SimCentral™ Simulation Platform

U6 - Hot Oil Network

Version 4.1
December 2019
© 2019 AVEVA Group plc and its subsidiaries. All rights reserved.

No part of this documentation shall be reproduced, stored in a ret rieval system, or transmitted by any
means, electronic, mechanical, photocopying, rec ording, or otherwise, without the prior written
permission of AVEVA. No liability is assumed wit h respect to the use of the information c ontained herein.
Although precaution has been taken in the preparation of this documentation, AVEVA assumes no
responsibility for errors or omissions. The information in this documentation is subject to change without
notice and does not represent a commitment on the part of AVEVA. The soft ware described in this
documentation is furnished under a license agreement. This soft ware may be used or copied only in
accordance with the terms of such license agreement.
ArchestrA, Aquis, Avantis, Citect, DYNSIM, eDNA, EYESIM, InBatch, InduSoft, InStep, Int elaTrac,
InTouch, OASyS, PIPEPHASE, PRiSM, PRO/II, PROV ISION, ROMeo, SIM4ME, SimCentral, SimSci,
Skelta, SmartGlance, Spiral Software, Termis, WindowMaker, WindowViewer, and Wonderware are
trademarks of AVEVA and/or its subsidiaries. An extensive listing of AVEVA trademarks can be foun d at:
https://sw.aveva.com/legal. All other brands may be trademarks of their respective owners.
Publication date: Tuesday, October 22, 2019
Contact Information
AVEVA Group plc
High Cross
Madingley Road
Cambridge
CB3 0HB. UK
https://sw.aveva.com/
For information on how to cont act sales, customer training, and technical support, see
https://sw.aveva.com/contact.
Acknowledgements
CSPARSE
To analyze and report proper variable specification, SimCent ral Simulation Platform makes use of
CSPARSE, a library of direct methods for sparse linear systems by Timothy Davis. CSPARSE is free
software and is distribut ed under the GNU Lesser General Public License
(http://www.gnu.org/licenses/lgpl.html) as published by the Free Software Foundation.
The source code for CSPARSE is available at
http://people.sc.fsu.edu/~jburkardt/c_src/csparse/csparse.html.
KLU
SimCent ral Simulation Platform us es KLU as its linear equation solver. KLU is an open-source solver
package with a focus on solving sparse linear systems of equations. Timothy A. Davis distributes KLU as
part of the SuiteSparse software (http://www.suitesparse.com) under the GNU Lesser General Public
License and a University of Florida copyright.
 SimCentral™ Simulation Platform U6 - Hot Oil Network

Contents
Acknowledgements .................................................................................................................. 3
Hot Oil Network......................................................................................................................... 7
Hot Oil Network Revision Log .................................................................................................. 7
Summary .................................................................................................................................. 7
Process Description .................................................................................................................. 8
Simulation Model ...................................................................................................................... 8
Library ................................................................................................................................ 8
Fluids ................................................................................................................................. 8
Mode Summary ................................................................................................................... 8
Process Mode ..................................................................................................................... 9
Fluid Flow Mode.................................................................................................................. 9
Dynamics Mode ................................................................................................................ 10
Results ................................................................................................................................... 10
Results Process Mode..................................................................................................... 10
Fluid Flow Mode................................................................................................................ 11
Dynamics Mode ................................................................................................................ 11
Snapshots ........................................................................................................................ 16
Excel Report ..................................................................................................................... 16
Referenc es ............................................................................................................................. 16

Version 4.1 5
 SimCentral™ Simulation Platform U6 - Hot Oil Network

Hot Oil Network

Revision Log
Date Who Change

11 Aug 2016 DK Initial release for SimCentral 1.5.

9 Dec 2016 SK Updates for SimCentral 1.6.

30 Dec 2016 SK Updates for SimCentral 1.7.

3 May 2017 DK Updates for SimCentral 2.0.

Please note that from time to time we make changes to SimCentral Simulation Plat form and the example
simulations. These changes may not be reflected in this document for every SimCentral Simulation
Platform soft ware release. There may be modeling details t hat are different, screenshots that do not
match, and numerical answers that are different. We will update the examples in a future version of
SimCent ral Simulation Platform.

Summary
Hot oil net works are used in process industries to trans fer thermal energy by using a non-boiling heat
transfer fluid. Hot oil net works use a liquid heat trans fer fluid that does not boil at high temperat ures
where water boils. They may be preferable over steam where steam is not readily available.
The objective of this simulation is to:
 Design a hot oil net work for the specified duty and outlet temperatures of the process -side heat
exchangers.
 Determine the load on the bypass valve if you shut down one of the proc ess consumers for
maintenance.
 Determine the load on the proc ess consumers if the temperature of the hot oil increases or
decreases.
 Determine the total hot oil flow if only one of two available pumps is operating.
 Validate the temperature control strategy by using dynamic simulation.

Version 4.1 7
SimCentral™ Simulation Platform U6 - Hot Oil Network Hot Oil Network

The following figure shows the schematic diagram of the Hot Oil Net work system, as modeled in
SimCent ral Simulation Platform.

Process Description
The hot oil system is a closed-loop heating system that uses a fired heater as the primary heat source. A
makeup line from a storage tank supplies hot oil to the system. Circulator pumps then feed the hot oil to
the fired heater, which heats the hot oil to a temperature of 400°C and supplies it to all process
consumers. After the heat exchange, hot oil returns to the main line through the expansion tank, which
creates a closed loop.
The design requirements are:
 The temperature of the process consumer is 220°C.
 The temperature of the hot oil that returns to the circulator pumps is 100°C.
 The heat trans fer fluid is based on DowTherm™ A.

Simulation Model
Library
This simulation uses the CWLib library.

Fluids
3
This simulation uses the DowTherm™ A fluid as an incompressible fluid with a density of 994 kg/m and
a specific heat of 1.8 kJ/kg-K.

Mode Summary
The following table provides a summary of the simulation operation in all three modes:

Process Fluid Flow Dynamics

Purpose Size the pipes for Determine the actual Perform dynamic
required flow rates. flow distribution studies.
Check the heat through the network.
exchanger outlet
temperatures.

Pumps Estimate the pressure Operate based on Operate based on

rise. performance curve. performance curve.

8 Version 4.1
Hot Oil Network SimCentral™ Simulation Platform U6 - Hot Oil Network

Process Fluid Flow Dynamics

Pipes Calculat e the diameter Set the inside diameter Set the inside diameter
to check nominal pipe based on nominal pipe based on nominal pipe
size requirements. size. size.

Mixers Use the minimum of Set all inlet and outlet Set all inlet and outlet
inlet pressures. pressures the same. pressures the same.

Splitters Set the split fraction to Calculat e the split Calculat e the split
the required flow rate. fraction based on the fraction based on the
flow from the system flow from the system
hydraulics. hydraulics.

Heat Exchangers Specify the required Calculat e the actual Calculat e the actual
flow for the required flow based on flow based on
heat transfer. Check reference conditions. reference conditions.
the outlet temperature.

Flow Controller Calculat e the set point Calculat e the process Adjust the controller
and process variable variable based on output position with
based on specified specified conditions. time.
conditions.

Temperature Calculat e the set point Calculat e the process Adjust the valve
Controller based on specified variable based on the position with time.
conditions. desired set point.

Process Mode
The purpose of Process mode is to:
 Check the pipe sizes.
 Specify a pressure drop for valves.
 Check the outlet temperatures of the process-side heat exchangers.
 Determine an initial solution for the transition to Fluid Flow mode.
You can model the heat exchangers by specifying the pressure drop and outlet temperature.

Fluid Flow Mode

The purpose of Fluid Flow mode for this simulation is to show that the network that we designed in
Process mode meets the hot oil net work requirements. In Fluid Flow mode, SimCentral Simulation
Platform moves the entire network to a pressure-balanced solution and therefore calculates the actual
flow available to maintain the process conditions.
We can begin analyzing the available flow thro ugh the system should one of the pumps trip. We make
the following assumptions:
 The Pumps operate on their performance curves.
 All of the Mixers provide a pressure -balanced solution.
 The Pipes use the actual pipe diameter from nominal pipe size.

Version 4.1 9
SimCentral™ Simulation Platform U6 - Hot Oil Network Hot Oil Network

The change to Fluid Flow mode moves the Heat Exchanger flows based on the network pressure
balance. The Wref and DP ref variables in Fluid Flow mode take values from the W and DP values in
Process mode. Therefore, SimCentral Simulation Plat form recalculates the DP value for each individual
Heat Exchanger by using the updated pressure-driven flows according to the following equation:
2
 W  DP
  
 Wref  DPref

Dynamics Mode
The purpose of Dynamics mode is to observe the response in the system when a particular change is
made. Specifically, we study the following cases, which we represent as Scenarios:

Results
Process Mode
The following table compares the pipe sizes with the calculated diameter required for a velocity of 3 m/s.

Velocity Calculated
Pipe NPS (in) Flowrate (kg/hr)
(m/s) Diameter (in)

PIPE1 4in 50000 3.0 3

PIPE2 4in 25000 3.0 2
PIPE3 4in 25000 3.0 4
PIPE4 4in 50000 3.0 3
PIPE5 4in 50000 3.0 3
PIPE6 3in 25000 3.0 2
PIPE9 3in 25000 3.0 2
PIPE10 4in 50000 3.0 3
PIPE11 3in 45000 3.0 3
PIPE12 2in 5000 3.0 2

10 Version 4.1
Hot Oil Network SimCentral™ Simulation Platform U6 - Hot Oil Network

Fluid Flow Mode

The following table compares the actual flow to the required flow for eac h heat exchanger and provides
the outlet temperature based on the required duty specified in Process Description on page 8.

Required Flow Actual Flow Required Outlet

Exchanger Duty (kW)
(kg/hr) (kg/hr) Temperature (°C)

E1 1280 16000 18207 80

E2 1280 26176 29334 80

FHTR 2698 20141 21427 400

The following table provides the pump requirements and pump performance with one of two pumps
operating. You can find the results for when Pump 2 trips in the Snapshot FF 2.

Pump Pump 1 (kg/hr) Pump 2 (kg/h) Total Flow (kg/h) DP (kPa)

Required Flow 25000 25000 50000 370

(Process Mode)

Two Pumps 25000 25000 50000 370

Operating

One Pump 35883 0 35883 130

Operating

Dynamics Mode
The following curves are represent ative of the different cases mentioned in Dynamics Mode on page 10.
Scenario 1: Hot Oil at 285C
Details: Change the TC.SP value to 285°C at time 30 seconds.

Version 4.1 11
SimCentral™ Simulation Platform U6 - Hot Oil Network Hot Oil Network

You can view the results for this Scenario by reverting to the Dyn 2 snapshot.

12 Version 4.1
Hot Oil Network SimCentral™ Simulation Platform U6 - Hot Oil Network

Scenario 2: Hot Oil at 200C

Details: Change the TC.SP value to 200°C at time 30 seconds.
You can view the results for this Scenario by reverting to the Dyn 3 snapshot.

Version 4.1 13
SimCentral™ Simulation Platform U6 - Hot Oil Network Hot Oil Network

Scenario 3: E1 Shutdown
Details: Close the E1 inlet valve, XV3, at time 30 seconds.
You can view the results for this Scenario by reverting to the Dyn 4 snapshot.

14 Version 4.1
Hot Oil Network SimCentral™ Simulation Platform U6 - Hot Oil Network

In this event, XV3 is closed to carry out maintenance of heat exchanger E1. The duties for the Fired
Heat er and heat exchanger E2 are affected, as shown by their duty profiles and their corresponding flow
profiles in the following figures. In this case, E2 picks up some of t he loss of heat exchange performed by
E1, thus indicating a more negative value.

Version 4.1 15
SimCentral™ Simulation Platform U6 - Hot Oil Network Hot Oil Network

Snapshots
This simulation includes the following snapshots.

Excel Report
You can find the system flows, pressures, and temperatures in the U6 – Hot Oil Network.xlsx file.

References
1. Mitra, S. "A technical report on design of hot oil system." University of Newc astle. June 2015.
Research Gate.
2. Ataei, A., Tahouni, N., Yoo C., and M.H. Panjeshahi. "A novel approach to hot oil system design for
energy conservation. Applied Thermal Engineering. May 2014. Research Gate.

16 Version 4.1