NIOEC-SP-00-72(1)

DOCUMENT CODE NO. OF PAGES: 8

PLAN/PRJ/SUB UNIT PHASE DISCIPLINE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG PR SP 0072 A1 JUNE 2017

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

PROCESS DESIGN OF
HOT OIL & TEMPERED WATER CIRCUITS

SECOND EDITION

JUNE 2017

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY.
 JUNE, 2017 NIOEC-SP-00-72(1)

IN THE NAME OF GOD

FOREWORD

By their very nature, technical Specifications are continuously subject to modifications and
revisions. To strengthen their merit and usefulness, continuous improvements, addendum, deletion
of disparate information and consequently provision of updated revisions are to be made in order to
ascertain that such Specifications meet the current requirements, inclusive of Iranian Petroleum
Standards (IPS) and the recognized and acceptable national and international Standards, as well as
the optimal codes and practices based on the accumulated in-house know-how and plant knowledge
and experiences.

However, in reality, due to several reasons, not to mention the complexity of the matter, the
ultimate goal of continuous direct embedment of the required changes on the relevant Specifications
may be far reaching. Therefore, in the interim periods between the officially issued revisions, the
required changes will appear in other documents related to the engineering and design work of the
on going projects.

In response to the initiative of the Design and Engineering Directorate, and considering that the task
of the execution of several important and mega projects for the realization of the new oil refineries,
pipelines and oil terminals as well as improvements of the existing facilities, has been assigned to
NIOEC, it was decided to update the NIOEC Specifications and to issue new official revisions.

The Design and Engineering Directorate was itself entrusted to carry out this important task, and as
such by forming several special technical committees, working in close co-operation and cohesion
and sharing their expertise and knowledge, the updated and revised NIOEC Specifications were
successfully prepared and complied.

These Specifications are intended to be used for Oil Refineries, Distribution Depots, Oil Terminals,
Pipelines and Pump Stations within NIOEC's projects, and have been proven to be of high value
for such purposes. It must however be appreciated that these Specifications represent the minimum
requirements and should in no way be interpreted as a restriction on the use of better procedures,
engineering and design practices or materials.

We encourage and highly appreciate the users and other clear sighted and experts to send their
comments on the Specifications to the Design and Engineering Director of NIOEC for evaluation
and approval.
 JUNE 2017 NIOEC-SP-00-72(1)

REVISION INDEX
REV. REV. REV. REV.
PAGE 1 2 3 4 5 PAGE
1 2 3 4 5 PAGE 1 2 3 4 5 PAGE 1 2 3 4 5
1 26 51 76
2 27 52 77
3 × 28 53 78
4 × 29 54 79
5 × 30 55 80
6 × 31 56 81
7 × 32 57 82
8 × 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100

NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL DOCUMENT.
3) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

2
1 JUNE, 2017 S.SHAKIBA M.H.MANSHADI M.KAREGAR NAJAFI M.KAREGAR NAJAFI
0 JULY, 2005 M.A.A.SAJEDI M.R.FARZAM M.A.A.SAJEDI
REV. DATE PREPARED CHECKED APPROVED AUTHORIZED
 JUNE 2017 NIOEC-SP-00-72(1)

CONTENTS: PAGE NO.

INTRODUCTION ...................................................................................................................... 2
1. SCOPE................................................................................................................................... 2
2. REFERENCES ..................................................................................................................... 2
3. UNITS (Modification) .......................................................................................................... 3
4. ADDENDUM TO IPS-E-PR-410 ........................................................................................ 3

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 JUNE 2017 NIOEC-SP-00-72(1)
INTRODUCTION
To satisfy the requirements of this NIOEC Specification, Iranian Petroleum Standard IPS-E-PR-410
May 2003 with the modifications as specified herein after shall be strictly followed.
Articles 1 and 2 of this document replace entirely the related articles in the referenced IPS Standard.

1. SCOPE
NIOEC specifications cover the general requirements for detailed engineering, procurements,
testing, inspection & construction of refinery/ oil plant, distribution depots, pump stations and
pipelines.
This NIOEC Specification is intended to cover the minimum requirements and recommendations
deem necessary to be considered in process design of "Hot Oil" and "Tempered Water" systems.
The scope is covered in two parts as:
Part I "Process Design of Hot Oil System"
Part II "Process Design of Tempered Water System"
Deviations from this Specification will only be permitted on obtaining written approval from
NIOEC.
Resolution on cases not explicitly stipulated in this Specification, or on cases where conflicts may
arise among the requirements of the referenced/relevant IPS and the international standards, shall be
made through written consent and approval of NIOEC.

2. REFERENCES
The following standards, codes, and specifications, to the extent specified hereinafter, shall
constitute a part if this NIOEC Specification. Latest edition of the undated referenced documents
and the cited edition of the dated references shall apply. The applicability of changes made to the
dated references, after the cited date shall be mutually agreed upon between NIOEC and the vendor/
contractor

ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

"ASME Code", Section VIII, Division 1

IPS (IRANIAN PETROLEUM STANDARDS)

IPS-E-PR-410 "Engineering Standard for Process Design of Hot Oil
& Tempered Water Circuits"

NIOEC-SP (NIOEC SPECIFICATIONS)

NIOEC-SP-00-10 "NIOEC Specification for Units"
NIOEC-SP-00-50 "NIOEC Specification for Process & Mechanics
Design Criteria"
NIOEC-SP-00-53 "NIOEC Specification for Layout & Spacing"
NIOEC-SP-44-01 "NIOEC Specification for Shell and Tube Heat
Exchangers"

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 JUNE 2017 NIOEC-SP-00-72(1)
NIOEC-SP-44-02 "NIOEC Specification for Air Cooled Heat
Exchangers"
NIOEC-SP-45-03 "NIOEC Specification for Fired Heaters"

2.1. Equivalent to IPS Standards

Substitute the following IPS Standards as referred to throughout IPS-E-PR-410 for the relevant
NIOEC's Specifications as follows:
IPS Standard Relevant NIOEC Specification
IPS-E-GN-100 NIOEC-SP-00-10
IPS-E-PR-190 NIOEC-SP-00-53
IPS-E-PR-440 NIOEC-SP-00-50
IPS-E-PR-771 NIOEC-SP-44-01
IPS-E-PR-785 NIOEC-SP-44-02
IPS-E-PR-810 NIOEC-SP-45-03
IPS-E-PR-850 NIOEC-SP-00-50

3. UNITS (Modification)
International system of units (SI) shall be used in accordance with NIOEC-SP-00-10, unless
otherwise specified.

4. ADDENDUM TO IPS-E-PR-410
This addendum revises the below listed articles of the referenced standard as follows:

5. SYMBOLS AND ABBREVIATIONS (MODIFICATION)

DM WATER = DEMINERALIZED WATER
HO = HOT OIL

5.1. Definitions and Terminology (Modification)

Expansion vessel: A vessel to accommodate expanded volume and surge of the hot oil.

Heater: The heat energy producer in the system, either a furnace or a waste heat recovery unit
(WHRU).

Hot oil: A mineral oil product stream used for heat transfer purposes.

Maximum allowable bulk temperature: The maximum bulk temperature of the HO allowed
anywhere in the circuit, as specified by the manufacturer.
Maximum film temperature: The maximum temperature to which the HO may be subjected in
the system. This highest temperature is on the tube inner wall of the heater skin and is
determined by the heat flux and heat transfer coefficient.
Maximum operating temperature: The maximum HO bulk temperature at which the system is
designed to operate and measured at the outlet of the heat source.
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 JUNE 2017 NIOEC-SP-00-72(1)
Minimum allowable bulk temperature: The minimum bulk temperature of the HO allowed
anywhere in the circuit, as specified by the HO manufacturer.
Minimum operating temperature: The lowest HO bulk temperature at which the system is
designed to start up. It should always be higher than the pumpability limit (fluid maximum
viscosity is 150 cm2/s).
Return temperature: The temperature at which the HO returns to the heat source.
Tempered Water: the DM water as a cooling medium for solutions that would freeze or
crystallize at usual cooling water temperatures is a common practice.

6.2.2. Disadvantages (Modification)

Low heat transfer properties

6.4.1. Heater Design (Modification)

6.4.1.12. Heaters shall be designed for uniform heat distribution. Multi pass heaters shall be
designed for hydraulic symmetry of all passes.
6.4.1.13. The number of passes for vaporizing fluids shall be minimized. Each pass shall be single
from inlet to outlet.
6.4.1.14. To provide sufficient operational flexibility and, in the case of organic fluids, allow for the
slowest possible degree of fluid ageing, the location of maximum HO film temperature
and peak heat flux should not coincide.

6.4.4. Heater Control and Instrumentation (Modification)

e) Stack low temperature alarm
h) Low/High draft alarm
- High combustible in stack alarm
- Loss of flame alarm
- Tube skin high temperature alarm

6.4.5. Hot Oil Surge Tank Design (Modification)

Purpose
The surge tank allows for thermal expansion of the HO and for venting low boiling
components generated in the HO during its ageing process, and is used to minimize the
consequences of upsets in the HO system operation. The designer shall take into account the
following:

6.4.5.4. The surge tank shall be provided complete with the following: (Addition)
h) DP gage and alarm
6.4.5.5. The need to accommodate the thermal expansion of the HO heated from minimum to
maximum operating temperature;
6.4.5.6. The need to maintain the required Net Positive Suction Head (NPSH) for the HO
circulating pumps under all operational scenarios;

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 JUNE 2017 NIOEC-SP-00-72(1)
6.4.5.7. The need to reduce the risk of HO loss into the flare system. In the event of a tube rupture
inside heat transfer equipment operating at process pressures above that of the HO circuit,
sudden displacement of fluid from the system into the vessel can result in HO loss into the
flare system.
6.4.5.8. Possible presence of water in the circuit during start-up;
6.4.5.9. The need for sufficient HO inventory to allow filling of equipment and during
recommissioning after shut down for maintenance.
6.4.5.10. The vessel and its piping should be designed for the full flow of the HO through the
vessel.
6.4.5.11. For operation at high temperatures, particularly approaching or exceeding the boiling point
of the HO, a positive pressure of at least 1 bar to 2 bar above the vapor pressure of the HO
(at this temperature) should be maintained.
6.4.5.12. The nitrogen supply shall be equipped with a split-range controller and a non-return valve,
which will regulate the nitrogen supply and its relief to flare.
6.4.5.13. A dead pressure zone is required between nitrogen supply pressure and relief to flare set
pressure. In this dead zone, the pressure is not controlled and is allowed to float freely
while the nitrogen supply and relief-to-flare valves are both closed. This dead zone will
reduce nitrogen consumption.
6.4.5.14. At a certain controller output, the relief-to-flare valve should be prevented from starting to
open while the nitrogen supply valve is not yet fully closed. (This could easily be the case
due to small valve misalignments.)
6.4.5.15. The non-return valve shall prevent HO and nitrogen back-flow into the nitrogen system in
the event of pressure increase in the vessel.
6.4.5.16. Low boiling degradation products shall be vented periodically. If regular venting of
vapours is unavoidable, the vent line should be routed through a condenser to the
collecting drum and flare, for further incineration or safe disposal.
6.4.5.17. The vessel shall be equipped with a safety relief arrangement capable of protecting the
system against over-pressure caused by fluid degradation, contamination, maloperation,
overheating or tube failure in equipment.
6.4.5.18. To allow for the pressure rise during steaming-out or purging the heater coils, relief
valve(s) shall be sized to accommodate a flow of steam or purge nitrogen equivalent to a
vapour velocity of 15 m/s in the heater coils. If necessary, the purge flow may be limited
by installing a restriction orifice in the common supply line.
6.4.5.19. If the ambient temperature can fall below the fluid’s or its degradation products’ freezing
points, or if accumulated high boilers can plug the lines, nitrogen, vent-back-pressure and
safety relief lines and valves shall be heat traced in order to prevent plugging.
6.4.5.20. If the ambient temperature can fall below the HO’s pumpability limit, heating the
expansion vessel should be considered. In order to eliminate the risk of HO contamination
in the event of coil rupture, either electrical heating or external heat tracing should be
applied.
6.4.5.21. Heating with steam or hot water should be avoided in order to minimize HO
contamination.
NOTE: The possibility to evacuate the total HO inventory would eliminate the need for a special
heating device for the vessel.
6.4.5.22. The expansion vessel shall be insulated.
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 JUNE 2017 NIOEC-SP-00-72(1)
6.4.9. Storage Tank (Addition)
HO storage tank shall have sufficient capacity to hold the full inventory of the system, plus
an additional 10% volume to accommodate make-up of losses caused by venting and
mechanical leaks.
The minimum fluid level in the tank shall be set to ensure sufficient NPSH for the make-up
pump. If the ambient temperature can fall below the HO minimum pump ability temperature,
the tank should be heated, preferably electrically, and the suction line to the pump should be
heat-traced and insulated. The storage tank shall be equipped with a dry nitrogen blanket to
serve as a barrier between the fluid and the atmosphere to limit degradation and moisture
ingress Sudden drainage of the hot HO to the storage tank (in case of emergency evacuation
of a part of or the whole fluid inventory) could result in excessive vapour release inside the
tank.
That shall be avoided either by installing a drop volume cooler (expensive option) or by
feeding the hot HO to the tank through a perforated pipe submerged in the cold fluid. The
latter option shall be designed so that there is thorough mixing of the hot fluid, giving rise to
rapid cooling and elimination of, or sufficient reduction in, vapour production. For the latter
option, this amount of cold HO shall be added to the minimum tank capacity as defined
above.

6.4.10. Piping (Addition)

6.4.10.1. Piping design and installation must include consideration to minimize vapor traps and to
relieve expansion and contraction stresses.
6.4.10.2. The number of flanges in a hot oil system should be minimized. To minimize the
possibility of leakage, the connections shall be welded as far as possible.
6.4.10.3. For systems with heaters arranged in parallel, sampling facilities shall be provided to
allow evaluation of hot oil degradation in the parallel loops.

6.4.11. Heat Exchangers (Consumers) (Addition)

6.4.11.1. If designed and operated properly, HO systems can be considered to be non-fouling, so U-
tube type heat exchangers may be applied if the HO flows inside the tubes. This is
cheaper than floating head type heat exchangers and significantly reduces the risk of
leakage and, consequently, contamination of the HO or process fluid.
6.4.11.2. To ensure proper design of the heat exchangers, the requisition sheet shall clearly mention
the type of HO to be used, or its trade name. For the design specification of HO systems a
fouling resistance of 0.00017 m2/kW shall be used.
6.4.11.3. If leakage of the HO into the process side (liquid or gas) could lead to hazardous
situations, the equipment design pressure shall be at least twice the highest working
pressure of the HO system. Flanged connections shall be avoided where possible.
6.4.11.4. All heat exchangers should be equipped with drains and vents to allow the HO to be
drained into a collection system from where it can be pumped back to the storage tank
(e.g. to allow maintenance of the system). To speed up the evacuation, a nitrogen purge
point may be considered.

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 JUNE 2017 NIOEC-SP-00-72(1)
6.4.12. Insulation (Addition)
Because of their low surface tension and low viscosity at operating temperatures, HOs have
a tendency to penetrate joints, gaskets and seals. This results in leaks that can lead to
accumulation of fluid inside insulation. Insulation materials such as mineral wool or similar,
when saturated with organic HOs, can cause slow exothermic oxidation starting at
temperatures above 250 °C. The large internal surface area, poor heat dissipation and the
possible catalytic activity of the insulation material may cause significant temperature
buildup within the insulation mass. Such slow reaction may progress undetected and may
lead to unsafe situations such as sudden fires when cladding is damaged or opened for
maintenance.
Non-absorbent insulation (e.g. foam glass) shall be used at potential fluid ‘creepage’
locations (instrument connections, valve stems, flanges and joints). For silicone-based fluid,
closed cell styrofoam (or similar) may be used.

6.5. Performance Guarantees (Modified)

6.6. Specific Project Requirements (Modified)

FIG.1. Typical Hot Oil System (Modified)

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FIG.2. Typical Physical Properties Of Hot Oil (Modified)

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 IPS-E-PR-410

ENGINEERING STANDARD

FOR

PROCESS DESIGN OF HOT OIL

AND

TEMPERED WATER CIRCUITS

ORIGINAL EDITION

MAR. 1996

This standard specification is reviewed and

updated by the relevant technical committee on
May 2003. The approved modifications are
included in the present issue of IPS.

This Standard is the property of Iranian Ministry of Petroleum. All rights are reserved to the owner.
Neither whole nor any part of this document may be disclosed to any third party, reproduced, stored in
any retrieval system or transmitted in any form or by any means without the prior written consent of the
Iranian Ministry of Petroleum.
 Mar. 1996 IPS-E-PR-410

CONTENTS : PAGE No.

0. INTRODUCTION ............................................................................................................................. 2
1. SCOPE ............................................................................................................................................ 3
2. REFERENCES ................................................................................................................................ 3
3. DEFINITIONS AND TERMINOLOGY ............................................................................................. 3
4. SYMBOLS AND ABBREVIATIONS ............................................................................................... 3
5. UNITS.............................................................................................................................................. 4

PART I PROCESS DESIGN OF HOT OIL SYSTEM

6. PROCESS DESIGN OF HOT OIL SYSTEM................................................................................... 5

6.1 General..................................................................................................................................... 5
6.2 Hot Oil Heater .......................................................................................................................... 5
6.3 Design ...................................................................................................................................... 6
6.4 Performance Guarantees ....................................................................................................... 9
6.5 Specific Project Requirements .............................................................................................. 9

PART II

7. PROCESS DESIGN OF TEMPERED WATER SYSTEM............................................................. 13

7.1 General................................................................................................................................... 13
7.2 General Layout and Operational Facilities ......................................................................... 13
7.3 Process Design Requirements ............................................................................................ 13

FIGURES :

FIG. 1 TYPICAL HOT OIL SYSTEM.............................................................................................. 11

FIG. 2 TYPICAL HEAT TRANSFER PROPERTIELS OF HOT OIL
(POLYPHENLY ETHER) ... ................................................................................................ 12

TABLES :

TABLE 1 - DATA IN DRAWING ....................................................................................................... 14

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 Mar. 1996 IPS-E-PR-410

0. INTRODUCTION
The primary purpose of IPS standard specifications on "Process Design of General Heating &
Cooling Systems" is to establish minimum requirements and design criteria needed in process
design of the following standards:

STANDARD CODE STANDARD TITLE

IPS-E-PR-400 "Process Design of Cooling Water Circuits"
IPS-E-PR-410 "Process Design of Hot Oil & Tempered Water Circuits"
IPS-E-PR-420 "Process Design of Heat Tracing and Winterizing"
This Engineering Standard Specification covers:

"PROCESS DESIGN OF HOT OIL & TEMPERED WATER CIRCUITS"

Thermal liquids are used for process heating and cooling in the form of liquid, vapor or a
combination of both. In addition to steam, thermal liquid include, hot and tempered water, mercury,
Na, K, Dowtherms A and E, molten salt mixtures, hot oils and many others, each of which can be
used for a specified field of application and can operate in different temperature ranges.

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 Mar. 1996 IPS-E-PR-410

1. SCOPE
This Standard Specification is intended to cover the minimum requirements and recommendations
deem necessary to be considered in process design of "Hot Oil" and "Tempered Water" systems.
The scope is covered in two parts as:

Part I "Process Design of Hot Oil System"

Part II "Process Design of Tempered Water System"

Note:
This standard specification is reviewed and updated by the relevant technical committee on
May 2003. The approved modifications by T.C. were sent to IPS users as amendment No. 1
by circular No. 221 on May 2003. These modifications are included in the present issue of
IPS.

2. REFERENCES

Throughout this Standard the following dated and undated standards/codes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this standard. For dated
references, the edition cited applies. The applicability of changes in dated references that occur
after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated
references, the latest edition of the referenced documents (including any supplements and
amendments) applies.

IPS (IRANIAN PETROLEUM STANDARDS)

IPS-E-PR-190 "Layout and Spacing"
IPS-E-PR-440 "Process Design of Piping Systems (Process Piping & Pipeline Sizing)"
IPS-E-PR-771 "Process Requirements of Heat Exchanging Equipment"
IPS-E-PR-785 "Process Design of Air Cooled Heat Exchangers (Air Coolers)"
IPS-E-PR-810 "Process Design of Furnaces"
IPS-E-PR-850 "Process Requirements of Vessels, Reactors and Separators"

ASME (THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

"ASME Code", Section VIII, Division 1

3. DEFINITIONS AND TERMINOLOGY

Not particular definition is implemented.

4. SYMBOLS AND ABBREVIATIONS

ASME = The American Society of Mechanical Engineers
CWS = Cooling Water Supply
CWR = Cooling Water Return
DP = Differential Pressure
DT = Differential Temperature

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 Mar. 1996 IPS-E-PR-410

FCV = Flow Control Valve

LHV = Low Heat Value
LIC = Level Indicator Controller
LG = Level Gage
OGP = Oil, Gas and Petrochemical
OD = Outside Diameter
PI = Pressure Indicator
TCV = Temperature Control Valve
TEMA = Tubular Exchanger Manufacturers Association, Inc
TI = Temperature Indicator
TIC = Temperature Indicator Controller
TT = Temperature Transmitter

5. UNITS
This Standard is based on International System of Units (SI), except where otherwise is specified.

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 Mar. 1996 IPS-E-PR-410

PART I
PROCESS DESIGN OF HOT OIL SYSTEM

6. PROCESS DESIGN OF HOT OIL SYSTEM

6.1 General

6.1.1 A simplified schematic of major components of a hot oil system is given in Fig. 1. The heat
transfer medium is pumped through a fired heater to the heat exchanger and returns to the pump
suction surge tank. In some cases a fired heater may be replaced by a waste heat source, such as
the exhaust stack of a gas turbine.
6.1.2 While the system is ordered and designed as a packaged system, all necessary equipment
such as ladders, and platforms, guards for moving parts, etc., shall be supplied as part of the
package.
6.1.3 Indoor equipment shall be suitably protected against damage by infiltration of moisture and
dust during plant operation, shutdown, wash down, and the use of fire protection equipment.
6.1.4 Outdoor equipment shall be similarly protected, and in addition, it shall be suitable for
continuous operation when exposed to rain, snow or ice, high wind, humidity, dust, temperature
extremes, and other severe weather conditions.
6.1.5 The system shall be laid out such that to make all equipment readily accessible for cleaning,
removal of burners, replacement of filters, controls and other working parts and for adjustment and
lubrication of parts requiring such attention. For similar reasons, the heater front and rear doors
shall be hinged or deviated.
6.1.6 Maintenance tools specially designed for the equipment shall be furnished with the system.
6.1.7 Spare parts must be readily available. If a stock of parts is not maintained by the
manufacturer, critical spare items shall be furnished with the system.

6.2 Advantages and Disadvantages of Hot Oils

6.2.1 Advantages
The advantages of hot oils are:
- Low vapor pressure at ambient temperature.
- Always liquid and easy to handle.
- Blended for a specific temperature range.
- Higher specific heat than normally occurring hydrocarbons.

6.2.2 Disadvantages
The disadvantages of hot oils include:
- Escaping vapors are environmentally undesirable.
- When overheated, the oils will oxidize and coke on the fire tube. Also, they can be ignited.
- Ethers if used, are expensive.
- Ethers are hydroscopic and must be kept dry.

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 Mar. 1996 IPS-E-PR-410

6.3 Hot Oil Heater Application

These heaters furnish a heating bath 300°C or higher, which is hot enough for process applications
such as dry desiccant or hydrocarbon recovery regeneration gas. Another less severe application is
heavier hydrocarbon vaporization prior to injection into a gas pipeline to raise the heating value.
Manufactured heat transfer oils are blended for about 90-95°C operating range. For example, Fig.
2, gives typical heat transfer properties for a 150 to 300°C polyphenyl ether.

6.4 Design
The following features and criteria shall be considered in process design of each component of the
hot oil system.

6.4.1 Heater design

6.4.1.1 Process design of the heater is critical for satisfactory operation. The heat transfer fluid must
have sufficient velocity, generally 1.2 to 3 m/s, to avoid excessive film temperatures on the heater
tubes.
6.4.1.2 Design and capacity of the heater should be limited so that the maximum film temperature
does not exceed the maximum recommended operating temperature of the fluid.
6.4.1.3 Hot spot occurrence should be avoided, since it can lead to tube failure and fluid
degradation.
6.4.1.4 The heater shall be rated for the specified output. Multiple identical units may also be
employed for the designed total heat load, but care shall be taken in system design to ensure
adequate and proportional flow through the heaters.
6.4.1.5 The preferred thermal efficiency of the heater to be 80% based on LHV of fuel. The
contractor shall specify the expected and guaranteed values for the thermal efficiency and the basis
for their estimation.
6.4.1.6 Based on total outside surface area of the firetube(s) and the return flue(s), the average
heat flux shall not exceed 17.35 kJ/s.m². The flame characteristics and combustion chamber design
shall ensure that the maximum heat flux at any point is limited to 23.66 kJ/s.m².
6.4.1.7 Heating medium (hot oil) shall clearly be specified and it’s discharge temperature from the
heater shall be limited to a specified value, in data sheet.
6.4.1.8 Under normal operating conditions, the rise in heating medium temperature across the
heater shall not exceed the allowable DT specified in the data sheet.
6.4.1.9 The heater shall be designed to give an efficient heater operation over the complete
operating load range.
6.4.1.10 Each heater (in case the use of multi-heater units), shall have a self-supporting stack
designed to carry the total exhaust under the maximum firing conditions.
6.4.1.11 In general reference should be made to IPS-E-PR-810, "Process Design of Furnaces" for
design of heater and auxiliary systems.

6.4.2 Firing system design

6.4.2.1 The hot oil heater shall be designed for a continuous and reliable operation.
6.4.2.2 The burner(s) shall be designed for a minimum of 120 percent of normal full load firing and
be suitable for firing the specified fuels (oil, gas or both) without undue maintenance or adjustment.
6.4.2.3 In case of a forced-draft type heater the burner design shall incorporate air/fuel ratio
system(s) to ensure complete combustion with minimum amount of excess air. The air/fuel ratio

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 Mar. 1996 IPS-E-PR-410

system shall be effective throughout the burner firing range i.e., from low to high fire positions.
6.4.2.4 The burner nozzles and other parts exposed to the radiant heat of the combusion chamber
shall be made from heat resisting alloy steel.
6.4.2.5 The burner fuel and air openings shall be arranged to provide suitable velocities for
complete mixing resulting in efficient combustion of the fuel.
6.4.2.6 Each burner shall have observation ports to permit sighting and inspection of the flame.
6.4.2.7 Suitable ignitor(s) shall be provided for firing fuel oil or gas and shall be of adequate output
to permit safe ignition of the fuel.

6.4.3 Combustion air fan design

In case of forced-draft type heater the following should be considered:
6.4.3.1 The fan shall be designed for maximum ambient temperature.
6.4.3.2 The fan(s), performance shall be stable over the complete firing range i.e., maximum firing
down to shut off.
6.4.3.3 Inlet screens shall be provided at fan(s) inlet.
6.4.3.4 Combustion air fan(s) shall be sized to handle a minimum of 120 percent of the normal full
quantity of combustion air.
6.4.3.5 Outlet ducts of air fan (s) shall have some equipment like damper(s) for adjustment of the
amount of intake air to the heater.

6.4.4 Heater control and instrumentation

The heater package shall be provided with the following control and instrumentation as minimum:
a) Fuel gas/oil control system complete with:
- pressure gages in important locations;
- pressure regulators;
- pressure relief valves;
- flow control valves(s) on heater inlet line;
- strainers;
- isolating valves.
b) Fuel gas/oil emergency shut-off valve.
c) Heater TIC (modulating type) for hot oil temperature control.
d) Heater manual control for fire regulation.
e) Temperature switches shall be supplied for the following alarm and shutdown functions:
- hot oil high temperature alarm;
- hot oil high high temperature shutdown;
- hot oil low temperature alarm;
- stack high temperature alarm;
- fuel oil low temperature alarm.
f) Pressure switches shall be supplied for the following alarm and shutdown functions:
- hot oil high pressure alarm;
- hot oil low pressure alarm;
- *fuel gas/oil high supply pressure alarm;
- *fuel gas/oil high supply pressure shutdown;
- *fuel gas/oil low supply pressure alarm;
- *fuel gas low low supply pressure shutdown.
g) Flow switches installed on the flow transmitter output shall be supplied for the following
functions:

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 Mar. 1996 IPS-E-PR-410

- turning Unit down to low flame position on low flow condition;

- shutting Unit down (including circulation pumps) on low low flow condition.
h) Additionally, the following instrumentation shall be provided on the hot oil heater:
- pressure gage complete with isolation and bleed valve;
- temperature indicators complete with thermowells for hot oil inlet and outlet streams;
- stack exhaust temperature indicator complete with thermowell;
- ASME rated relief valve(s), factory set and sealed and located suitably. Relief valves shall
have stainless steel trim.
i) Automatic start up/shutdown sequence control is normally not recommended, but if specified
by the Company shall consist of:
- pre-ignition purge of the combustion chamber;
- ignition;
- pilot proving;
- firing rate modulation between low flame position and the maximum output;
- post purge after shutdown.
j) The burner management system if specified by the Company shall be housed in a locally
mounted panel, suitable for the area classification in which it is installed.
k) The burner management system shall incorporate a remote shutdown facility so that the main
burner(s) and pilot(s) can be extinguished by a push-button located in central control room.
l) All other instrument, and controlling systems as per Vendor specification such as flame failure
detector, pilot flame monitoring etc., should also be considered.
* Pressure switches shall be installed on each fuel supply line.

6.4.5 hot oil surge tank design

6.4.5.1 A surge tank shall be provided, suitably sized to handle expansion of inventory in whole
system, and shall be designed as a pressure vessel in accordance with IPS-E-PR-850.
6.4.5.2 The surge tank shall be arranged on the pump suction side and shall be blanketed with fuel
gas or inert gas.
6.4.5.3 The surge tank shall be located inside the heater building.
6.4.5.4 The surge tank shall be provided complete with the following:
a) Level gage(s), spanning the entire operating range.
b) Pressure gage.
c) Pressure relief valve.
d) Blanket gas pressure make-up regulator.
e) Pressure regulator to vent tank over pressure due to expansion or filling.
f) Make-Up connection complete with isolation valve and non-return valve.
g) Level alarm high and low.

6.4.6 Circulating pump design

6.4.6.1 At least two centrifugal pumps (one operating and one spare) with 10% over design capacity
at the design head shall be provided. However the following requirement shall also be considered in
design.
6.4.6.2 Strainer shall be provided at the suction of each pump.
6.4.6.3 Valving around each pump shall include the following:
a) Suction isolation gate valve of the same size as the suction line.
b) Non-Return valve in discharge line.

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 Mar. 1996 IPS-E-PR-410

c) Isolation gate valve in discharge line.

d) Casing vent and drain valves.
6.4.6.4 In design of pump suction and discharge lines, the differential thermal expansion of the lines
due to temperature variation shall be taken into account.

6.4.7 hot oil filter

6.4.7.1 A hot-oil filter shall be provided to handle a slipstream equal to 10% of the design flow rate.
6.4.7.2 The filter shall be of disposable cartridge type, capable of removing all solid particles above
5 micrometers (microns).
6.4.7.3 The hot-oil filter shall be provided complete with the following:
a) DP gage.
b) Isolation valves at inlet and outlet.
c) Restriction orifice, sized for the required flow rate.
d) Vent and drain valves.
e) Relief valve.
f) Filter by-pass line.

6.4.8 Carbon filter

6.4.8.1 A bulk-pack type carbon absorber in consistent with the heating medium should be provided
downstream of the heating medium filter to remove any products of degradation.
6.4.8.2 The design flow rate of carbon filter shall be the same as the hot-oil filter flow-rate.
6.4.8.3 The carbon filter shall be provided complete with the following:
a) DP gage.
b) Isolation valves at inlet and outlet.
c) Vent and drain valves.
d) Relief valve.
e) Filter by-pass line.

6.4 Performance Guarantees

6.4.1 The Vendor, unless he expressly states any exceptions in his proposal, shall specify the
guarantees on which the system furnished by him to meet the requirement with regard to process
design, as flow rate, hot-oil delivery pressure and temperature, safety and reliability under all
specified operating conditions.

6.5 Specific Project Requirements

6.5.1 The Vendor shall specify the following data and information as the "Specific Project
Requirements" in his proposal.
• Project: …............................................................................................................
• Location: ..................................Elevation ......................................................... m
• Environment: .......................... non-corrosive.................corrosive .....................

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 Mar. 1996 IPS-E-PR-410

• Barometric pressure................ kPa (abs)

• Heat transfer medium fluid ..................................................................................
• Concentration: .........................................mass% in water
• Circulation rate: .........................................................m³/h
• Pump differential .........................................................kPa
• Temperature of heat transfer fluid to heater: ........................................... °C
• Temperature of heat transfer fluid from heater: ....................................... °C
• Design circulation rate: ..........................................................................m³/h
• Design pump differential: ........................................................................kPa
• Design temperature, heater outlet: .......................................................... °C
• Design, heater duty: .............................................................................MJ/h
• System Design pressure: ...............................kPa (ga)at ....................... °C
• Maximum pressure drop accross heater: ……….................................... kPa
• Surge tank:.............................. Required.............................Not required
• Circulation pump: .....................Required.............................Not required
• Hot oil filter: ..............................Required..............................Not required
• Carbon adsorber: .....................Required..............................Not required
• Supply header size:...................................................... mm
• Return header size:.......................................................mm
• System capacity, excluding heater package: ................................ m³
• Instrument air: ....................Instrument gas
- Supply pressure..................... kPa (ga) normal
- Design pressure .................... kPa (ga) at ................................ °C
• Area classification:
• Fuel gas.......................... sweet ...............................sour
- Supply pressure .................................kPa (ga) normal
- Design pressure .................................kPa (ga) at ..................... °C
- Relative density (specific gravity) (Air=1.0)….. Molecular mass (MW)..........
•Composition: .......................................................................................................
..............................................................................................................................
..............................................................................................................................
...............................................................................................................................

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 Mar. 1996 IPS-E-PR-410

TYPICAL HOT OIL SYSTEM

Fig. 1

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 Mar. 1996 IPS-E-PR-410

TYPICAL HEAT TRANSFER PROPERTIES OF HOT OIL (POLYPHENYL ETHER)

Fig. 2

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 Mar. 1996 IPS-E-PR-410

PART II
PROCESS DESIGN OF TEMPERED WATER SYSTEM

7. PROCESS DESIGN OF TEMPERED WATER SYSTEM

7.1 General

7.1.1 Using tempered water as a cooling medium for solutions that would freeze or crystallize at
usual cooling water temperatures is a common practice.
7.1.2 A special tempered water circulating system shall be designed to minimize the chance of
fouling by deposition of these type materials on heat exchanger surfaces.
7.1.3 Condensate or treated process water shall be used as circulating tempered water, the water
should efficiently be treated for corrosion inhibition according to material specification and design
procedures. Provisions for corrosion inhibitor facilities shall be made. Tempered water system
typically consists of a surge drum, circulating pumps, air cooler and/or shell-tube heat exchanger
and associated piping and measuring devices.
7.1.4 Single or multiple user(s) may be incorporated in a single tempered water system. All
components of the system should accordingly be designed to maintain required cooling load
capacity when all or parts of the user(s) are in operation.
7.1.5 The water return from the various users shall be cooled to specified temperature depending
on the local climatic conditions.
7.1.6 All applicable parts of general requirements set forth in Clause 6, "Part I" of this Standard shall
be considered for this part unless is in contrary with Vendor specification.

7.2 General Layout and Operational Facilities

7.2.1 For layout and operation of the system, Vendor should take into account an adequate space
being allowed for operational access, cleaning and maintenance.
7.2.2 The arrangement of installations should be such that, instruments and indicators can readily
be seen from the appropriate working position. Valves and controls should be nearly arranged and
accessible.
7.2.3 In case the system admitted for indoor installation, access facilities should be so arranged that
major items of the system can be brought in and taken out or removed as necessary.
7.2.4 Applicable provisions of IPS-E-PR-190, should also be considered in system layout design by
the Vendor.

7.3 Process Design Requirements

7.3.1 General

7.3.1.1 Design of the system and it’s associated controls should take into account the following:
a) The nature of the application.
b) The type of installation i.e., indoor or outdoor installation.
c) Cooling load patterns.

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 Mar. 1996 IPS-E-PR-410

d) Tempered water supply requirements.

e) Economic factor and minimizing the use of primary energy.

7.3.2 Surge drum

7.3.2.1 The Pressurized type surge drums for required capacity shall be designed in accordance
with IPS-E-PR-850. Atmospheric surge tanks shall be designed as per API-650 with steam
blanketing system for oxygen removal.
7.3.2.2 Make up water to surge drum will be taken from condensate system, moderately heated to
required temperature by hot condensate circulation and chemical treatment should be practiced to
minimize corrosion.
7.3.2.3 The drum should be blanketed with steam. Provisions shall be considered for automatic
controlling of water level and adding make-up water as required.
7.3.2.4 The pressurized type surge drum operating above 7.0 kPa shall have a minimum design
pressure of 110 kPa (abs). The drum shall be designed for full vacuum.
7.3.2.5 All applicable loads, including wind load, earthquake and hydrostatic testing load shall be
considered in design as acting simultaneously.
7.3.2.6 All outline drawing shall be furnished and shall contain the data indicated in Table 1 below.
Location of the drum marking or nameplate shall be indicated on this drawing.

TABLE 1 - DATA IN DRAWING

DESCRIPTION UNIT DATA
·Design pressure kPa ----
·Design temperature °C ----
·Operating pressure kPa ----
·Operating temperature °C ----
·Maximum allowable stress at design temperature kPa ----
·Hydrostatic test pressure at uppermost part of drum kPa (ga) ----
·Hydrostatic test temperature °C ----

7.3.2.7 A manufacturer’s data report shall be furnished and shall contain the same information as
required by form U-1 of ASME Code, Section VIII, Division 1.
7.3.2.8 Provisions for entering, cleaning, venting and draining of vessel shall be considered on the
bases of basic practice as specified by the Vendor/manufacturer.
7.3.2.9 Surge drum shall be furnished with following auxiliaries:
a) Pressure gage.
b) Temperature gage.
c) Level gage.
d) Steam blanketing regulator.
e) All inlet, outlet piping nozzles.

7.3.3 Circulating/recirculating centrifugal pumps

7.3.3.1 The circulating and recirculating pumps shall be centrifugal with 100% spare and shall be
designed in accordance with the following requirements:
a) Unless otherwise specified, the pumps and auxiliaries shall be suitable for unsheltered

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 Mar. 1996 IPS-E-PR-410

outdoor installation in the climatic zone specified.

b) Flanged suction and discharge nozzles shall be integral with the casing.
c) Gate valves shall be used for vents and drains.
d) All required vents shall be valved.
e) Nameplate data shall be in SI units.
f) Vendor’s piping shall terminate with a flanged or threaded connection, of a line rating at least
equal to the design pressure and design temperature rating of the equipment.
g) Vendor shall specify the spare parts and shall include his proposed method of protection from
corrosion during shipment and subsequent storage.
h) Vendor’s proposal shall state the minimum flow rate recommended for sustained operation on
the specified tempered water.
i) Isolation gate valves shall be used at suction and discharge line with the same respective line
size.
j) Non-return valves shall be installed in discharge lines.
k) Globe valve shall be sized for blanketing line.
7.3.3.2 The pumps shall be of proven modern design and shall have operating characteristics as
specified in pump data sheet.
7.3.3.3 The arrangement of equipment, including piping and auxiliaries shall provide adequate
clearance area and safe access for operation and maintenance.
7.3.3.4 The equipment and component parts shall be warranted against defective materials, design
and workmanship for specified guaranteed period.

7.3.4 Cooler

7.3.4.1 Unless otherwise required, air cooler shall be used in tempered water system, in
accordance with IPS-E-PR- 785.
7.3.4.2 In case shell-tube heat exchanger is required, its design shall be in accordance with IPS-E-
PR-771.

7.3.5 Piping design

7.3.5.1 All applicable portions of IPS-E-PR-440 shall be considered in pipe sizing and design of the
tempered water system. It shall apply to auxiliary piping connecting the equipment of the system
and the piping between the system and the consuming Units. However, the following considerations
shall be admitted to accomplish the whole requirements of piping process design.
1) In piping layout, the location of operating and control points such as valves, flanges,
instruments, vents and drains shall enable operation of the system with minimum difficulties.
2) The piping system shall be laid out to allow easy repair or replacement of any portion of the
system.
3) Basic design data for each line shall be given in the line designation table as per Company’s
project specification.
4) The actual minimum corrosion allowance shall be listed for each line in the line designation
table.
5) Flanges or other removable connections shall be provided throughout the piping system to
permit complete removal of the piping.

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 Mar. 1996 IPS-E-PR-410

6) A gate valve shall be installed in each instrument take-off connection except thermowells and
shall be located close to the pipe.
7) All piping connections to equipment shall be suitable for the equipment design and the
hydraulic test pressure.

7.3.6 Other requirements

7.3.6.1 The whole system should be arranged and sized so that the design-cooling load can be met
by an appropriate flow of tempered water within the applicable system temperature limits.
7.3.6.2 Circulating piping should be thermally insulated and traced where local climatic condition
implies.
7.3.6.3 Isolating valves are normally fully open or fully shut and should be provided to facilitate
isolation of individual items of equipment.
7.3.6.4 An appropriate and compatible automatic controls should be arranged for the system
elements.

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