Process Control Philosophy of

Hot Oil System

The hot oil system is a closed circuit heating system used to deliver heat to process heat
exchangers using hot oil as a heating medium. Hot oil fired heater (H-2701) provided to heat the
hot oil, is designed for 100% heat load. Fired heater will be on line and started manually from
field.
Hot oil fired heater requires a minimum flow of hot oil through the tubes to prevent the
development of hot spots, potentially leading to tube failure, and also to avoid degradation of the
oil.
A Hot Oil Dump Cooler (A-2701) is provided for managing rapid reductions in hot oil demand.

1. Hot Oil Header Pressure Control

1.1 Hot Oil Supply Header (250 °C) Pressure Control
A pressure controller PIC-2701-10 is provided at the hot oil supply header, which would monitor
and control the overall hot oil flow through the fired heater and dump cooler. Heater is started at
minimum load of 40 % heater duty (Turndown Duty). Once heater is taken online, the pressure
controller PIC-2701-10 is switched to auto mode and it will start increasing the hot oil flow through
the heater until the required hot oil flow is met. When demand decreases, the hot oil flow to heater
is reduced first to the minimum load of 40% of the heater duty. If the header pressure is still higher
due to sustained reduction in load of consumers or due to trip of any consumer heat exchanger,
the header pressure controller opens the letdown control valve PV-2701-10 in the dump line to
maintain the pressure of hot oil supply header.
If the heater main burner trip is activated (not due to leakage in tube), then it is not recommended
to stop the hot oil flow immediately. It is recommended to keep the hot oil flow at least higher than
the minimum flow rate until the pilots are also closed or keep the hot oil circulation until the main
burners’ operation is resumed. In the case of both main burners and pilots tripped, continue the
hot oil circulation for five more minutes. Then the hot oil circulation can be stopped.

2. Temperature Control
2.1 Hot Oil Supply Header (250℃) Temperature Control
Each individual consumer heat exchanger has demand control based on a measured process
parameter, temperature. The exchanger outlet process fluid temperature controller controls the
heat input by modulating on temperature control valve at the hot oil outlet. In the event of sudden
drop in flow or trip of the specific heat exchanger the supply header pressure tends to increase
and the corrective action as described under pressure control takes place.

2.2 Hot Oil Return Header (179℃) Temperature Control

Hot Oil Supply Header pressure controller PIC-2701-10 would letdown the excess material into
Hot Oil Dump Cooler, A-2701 in the event of pressure rise due to sudden drop out of some
consumers.
With the Hot Oil Dump Cooler, A-2701 the hot oil is cooled to 179℃ in air coolers prior to send to
hot oil to return header. The temperature of the cooler outlet is controlled by means of temperature
controller (TIC-2701-06) by adjusting fan blade pitch automatically by use of pneumatic actuator
for one fan and the blade pitch control of the second fan shall be manual. Moreover, manual
louver is also provided for further control.
It is recommended that at least one fan be in operation at all times to allow for any sudden
automated demand on the cooler.

3. Heater Controller Configuration

3.1 Flow Controller
The hot oil fired heater is provided with hot oil flow controller FIC-2703-04 for which the pressure
controller PIC-2701-10 provides set point depending on the demand of hot oil to consumers.
However at all the time, hot oil flow through fired heater shall not be less than the minimum flow
recommended by fired heater vendor (82160 kg/hr which is about 107 m3/hr at inlet temperature
of 179℃).

3.2 Temperature Controller

The fired heater hot oil outlet temperature is controlled by temperature controller TIC-2701-106,
which varies the LP fuel gas flow rate to the fired heater by pressure control valve on the LP fuel
gas supply to burners. The heater temperature controller maintains the hot oil outlet temperature
at 250℃.

4. Hot Oil Filtration Stream Control

2% of the overall hot oil circulation flow is filtered to prevent accumulation of solid materials in
the hot oil system and the associated fouling problems.
This slipstream is in parallel to the bypass from the pump discharge header to the hot oil return
header (pump suction) by means of RO. The flow is measured in FI-2701-01A.

5. Hot Oil Equipments Pressure Control

Hot oil expansion vessel (V-2702), Hot oil Drain Vessels (V-2701 & V-2703), Hot Oil Main
Circulation Pumps (P-2703 A/B) form part of the hot oil circulation system. The following section
describes the various control schemes associated with these equipment.

5.1 Vessels Pressure Control

The Hot Oil Expansion Vessel is provided with dedicated pressure control system to maintain
the equipment operating pressure. Self regulated pressure control valves PCV-2702-04 & PCV-
2702-05 are provided for inbreathing / out breathing application. Fuel gas blanketing is provided
for the above equipments to prevent air ingress and consequent flammable mixture of hot oil
vapour and air. The vapour from Expansion Vessel, V-2702, which is mainly fuel gas, is vented
to ground flare.

5.2 Hot Oil Pumps Minimum Flow & Discharge Pressure Control
The Hot Oil Main Circulating Pumps are provided with common minimum flow control FIC-2703-
01, which is cascaded with PIC-2703-03 to control PV-2703-03. This valve ensures that the pump
stable minimum flow is maintained during reduced or blocked Discharge condition.

5.3 Hot Oil Drain Pump Control

Both hot oil drain vessels, V-2701 & V-2703 have been provided to collect the hot oil from the
system in utility area and process area respectively. Both vessels are fitted with pumps, P-2701
& P-2702 respectively.