
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This PTS 16.39.01 replaces PTS 20.05.50.10 (January, 2011).

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2.0 HOT OIL SYSTEM

GENERAL REQUIREMENTS

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

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

2.1.3 Refer Appendix 1 for typical layout of a hot oil system.

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2.1.4 Refer Standard drawing D.16.92.005 for detailed design guidance reference.

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

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2.1.6 Process Flow Diagram (PFD) for different operating case shall be prepared in accordance to

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PTS 16.51.01 and PTS 12.00.02.

2.1.7 Hot oil system is normally purchased as package unit. Therefore, necessary equipment such
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as ladders, platforms and guards for moving parts are to be supplied as part of the package.
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2.1.8 Hot oil system should be automatically controlled from start-up to minimum stable operating
condition. The heater should be designed with minimum fuel consumption in all operating
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cases.
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2.1.9 The Contractor shall specify the minimum flash point for design and operation; type of hot oil
and MOT, subject to Technical Authority approval.
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2.1.10 IPF classification shall (PSR) be conducted (according to PTS 14.12.10) to determine measures
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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
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flare system.
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3.0 HEAT EXCHANGER

HOT OIL HEATER

3.1.1 Hot oil can be heated up via furnace, waste heat recovery unit (WHRU), and heat exchanger.

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

3.1.3 Maximum operating temperature (MOT) shall be higher than maximum allowable bulk
temperature (MABT); for MOT lower than MABT, subject to Technical Authority’s approval.

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3.1.4 General requirements for heater design:

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

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requirement. 10% margin should be added to duty based on the highest thermal
process demand. Any additional margin is not required for the heater.

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ii. Margin of heat losses from the system shall be specified accordingly.
iii.
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For parallel bundles’ manifold, the ratio of lowest to highest flow shall be less than
0.95.
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iv. Design pressure of the heating coil in WHRU shall (PSR) be doubled of operating
pressure. Final tube thickness and material selection to be of next higher schedule to
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avoid tube leakage.

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(PSR)
v. Hot oil heater shall be designed with two-thirds rules according to PTS
01.00.01.30.
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(PSR)
vi. Safety relief valves or rupture disks shall be installed outlet of heaters for
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overpressure protection.

PROCESS USER’S HEAT EXCHANGER

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3.2.1 U-tube type heat exchanger should be considered instead of floating head type heat
exchanger to reduce risk of leakage, consequently contamination of hot oil.
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3.2.2 Types of hot oil and its trade name shall be clearly mentioned in heat exchanger datasheet.
Product technical data or MSDS to be attached. Hot oil fouling resistance shall follow
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PTS 16.12.01.

3.2.3 Strength welded tube-to-tubesheet connection shall be used to avoid leakage.

3.2.4 Hard piped drains and vents routed into a collection system shall be installed.

3.2.5 Nitrogen purge connection shall be made available for evacuation.

HOT OIL TRIM COOLER

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

3.3.2 Separate trim cooler is required outlet of WHRU to maintain constant hot oil supply
temperature to the process consumers.
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3.3.3 Typically, an air-cooled heat exchanger selected as trim cooler.

3.3.4 Process cooler (e.g. column overhead condenser) can act as a trim cooler.

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4.0 HOT OIL EXPANSION VESSEL

DESIGN REQUIREMENTS

4.1.1 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 inerts and vaporised water during start-up and initial hot oil drying.

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4.1.2 Expansion vessel shall be designed to accommodate thermal expansion covering minimum to

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maximum operating temperature and in accordance to the following:

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i. Expansion vessel shall be designed according to PTS 16.52.09.
ii. Expansion vessel shall be vertical vessel and insulated.

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iii. Expansion vessel shall allow degassing of hot oil and fitted (minimum

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requirement) with half-open pipe inlet device.
iv. NPSHR to be maintained for all operational scenarios.
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To provide sufficient NPSHA and facilitate proper venting, vessel shall be elevated
higher than the highest possible hot oil level in the system.
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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.
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v. To vent off residual water in the system during start-up;

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vi. Sufficient to accommodate hot oil inventory which determine by the volume of
largest individual equipment in the system.
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vii. Expansion vessel shall be located at system return line on circulation pump
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suction line.
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viii. Make-up and draw-off facility to be manually initiated by operator.

ix. Vessel shall be designed for full flow. “Single-leg” design (“cold fluid” expansion
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vessel) subjected to Technical Authority approval.

x. Vessel shall (PSR) be equipped with safety relief valve that is connected to flare to
protect against over-pressure.
xi. Vessel to be equipped with nitrogen blanketing of minimum 98% purity and shall
be provided with split-range controller and non-return valve; where vapour and
nitrogen back-flow due to pressure built up in the vessel can be avoided.
To avoid degradation of hot oil and generation of corrosive acid compounds,
vessel’s vapour space shall be prevented from contacting the atmosphere.
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xii. A positive pressure of approximately minimum 1-2 bar above the hot oil vapour
pressure should be maintained for at high temperature operations, especially
when system temperature approaching or exceeding the hot oil boiling point.
xiii. Regular venting shall (PSR) be on pressure control and routed to flare. For special /
abnormal cases (e.g. operational emergency, HSE reasons) vent line shall (PSR) be
routed to drain collection drum via condenser prior venting off to flare.
xiv. Factors that effects the size of the expansion vessel are:
a) Expansion coefficient;
b) Maximum temperature of the hot oil;

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c) Quantity of the hot oil in the system.

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xv. Preliminary sizing of the vessel shall depend on the estimated quantity of fluid

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and shall be adjusted upon completion of the final design stage. Expansion vessel
level setting shall follow below criteria:

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a) Low Low Level (LL) to Low Level (L)

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Vessel shall (PSR) be elevated high enough to ensure adequate NPSH at
all operating scenarios.
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 Inventory of hot oil should be 25% of vessel’s volume.
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b) Low Level (L) to High Level (H)

 Volume shall (PSR) be equal total hot oil expansion volume from
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minimum to MOT.
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 20% additional volume margin shall be added to cater for operation

upsets.
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c) High Level (H) and above


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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

5.1.1 Storage tank shall be designed to hold full system inventory (including in piping and
equipment) with additional 10 % volume to cater for losses due to component venting,
leakage and contamination by process fluid.

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

5.1.3 Storage tank shall (PSR) be equipped with nitrogen blanketing to avoid hot oil oxidation,

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degradation, and moisture ingress.

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5.1.4 Hot drained hot oil shall be cooled prior to storage.

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5.1.5 Complete spare of hot oil inventory shall be made available in warehouse (i.e containers,
drums).

5.1.6
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Drained hot oil shall be confirmed its suitability for re-use to avoid contamination. Degraded
(aging, fouling or contaminated) hot oil shall be removed from the system
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5.1.7 Road tanker connection facility shall be provided for draining off cooled hot oil out the system.
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5.1.8 System shall be cleaned before fresh / new batch of hot oil is introduced.
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6.0 PIPING

DESIGN REQUIREMENT FOR PIPING

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

6.1.2 Piping shall be designed with carbon steel.

6.1.3 Piping connections shall be welded to avoid leakage. Flanged connections shall be minimized.
Leakage may occur due to formation of low boiling point components from reduction of hot
oil flash point.

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6.1.4 All low/high points of piping and fittings shall be equipped with hard piped drains and vents

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and routed as short as possible to closed drain system. Sight glass shall be made available at
the vent’s down-flow line.

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(PSR)
6.1.5 Piping shall be purged free from hydrocarbon and moisture prior to start-up using

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nitrogen.

6.1.6 Supply header from heater to hot oil consumer shall be as short as possible to reduce
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decomposition and degradation of hot oil due to prolong exposure to MOT.
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6.1.7 Large hot oil system shall consider Motor Operated Valve (MOVs) for sectionalising during
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leakage and emergency cases for inventory management.

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7.0 PUMPS

DESIGN REQUIREMENT FOR PUMPS

7.1.1 Pump shall be designed according to PTS 12.11.01.

7.1.2 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.

7.1.3 Circulation pump shall be designed on (n + 1) operating philosophy. 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

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across discharge check valve and be routed through pump casing drain.

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

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7.1.5 Pump shall be designed with the assumption that the hot oil vapour pressure is equal to the

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pressure of expansion vessel during normal operating temperature.
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8.0 INSTRUMENTATION AND CONTROL

DESIGN REQUIREMENTS FOR INSTRUMENTATION AND CONTROL

8.1.1 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.

8.1.2 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.

8.1.3 Heater outlet temperature shall be maintained via trim cooler. Heater outlet temperature and

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flow controllers will decrease return temperature controller’s set point; which will then
increase the flow thru trim cooler.

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8.1.4 If a WHRU is used as hot oil heater, heater outlet temperature is controlled via flow thru

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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

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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
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cooler bypass.

8.1.5 Alarm with trip setting shall (PSR) to be provided should the flow to the heater falls below
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minimum. Minimum circulation trip flow shall be set at 70% of minimum flow into the heater.
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8.1.6 Other control schemes and strategies may be proposed and subjected to Technical Authority’s
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approval.
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9.0 INSULATION

DESIGN REQUIREMENTS FOR INSULATION

9.1.1 Insulation requirement for hot oil system shall follows PTS 15.13.01.

9.1.2 No insulation or non-absorbent insulation type (e.g. foam glass) shall be considered at flanges,
joints, edge, and instruments connection. Closed cell Styrofoam (or similar) should be
considered for silicone-based hot oil. This is due to the fact that hot oil has a tendency to leak
and penetrate this potentially creep location thus accumulate inside the insulation. Hazard
such as sudden fires may occur due to temperature built-up within insulation and slow

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exorthemic oxidation at high temperature.

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10.0 STRAINERS AND FILTERS

DESIGN REQUIREMENTS FOR STRAINERS AND FILTERS

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

10.1.2 No permanent filter to be installed. Connection points with block valves shall be provided for
periodic line maintenance.

10.1.3 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. In these cases,

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minimum two filters (of 75µm to 100µm elements) shall be installed. Differential pressure
indicator shall be installed across the filters to monitor fouling.

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11.0 DRAIN SYSTEM

DESIGN REQUIREMENTS FOR DRAIN SYSTEM

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

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

11.1.3 Hot oil drain system shall (PSR) be independent and separated from plant drain system.

11.1.4 Piping drain should be installed underground and is solely for collection and draining of cooled

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down hot oil.

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

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

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11.1.7 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. Collecting
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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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12.0 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

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Reading Guide

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Design Conditions : Temperature, Pressure & Toxicity PTS 16.50.01

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Preparation of process flow schemes and process PTS 16.51.01
engineering flow schemes

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Heat Transfer Equipment Fouling Factor PTS 16.12.01

Handbook) lU
Thermal insulation (amendments/supplements to the CINI PTS 15.13.01
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Symbols and identification system - Mechanical PTS 12.00.02
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Separator: 2- Phase PTS 16.52.09

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Shaft sealing systems for centrifugal and rotary pumps PTS 12.12.03
(amendments/supplements to ISO 21049:2004)
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Pump – Type Selection And Basic Design Requirements PTS 12.11.01

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Piping - general requirements PTS 12.30.02

Piping classes – Refineries, Chemical And Gas Plants, PTS 12.31.01
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Onshore Exploration And Production Facilities

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Pipe supports PTS 12.30.04

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Instruments for measurement and control PTS 14.10.02

Control Valves : Selection, Sizing and Specification PTS 14.10.04
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Classification and implementation of instrumented PTS 14.12.10

protective functions
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APPENDIX 1: TYPICAL LAYOUT OF HOT OIL SYSTEM

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