I - Part 1

GL 2008

Section 7b

Thermal Oil Systems

Chapter 2
Page 7b1

Section 7b
Thermal Oil Systems
A.

General

1.

Scope

3.3
The "discharge temperature" is the temperature of the thermal oil immediately at the heater outlet.

The following requirements apply to thermal oil systems in which organic liquids (thermal oils) are heated
by oil fired burners, exhaust gases or electricity to
temperatures below their initial boiling point at atmospheric pressure.
2.

Other applicable requirements

In addition, the following GL Rules and Guidelines

are to be applied analogously:
Section 7a, B., C. and D.

For materials, fabrication

and design of the heaters

Section 8, B., C. and D.

For materials, fabrication

and design of the expansion vessel and the tanks

Section 9, A. and B.

For oil burners and oil

firing systems (additional
shutdown criteria see B.4
and C.4)

Section 10, A., B. and D.

For thermal oil tanks

Section 11, A. to D., Q.

and R.

For pipes, valves and

pumps

Section 12

For fire protection and

fire fighting equipment

Chapter 3 Electrical
Installations

For electrical equipment

items

Chapter 4 Automation

For automated machinery

systems

VI Additional Rules and For type approved comGuidelines, Part 7 Guide- ponents
lines for the Performance
of Type Approvals
3.

Definitions

3.1
The "maximum allowable working pressure"
is the maximum pressure which may occur in the
individual parts of the equipment under service conditions.
3.2
The "thermal oil temperature" is the temperature of the thermal oil at the centre of the flow crosssection.

3.4
The "return temperature" is the temperature
of the thermal oil immediately at the heater inlet.
3.5
The "film temperature" is the wall temperature on the thermal oil side. In the case of heated surfaces, this may differ considerably from the temperature of the thermal oil.
4.

Documents for approval

The following documents are to be submitted for approval:

a description of the system stating the discharge

and return temperatures, the maximum allowable film temperature, the total volume of the
system and the physical and chemical characteristics of the thermal oil

drawings of the heaters, the expansion vessel

and other pressure vessels

piping and equipment schedules (for information)

circuit diagrams of the electrical control system,

respectively monitoring and safety devices with
limiting values

a functional diagram with information about the

safety devices and valves provided (for information)

If specially requested, mathematical proof of the

maximum film temperature in accordance with DIN
4754 is to be submitted.
5.

Thermal oils

5.1
The thermal oil has to remain serviceable for
at least 1 year at the specified thermal oil temperature.
Its suitability for further use is to be verified at appropriate intervals, but at least once a year.
5.2
Thermal oils may only be used within the
limits set by the manufacturer. A safety margin of
about 50 C is to be maintained between the discharge
temperature and the maximum allowable film temperature specified by the manufacturer.
5.3
Precautions are to be taken to protect the
thermal oil from oxidation.
5.4
Copper and copper alloys are to be avoided
due to their catalytic effect on the thermal oil.

Chapter 2
Page 7b2

6.

Section 7b

Thermal Oil Systems

Manual operation

6.1
The facility is to be provided for manual
operation. At least the temperature limiters on the oil
side and flow limiters shall remain operative even in
manual operation.
The heater heated by exhaust gas may be operated
without temperature and flow monitoring if the permissible header temperature can be kept.
6.2
Manual operation demands constant and
direct supervision of the system.
For details of requirements in respect of the manual
operation of the oil firing system, see Section 9.

I - Part 1
GL 2008

3.5
Heaters heated by exhaust gas are to be provided with manholes serving as inspection openings at
the exhaust gas intake and outlet.
3.6
Oil fired heaters are to be provided with inspection openings for examination of the combustion
chamber.
3.7
Sensors for the temperature measuring and
monitoring devices are to be introduced into the system through welded-in immersion pipes.
3.8
Heaters are to be fitted with means enabling
them to be completely drained.
3.9
For electrically heated heaters the requirements are to be applied analogously to oil fired heaters.

B.

Heaters
4.

1.

Acceptable materials

Equipment

Heaters of thermal oil systems are to be fabricated

from the same materials as boilers as per Section 7a,
B.2.

The suitability of safety and monitoring devices (e.g.

valves, limiters/alarms for temperature, flow and leakage monitoring) for marine use is to be proven by type
testing.

2.

4.1

Testing of materials

The materials of the parts of the heaters which are in

contact with the thermal oil are to be tested in accordance with Section 7a, B.3.
For coils with a maximum allowable working pressure
up to 10 bar and an allowable operating temperature
up to 300 C Manufacturer Inspection Certificates 1
are sufficient.
3.

Design

3.1
Heaters are to be designed thermodynamically and by construction that neither the surfaces nor
the thermal oil become excessively heated at any
point. The flow of the thermal oil is to be ensured by
forced circulation.
3.2
The surfaces which come into contact with
the thermal oil are to be designed for the maximum
allowable working pressure subject to a minimum
gauge pressure of 10 bar.

4.1.1
The equipment on the heaters has to be suitable for use at thermal oil heaters and on ships. The
proof of the suitability of the limiters (e.g. temperature, flow, pressure) is to be demonstrated by a type
approval test according to the requirements of GL
Rules listed in A.2.
4.1.2
The alarms and the activation of the limiters
have to create optical and acoustic fault signals in the
installation space of the heater resp. in the engine
control room and another suitable location.
4.2

3.4
The exhaust gas intake is to be arranged that
the thermal oil cannot penetrate the engine or the
turbocharger in case of a leakage in the heater respectively the cleaning medium cannot penetrate during
heater cleaning.

See GL Rules II Materials and Welding, Part 1 Metallic

Materials, Chapter 1 Principles and Test Procedures, Section
1, H.

Safety valves

Each heater is to be equipped with at least one safety

valve having a blow-off capacity at least equal to the
increase in volume of the thermal oil at the maximum
heating power. During blow-off the pressure shall not
increase above 10 % over the maximum allowable
working pressure.
4.3

3.3
Heaters heated by exhaust gas are to be designed that damages by resonances resulting from
oscillation of the exhaust gas column cannot occur.

General

Temperature, pressure and flow

indicating devices

4.3.1
Pressure indicating devices are to be fitted at
the discharge and return line of both oil fired heaters and
heaters heated by exhaust gas. The maximum allowable
working pressure PB is to be shown on the scale by a
red mark which is permanently fixed and well visible.
The indicating range has to include the test pressure.
4.3.2
Temperature indicating devices are also to be
fitted in the flue gas or exhaust gas stream at the heater's outlet.
4.3.3

The flow of the thermal oil is to be indicated.

I - Part 1
GL 2008

4.4

Section 7b

Thermal Oil Systems

Temperature control

4.4.1
For automatic control of the discharge temperature, oil fired heaters are to be equipped with an
automatic rapidly adjustable heat supply in accordance
with Section 9.
4.4.2
The discharge temperature of heaters heated
by exhaust gas is to be controlled by automatic regulation of the heat input or by recooling the thermal oil in
a dumping cooler, but independently from the control
of the engine output.
4.5

Temperature monitoring

Chapter 2
Page 7b3

4.6.5
An alarm has to be created for the case that at
an undercut of the minimum flow through the heater
heated by exhaust gas (e.g. at standstill of the circulation pump, closed shut-off valves) the engine delivering the exhaust gas for heating of the heater is to be
started.
4.7

Leakage monitoring

4.7.1
Oil fired heaters are to be equipped with a
leakage detector which, when actuated, shuts down
and interlocks the firing system. If the oil fired heater
is in "stand-by" the starting of the burner has to be
blocked if the leakage detector is actuated.

4.5.1
If the allowable discharge temperature is
exceeded, for oil fired heaters the heat supply is to
be switched off and interlocked by a temperature limiter.

4.7.2
Heaters heated by exhaust gas are to be
equipped with a leakage detector which, when actuated, trips an alarm and a request shall be provided to
reduce the power of the engine, which delivers exhaust gas to the heater.

4.5.2
If the allowable discharge temperature is
exceeded for heaters heated by exhaust gas an alarm
shall be tripped.

4.8

4.5.3
The discharge temperature of parallel-connected heating surfaces in the heater is to be monitored individually at the outlet of each heating surface.

Shut-off devices

4.8.1
Heaters are to be fitted with shut-off devices
and, if necessary with by-pass valves, which can also
be operated from a position outside the immediate
area in which the heater is installed.

With heaters heated by exhaust gas, individual monitoring of heating surfaces connected in parallel may
be dispensed with if the maximum exhaust gas temperature is lower than the maximum allowable film
temperature of the thermal oil.

4.8.2
The heater has to be capable of being drained
and ventilated from the same position.

4.5.4
If the specified maximum flue gas temperature of the oil fired heaters is exceeded, the firing
system is to be switched off and be interlocked.

4.9.1
The temperature switch for fire detection, required according to Section 12, C.4.3 is to be provided
additionally to the temperature switch according to
4.5.5 and shall be set to a temperature 50 to 80 C
higher. If actuated, alarm shall be given by group
alarm.

4.5.5
Heaters heated by exhaust gases are to be
equipped with a temperature switch which, when the
maximum design exhaust gas temperature is exceeded,
signals by means of an alarm that the heating surfaces
are badly fouled.
4.6

Flow monitoring

4.6.1
Precautions are to be taken to ensure that the
maximum allowable film temperature of the thermal
oil is not exceeded.
4.6.2
A flow monitor switched as a limiter is to be
provided at the oil fired heater. If the flow rate falls
below a minimum value the firing system has to be
switched off and be interlocked.
4.6.3
Start-up of the burner is to be prevented by
interlocks if the circulating pump is stationary.
4.6.4
A flow monitor is to be provided at heaters
heated by exhaust gas. An alarm is to be triggered in
case the flow rate falls below the minimum value.

4.9

Fire detection and fire distinguishing

system

4.9.2
Thermal oil heaters heated by exhaust gas are
to be fitted with a permanent system for extinguishing
and cooling in the event of fire, e.g. a pressure water
spraying system. For details see Section 12, Table 12.1 and L.2.2.

C.

Vessels

1.

Approved materials

Vessels are to be fabricated from the materials conforming to Section 8, B.3., in the pressure vessel class
appropriate to the thermal oil system.
2.

Testing of materials

The vessel materials are to be tested in accordance

with Section 8, B.4.

Chapter 2
Page 7b4

3.

Section 7b

Thermal Oil Systems

Design

3.1
All vessels, including those open to the atmosphere, are to be designed for a pressure of at least
2 bar, unless provision has to be made for a higher
working pressure. Excepted from this requirement are
tanks designed and dimensioned according to Chapter 1 Hull Structures, Section 12.
3.2
An expansion vessel is to be placed at a high
level in the system. The space provided for expansion
must be such that the increase in the volume of the
thermal oil at the maximum thermal oil temperature
can be safely accommodated. The following are to be
regarded as minimum requirements: 1,5 times the
increase in volume for volumes up to 1000 litres, and
1,3 times the increase for volumes over 1000 litres.
The volume is the total quantity of thermal oil contained in the equipment up to the lowest liquid level in
the expansion vessel.
3.3
At the lowest point of the system a drainage
tank is to be located, the capacity of which is sufficient to hold the volume of the largest isolatable system section.
3.4
A separate storage tank is to be provided to
compensate any losses. The stock of thermal oil is to
be at least 40 % of the capacity of the system. Depending on the system design or the ship's geographical area of service, a smaller stock may be acceptable.
3.5
In exceptional cases, approval may be given
for the drainage tank and the storage tank to be combined. Combined storage/drainage tanks are to be
dimensioned that in addition to the stock of thermal
oil, there is room for the content of the largest isolatable system section.
4.

Equipment of the expansion vessel

4.1

General

4.1.1
The equipment on the expansion vessel (e.g.
level indicator) has to be suitable for use at thermal oil
heaters and on ships. The proof of the suitability of the
limiters (e.g. filling level) is to be demonstrated by a
type approval test according to the requirements of GL
Rules listed in A.2.
4.1.2
The alarms and the activation of the limiters
have to create optical and acoustic fault signals in the
installation space of the heater resp. in the engine
control room and another suitable location.
4.2

Level indication device

I - Part 1
GL 2008

4.3

Low level limiter and alarm

4.3.1
A limit switch is to be fitted which shuts
down and interlocks the firing system and switches off
the circulating pumps if the liquid level falls below the
allowable minimum.
4.3.2
Additionally an alarm for low liquid level is
to be installed, e.g. by means of an adjustable level
switch on the liquid level gauge which gives an early
warning of a falling liquid level in the expansion vessel (e.g. in the event of a leakage).
4.3.3
An alarm is also to be provided for the
maximum liquid level.
4.4

Quick drainage valve and emergency

shut-off valve

4.4.1
For rapid drainage in case of danger, a quick
drainage valve is to be fitted directly to the vessel with
remote control from outside the space in which the
equipment is installed.
4.4.2
Automatic means are to be provided to ensure
a sufficient air supply to the expansion vessel when
the quick drainage valve is operated.
4.4.3
Where the expansion vessel is installed outside the engine room, the quick drainage valve may be
replaced by an emergency shut-off device (quick closing valve).
4.4.4
The opening of the quick drainage valve or
the operation of the emergency shut-off device shall
cause the automatic shutdown of the firing system and
the circulating pumps.
4.4.5
The dimensions of the drainage and venting
pipes are to be applied according to Table 7b.1.
Table 7b.1

Nominal diameter of drainage and

venting pipes as well as of expansion
and overflow pipes depending on the
performance of the heater

Performance
of heater
[kW]

Expansion and
overflow pipes
Nominal
diameter DN

Drainage and
venting pipes
Nominal
diameter DN

600

25

32

900

32

40

4.2.1
The expansion vessel is to be equipped with a
liquid level gauge with a mark indicating the lowest
allowable liquid level.

1200

40

50

2400

50

65

4.2.2
Level gauges made of glass or plastic are not
allowed.

6000

65

80

I - Part 1
GL 2008

4.5

Section 7b

Thermal Oil Systems

Connection lines

Chapter 2
Page 7b5

3.2
The outlets of the circulating pumps are to be
equipped with pressure gauges.

4.5.1
A safety expansion line has to connect the
system to the expansion vessel. This shall be installed
with a continuous positive gradient and is to be dimensioned that a pressure rise of more than 10 %
above the maximum allowable working pressure in the
system is avoided.

3.3
It shall be possible to shut down the circulating pumps by an emergency switch which can also be
operated from a position outside the room in which
they are installed.

4.5.2
The expansion vessel is to be provided with
an overflow line leading to the drainage tank.

3.4
Devices for safe sampling are to be provided
at a suitable location in the thermal oil circuit.

4.5.3
The quick drainage line may be routed jointly
with the overflow line to the drainage tank.

3.5
Means of venting are to be provided at the
highest points of isolatable sections of the thermal oil
system and drainage devices at the lowest points.

4.5.4
All parts of the system in which thermal oil
can expand due to the absorption of heat from outside
is to be safeguarded against excessive pressure. Any
thermal oil emitted is to be safely drained off.

Venting and drainage via open funnels are to be avoided.

4.5.5
The dimensions of the expansion and overflow pipes are to be applied according to Table 7b.1.
4.6

Pre-pressurised system

4.6.1
Pre-pressurised systems are to be equipped
with an expansion vessel which contents are blanketed
with an inert gas. The inert gas supply to the expansion vessel has to be guaranteed.
4.6.2
The pressure in the expansion vessel is to be
indicated and safeguarded against overpressure.
5.

Equipment of the drainage and storage

tank

For the equipment of the drainage and storage tank see

Section 11, Q.4.

D.

Equipment Items

1.

Approved materials

1.1
Materials for pipes, valves and pumps see
Section 11, B.
1.2
Grey cast iron is unacceptable for equipment
items in the hot thermal oil circuit and for safety valves.
2.

3.7
Electric equipment items are governed by
Chapter 3 Electrical Installations.

E.

Marking

1.

Heaters

The following information shall be stated on a durable

manufacturer's nameplate permanently attached to the
heater:

manufacturer's name and address

serial number

year of manufacture

maximum allowable heating power

maximum allowable working pressure

maximum allowable discharge temperature

minimum flow rate

liquid capacity

2.

Vessels

Testing of materials

Pipe, valve and pump materials are tested in accordance with Section 11, B.3.
3.

3.6
For fitting and draining pumps see Section
11, Q.1.2.

Equipment

3.1
Pipes, valves and pumps are governed, in
addition to the following specifications, by the provisions of Section 11, Q.

2.1
Vessels are to be fitted with nameplates bearing the following information:

manufacturer's name and address

serial number

year of manufacture

maximum allowable working pressure

Chapter 2
Page 7b6

Section 7b

Thermal Oil Systems

maximum allowable working temperature

capacity

2.2
For vessels with an open connection to the
atmosphere, the maximum allowable working pressure
is to be shown on the nameplate as "0" or "Atm.", even
though a gauge pressure of 2 bar is taken as the design
basis in accordance with C.

I - Part 1
GL 2008

G.

Testing

1.

Heaters

The thermal oil heaters are to be subjected to a constructional check and a hydrostatic pressure test, at 1,5
times the maximum allowable working pressure, at the
manufacturer's works in the presence of the GL Surveyor.
2.

F.

Fire Protection

The fire precautions are governed by the provisions of

Section 12.

Thermal oil system

After completion of installation on board, the system

including the associated monitoring equipment is to be
subjected to pressure, tightness and functional tests in
the presence of the GL Surveyor.