SECTION 2.

8
FUEL OIL SYSTEM





























CONTENTS



1.0 INTRODUCTION ............................................................................................................. 3
2.0 CODES AND STANDARDS ............................................................................................ 3
3.0 DESCRIPTION OF SYSTEMS ........................................................................................ 4
4.0 DESIGN CRITERIA ......................................................................................................... 4
5.0 SCOPE OF WORK .......................................................................................................... 6
6.0 LAYOUT REQUIREMENTS ............................................................................................. 7
7.0 CONTROL AND OPERATION PHILOSOPHY ................................................................ 8
8.0 POWER SUPPLY ............................................................................................................ 8
9.0 SPECIFIED DESIGN DATA ............................................................................................ 9

ANNEXURE 1 SPECIFIED DESIGN DATA FUEL OIL SYSTEM ...................................... 10
ANNEXURE 2 TYPICAL FUEL OIL CHARACTERISTICS - LDO ........................................ 14


















1.0 INTRODUCTION

This specification covers the general design & engineering, manufacture & assembly,
inspection & testing at manufacturers works, painting at manufacturers works, duly
packed for transportation, delivery CIF Singapore / FOB Indian Port, supervision of
erection, testing & commissioning, and conducting the performance & guarantee testing
and handing over of Fuel Oil System

Compliance with this specification shall not relieve the Bidder of the responsibility of
furnishing material and workmanship to meet the specified conditions.

2.0 CODES AND STANDARDS

The design, manufacture, inspection and testing of the Fuel Oil Handling System shall
comply with all the currently applicable status, regulations and safety codes in the
locality where the equipment is to be installed. The equipment will confirm to the latest
edition of the following standards & codes.

API 620 Recommended rules for design and construction of
large welded low pressure storage tanks

API 650 Welded steel tank for oil storage

ASME Section IX 2010 Welding & Brazing qualifications

API 12D Large welded production tanks

ANSI B31.3 American Society of Mechanical Engineers code for
Process piping

API 600 Code for design & construction of gate valve for sizes
50 NB or above

API 602 Code for design & construction of gate valve for sizes
below 50 NB
API 676 Positive displacement pump Rotary
API 598 Code for testing of gate valve

BS 1873 Code for design & testing of globe valve

BS 1863 Code for design & testing of check valve

BS 5351 Code for design & testing of ball valve

API 1110 Pressure Testing of Liquid Petroleum Pipelines

NFPA 70 National Electrical Code

NFPA 11 Standard for Low-Expansion Foam

NFPA 15 Standard for Water Spray Fixed Systems for Fire
Protection


NFPA 30 Flammable and Combustible Liquids Code

ASTM A36 Standard Specification for Carbon Structural Steel












3.0 DESCRIPTION OF SYSTEMS

1. LDO Unloading and Storage system
2. Fuel Oil Drain system and Oily water collection system

The Light Diesel Oil (LDO) unloading and storage system: LDO will be received at site
through road tankers and unloaded to a LDO storage tank. LDO shall be used for light
up (start up) of the boiler.

3.1 Process Description of LDO Unloading and storage system

The LDO shall be delivered to power station site by road tankers. The oil from the road
tankers will be unloaded to unloading header through neoprene hoses.

The LDO from unloading header will be pumped to LDO storage tank.

Service and instrument air shall be provided for cleaning and for operating valves
respectively.

For complete piping and instrumentation of the system, refer P & I Diagram LDO
Unloading and Storage System, drawing no: 30-3208188-SBME-SPC-131-001.

3.2 Process Description of Drain oil and Oily water collection system

The drain oil from various equipment of LDO Unloading system shall be collected in a
drain oil tank. The drained oil shall be transferred to the LDO storage tanks by drain oil
pump. The oily water mixture from road tankers unloading area in the Unloading pump
house shall be led to the oily water separator and the oily water from the tank dyke area
shall be led directly to the oily water separator located in the dyke area.

Recovered oil from the oil water separator, if suitable for use, will be returned to LDO
storage tank whereas the separated water shall be pumped to the common monitoring
basin.

For complete piping and instrumentation of the system, refer P&ID Drain oil, & Oil
water collection system, drawing no: 30-3208188-SBME-SPC-131-002.

4.0 DESIGN CRITERIA

The requirements of LDO are based on four hours of continuous heating of the boiler
bed to start coal feeding. LDO requirement is about 5.5 KL for per start-up of the boiler

as per BHEL. It has been considered that LDO will be transported through road tankers
from the nearest oil Depot to the project site.

4.1 LDO Unloading Pumps

LDO Unloading pumps shall be sized to unload the oil simultaneously from 2 road
tankers in a 60 minutes time into one LDO storage tank. The Capacities of road tankers
and unloading pumps are as given below.

LDO Capacity

Capacity of each road tanker considered - 12 m
3
(Assumed)


Capacity of pump - 25m
3
/hr

Number of Pumps to be offered - 2 (1W+1S)

4.2 LDO Storage Tank

Considering lead time for LDO ordering and receipt at site and also storage margin,
25m
3
capacity storage at site is proposed. The proposed capacity will also be adequate
for three 18MW units and also the quantity considered is adequate for commissioning
purpose.

One LDO storage tank of 25m
3
capacity has been considered (As per standard sizes at
tanks recommended in API Standards 650).The fuel oil storage tank is vertical,
cylindrical, fixed cone roof type, crowned bottom above ground, atmospheric storage
tanks of welded steel construction. Each fuel oil storage tanks shall have two hinged
nozzle type manholes on the shell and one on the roof for inspection and cleaning of the
tank interior, a local level indicator, and level instrumentation as shown in the P&I
Diagram. Oil from the tank is being sourced after leaving some dead volume in the tank
thereby preventing sourcing of dirty oil.

A float and arrow type Level Indicator with all accessories shall be provided for the tank.
The tank shall be designed with provisions for attachment of foam chambers for fire
suppression. Fire Alarm system has been provided on the tank. All required tank
accessories will be provided in accordance with the design codes.





4.3 Drain Oil Tank

It is proposed to provide a one drain oil tank 2 m
3
near the unloading area. The tank shall
be of carbon steel construction.

4.4 Drain Oil Pump and Oil Recovery Pump

One number drain oil Vertical tank mounted pump of capacity 2 m
3
/h, positive
displacement type, and twin screw is envisaged to transfer the drained oil to the Light
Diesel oil storage tank.

The same kind and capacity of pump shall be used to transfer the recovery oil from oil
water separator to drain oil tank.

4.5 Waste water pump


Waste water from the oil water separator shall be transferred to reusage system by one
number pump of capacity 2 m
3
/h ,wet pit, non clog, Centrifugal type, vertical pump with
motor.

4.6 Piping Design Criteria

The fuel oil unloading and storage system piping, valves shall be as per the P & ID
drawing no: 30-3208188-SBME-SPC-131-001, 30-3208188-SBME-SPC-131-002.

The velocities considered for line sizing of fluids (Oil) are given below. The permissible
velocities for LDO pump suction and discharge will be as follows.

Line Sizing Criteria

The fuel oil piping and valves shall be sized based on the maximum oil pump capacities.
The Sizing Criteria for oil piping shall be based on flow rate, viscosity and head loss.

For design / sizing criteria, follow LP Piping Specification Annexure-1 and 2 for details.

5.0 SCOPE OF WORK
Terminal points and exclusions shall be depicted in Vol-II- General Technical Specification
The list is by no means exhaustive and the items though not specifically mentioned but
needed for safe, efficient, trouble-free and coordinated operation of the system shall be
supplied and erected by the Contractor of this specification, without any additional cost to
Purchaser.
5.1 Scope of Supply
LDO System
a. Two (2) nos. unloading manifold complete with one oil unloading header,
one (1) no. stand pipe with isolation valve and cap, flexible hoses of
approx. 8 meter length, each hose fitted with a universal type coupling and
necessary matching pieces for connecting to roads tanker.
b. Two (2) nos.(1W + 1S) 25 m
3
/hr capacity rotary positive displacement,
twin -screw type FO unloading pumps with relief valves and all
accessories, anchor bolts, inserts, lifting lugs, base plates, etc. complete
with flame/explosion proof electric drive motors, coupling, coupling guards
and grounding pads.
c. Two (2) nos. duplex type heavy-duty oil suction strainer of 25 m
3
/hr
nominal capacity and filtration quality down to 0.80 mm particles, common
for the above unloading pumps with isolating valves, drain valves, thermal
relief valve, vent valves with goose neck piping and other accessories.
d. One (1) no. LDO storage tank, of capacity 25 m
3
complete with flame
arrestor, Air breather, level transmitter, level switches, lightning protection,
manholes, vent, drain, water draw-off, dip hatch, shell inspection hole,
sludge sumps, access staircase, platforms and other accessories as
necessary.
e. Piping with supports, valves and specialties, traps, low point drain and high
point vent connections etc. within the battery limits as necessary for the
following systems:

At the inlet flange of the FO unloading to the exit flange of FO
pressurizing pump inlet.
Instrument Air.
Drain Oil System
o One (1) no drain oil tank, capacity 2 m
3
, located within storage tank dyke,
flame arrestor, level indicator, level switches, manholes, vent, dip hatch,
shell inspection hole, inside access ladder and other accessories as
necessary.
o One (1) nos. 2 m
3
/hr capacity positive displacement single screw vertical
pumps, suitable for direct mounting on drain oil tank, with all accessories,
fixing bolts, lifting lugs, base plates, etc. complete with flame/explosion
proof electric drive motors, coupling and coupling guards for transfer of
collected drain oil to the FO storage tank.
o Piping with supports, valves and specialties, low point drain and high point
vent connections etc. within the battery limits as necessary for the following
systems :
Drain oil collection from different equipment in oil unloading area
and day oil tank area upto the drain oil tank.
Drain oil transfer to LDO storage tank.
Instrument Air



Access Platforms
All access platforms for various valves & all pipe cross-over platforms, as required
for necessary approach and crossings within the battery limits.
Civil
Please refer Civil Section and their scope in Volume II, Section 5 Detailed
Technical Specification Civil & Structural

6.0 LAYOUT REQUIREMENTS
Fuel oil storage tank shall be surrounded by a containment dyke of sufficient capacity to
hold the entire contents of the fuel storage tank plus sufficient free board. The draw off
water from each tank will be led to the oily water separator through open trenches inside
the dyke.
The Road tankers unloading station aprons shall be concrete surfaced and shall be
curbed and provided with catch basin to collect the oily water. The oily water so collected
will be led to oily water separator.

The LDO unloading pumps shall be located inside the Fuel Oil unloading pump house.


7.0 CONTROL AND OPERATION PHILOSOPHY
For the Control and Operation Philosophy of Fuel Oil system and other related
information, refer to Section -4 of VOL-II of BOP EPC Specification for the subject
Project.

8.0 POWER SUPPLY

8.1 Electrical Power distribution Philosophy:

To feed Fuel oil MCC, 2 nos. 380 V feeders will be provided from Station Switchboard.

The 380 V MCC located in Fuel oil Handling area shall comprise 2 incomers and one
bus-coupler to supply LT loads.

Motors rated less than 200 KW shall be connected to 380V system. All motors shall
have direct on line starter. 110kW and above capacity motors shall to be fed by ACBs at
380V level. Less than 110kW capacity motors shall be fed by MCCB switch fuse units
and contactors. However, the duty of the drive/application, i.e. high impact loading, etc.
to be considered as criteria for selecting ACB operated motors even for rating < 110kW.

8.2 Lighting system:

Lighting level design shall include a Maintenance factor to account for lamp lumen
depreciation, luminaries surface dirt and room surface dirt, etc.

Lux level shall be maintained as per recommendations of Standards. Lux levels for
important areas are given below:

Sl. No. Description LUX level
1. Fuel Oil Handling Area (Loading/
Unloading)
200
2. Tank form 150
3. Secondary road 10
4. Switchgear / MCC room 200

Type of Fixtures

Lighting fixtures will be selected to suit the ambient conditions, mounting height and
special requirements such as aviation warning, street lighting etc.

Area Type of Fixtures

Fuel Oil Handling Area
(Loading/ Unloading)
MH well glass fixture/flame proof type
Tank form High Mast / MH well glass fixture/flame
proof type
Secondary road
MH Street light fixture
Switchgear / MCC room
Fluorescent fixture

8.3 Earthing System

Buried earth grid conductors shall be provided in entire Fuel Oil Handling areas and shall
be interconnected with the main plant earth mat at places through isolating link installed

in Earth pits. Earthing mat design shall be carried out as per IEE 665-1995. Earth mat
shall be designed such that ground grid resistance shall not exceed 1.0 ohm. For earth
mat design the following shall be considered: Earthing conductor shall be buried at a
depth of not less than 600 mm from FGL. Two number of earth pits shall be provided at
the LDO Unloading & Storage system.

Earth continuity conductor shall run throughout the plant as part of personnel safety &
E/F return current path

The main earth conductor which runs along the building columns / walls shall be
securely fixed to the same by welding / clamping at intervals not exceeding 1000mm.

Electronic earthing shall be provided for PLC system and shall be completely isolated
from the Plant earthing system.

8.4 Cabling

Cables shall be laid on ladder / Perforated type trays. Cable trays shall be supported at
an interval of 1500 mm approximately.
Cable trays shall be Galvanized Iron. Cable trays complete with matching fittings (like
elbows, bends, reducers, tees, crosses, side coupler plates, Tray cover etc.) and
hardwires as required. Cable trays shall be standard width of 150mm, 300mm, 450 mm
& 600mm and standard lengths of 2.5 M or more.
The Support system shall be fabricated from epoxy painted steel members.
Cables shall be terminated using double compression cable glands suitable for the
voltage grade of cables. Cable glands shall be heavy duty brass. Cable lugs for power
and control cables shall be tinned copper solder less crimping type conforming to IEC
Standard.
Conduits/pipes offered shall be complete with fittings and accessories (like tees,
elbows, bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples
etc.). The size of the conduit/pipe shall be selected on the basis of maximum 40% fill
criteria. Rigid steel galvanized conduits conforming to IEC Standard. Fittings and
accessories shall also be hot dip galvanized. Flexible conduits where required, near
equipment terminations, shall be made with bright, cold rolled, annealed and electro-
galvanized mild steel strips.

For Further information please refer Volume II, Section-3


9.0 SPECIFIED DESIGN DATA
The specified design data and Material of Construction for various equipment and
components of Fuel Oil System are furnished in Annexure I of this document.



































ANNEXURE 1

SPECIFIED DESIGN DATA FUEL OIL SYSTEM

Sl.No Description Unit Data
I LDO UNLOADING PUMPS
1 Type
Rotary positive displacement, twin -screw
type
2 Number nos. 2(1W + 1S)
3 Rated capacity m
3
/hr 25
4 Rated head mlc ~ 20 ( Tentatively)
5 Duty
Intermittent / Designed for Continuous
Operation
6 Type of drive Directly driven by electric motor
7 Relief Valve Yes
8 Material of construction
8.1 Casing ASTM A48 / AS1830
8.2 Driver/ Idle spindle SS 304 / Nitride steel
8.3 Shaft SS 304
8.4 Shaft sealing Mechanical Seal
9 Location Under shed
10 Design Code API 676 / VDMA - 24284

Sl.No Description Unit Data
II LDO STORAGE TANK
1 Number nos. 1
2 Effective Capacity m
3
25
3 Tank Dimensions m x m 3 x 3.6 (diameter x height) minimum
4 Roof and bottom slope 1:12 and 1:120
5 Type of construction Vertical, cylindrical, fixed cone roof type
6 Design Code API 650
7 Operating Temperature Deg. C ambient
8 Design Temperature Deg. C 50
9 Operating Pressure Atmospheric
10 Design Pressure 1.5 x Operating Pressure
11 Material of construction
11.1 Steel plates ASTM A 1011M
11.2 Structural Members ASTM A 1011M
11.3 Nozzles ASTM A 1011M
11.4 Flanges ASTM A 1011M
12 Insulation As required.
13 Venting Capacity API 2000
III DRAIN OIL TANK
1 Number 1
2 Capacity m
3
2
3 Type of construction Vertical, Rectangular type
4 Design Code API 650
5 Operating Temperature Deg. C ambient
6 Design Pressure bar 1.5 x Operating Pressure
7 Material of construction ASTM A 1011M
8 Insulation No
9 Venting Capacity API 2000
IV DRAIN OIL PUMP
1 Number 1
2 Type Positive displacement, screw type.

Sl.No Description Unit Data
3 Rated Capacity m
3
/hr 2
4 Head mwc As per design criteria
5 Material of construction
5.1 Driver/ Idle spindle SS 304 / Nitride steel
5.2 Shaft SS 304
V WASTE WATER PUMP
1 Number 1
2 Type Wet pit, non clog, Centrifugal type, vertical
3 Rated Capacity m
3
/hr 2 (Bidder to verify)
4 Head mlc As per design criteria
5 Type of Drive Direct
6 Material of Construction
6.1 Impeller AISI 304L
6.2 Shaft AISI 304L
VI STRAINERS
1 Type
Duplex type for LDO Fuel pump suction and
simplex type for other pumps suction
2 Material of Construction
2.1 Body Fabricated carbon steel/Cast carbon steel
2.2 Basket Stainless Steel
VII PIPING/FITTING
MATERIALS


1 FO pipes ASTM A106 Grade B schedule 40 for pipe
sizes up to 150 NB
API 5L Gr. B ERW/SW for sizes 200-400
NB and rolled & welded from 8 mm thick
plates conforming to ASTM A 570M for
sizes above 400 NB
Minimum thickness of API pipes shall be
as follows:
300 NB & ABOVE- 6.35 mm
250/200NB- 5.56 mm
VIII VALVES (Fuel Oil Lines)
1 Type Ball Valves in LDO

Sl.No Description Unit Data
2 Material of Construction ASTM A 216 WCB for 65 NB or larger
ASTM A 105 for 50 NB or smaller
IX VALVES (Oily water)
1 Type Gate Valves, Globe valve and Check valve
2 Material of Construction
ASTM A 216 WCB for 65 NB or larger
ASTM A 105 for 50 NB or smaller
X HOSES
Fuel Oil Unloading Hoses
1 Type
Smooth Bore, Medium Duty, Leakage
Proof, Made From Neoprene (As Per BS
1435) Types-7
2 Standard Manufacturers standard
XI MOTORS


1 Nominal Voltage Volts 380
2 Frequency Hertz 50
3 Horsepower Ratings
As required by design, with 1.15 service
factor
4 Temperature Rise Class B (50
o
C ambient)
5 Enclosure TEFC
6 Insulation Classification Class F, sealed system
7 Type Flame Proof.
XII INSTRUMENT
1 Level Indicators Float & Chord type
2 Level Transmitter Radar Type (Non- Contact)
3 Flow Transmitter PD Flow Meters


















ANNEXURE 2

TYPICAL FUEL OIL CHARACTERISTICS - LDO


Description

Unit

Design

Range
Heating value (LHV) kJ/kg 42500 42000-44000
Density Kg/m
3
0.850 0.820-0.870
Pour point
0
C -5 0-40
Viscosity cP 3.1 2.0-4.6
Carbon %wt 86.9 86.1-88.2
Hydrogen %wt 12.9 11.8-13.9
Sulphur %wt 0.3 0.1-0.6