ISSN 2347 - 3258 International Journal of Advance …

1 Volume 5 Issue 2 (2017) 290-292 ISSN 2347 - 3258. International Journal of Advance Research and Innovation Study of Fuel oil Handling System in Thermal power Plants Rajesh Kumar, Roshan Kumar, PV Ramkumar, RS Mishra Department of Mechnical Engineering, Delhi Technological University, Delhi, India Article Info Abstract Article history: Study of fuel oil handling system (FOHS) in thermal power plants is intended towards Received 25 January 2017 achieving the goal of designing fuel oil handling system in thermal power plants. Designing &. Received in revised form process parameters have been proposed in this study analysis. The overall system consists of 20 February 2017 three stages Fuel oil unloading, storage & forwarding. Three stages required heat tracing to Accepted 28 February 2017 make the heavy density fuel oil properties suitable to flow through pipes for process Available online 15 June 2017 requirement in thermal power plants with the help of pumping media.

2 Theoretically, it was Keywords: power plant, heavy found that the proposed Design of fuel oil handling system using electrical heat tracing shows fuel oil, electric heat tracing better result as compared to steam heat tracing. The study was done to make existing system of FOHS more refined which is maintenance free and more reliable The fuel oil handling and storage system in a thermal power station pumps. During this process the fuel is freed from mechanical covers unloading of the fuel oil, its storage and transfer to the day oil impurities by means of filters. The provision of day tank may not be tanks. Heavy Fuel oil (FO/LSHS/HPS) are generally used for the required where LDO tanks are located close to boilers. The LDO day initial startup of the boiler and up to a load of 30% MCR. Fuel oil is tank is also provided for auxiliary boiler, if envisaged. also used for coal flame stabilization up to 40-50% MCR of the steam Steam and Condensate System generator.

3 In addition to above, light diesel oil (LDO) system, of The heating steam required for floor heater and suction heater in MCR capacity, is also provided to start the unit from cold condition HFO/LSHS/HPS storage tanks, HFO/LSHS/HPS unloading headers, when steam is not available for HFO heating. Light Diesel Oil (LDO) piping and pumps is supplied at about 16 kg/cm2 (a) at saturated is also used for auxiliary boiler (if envisaged). The fuel oil may be condition from auxiliary steam header. Steam pressure is reduced to 4. received in a power station by rail tankers or by road tankers or by kg/cm (a) through a pressure reducing station, located near the fuel ships for coastal plants depending on the logistics. Based on the kind oil tank farm area, and distributed to the following heating of tankers received the unloading facilities are planned. applications: 2. System Description a) HFO/LSHS/HPS unloading header and piping b) HFO/LSHS/HPS railway wagons.

4 The Fuel Oil Handling system of a power station essentially consists c) HFO/LSHS/HPS unloading and transfer pumps and valves. different parts. d) HFO/LSHS/HPS storage tank floor heaters and suction heaters. Fuel Oil Unloading System e) HFO/LSHS/HPS unloading and transfer piping upto the day tank. Heavy Fuel oil (HFO/LSHS/HPS) is generally unloaded by rail f) Drain oil tank at main tank farm area. tankers. Till recently, oil rake consisted of 80 wagons (TOH/TORX. Drain Oil System type) of kL each. Currently rakes consisting of 48 wagons (BTPN. Clean oil spillage from unloading and transfer pumps in pump house type) of about 58 kL each are also being received. Unloading system is collected in a drain oil tank. This drain oil tank is located in the involves heating of high viscosity fuels such as furnace oil, LSHS &. unloading pump house area. Drain oil pumps transfer the drained oil HPS. The heating is normally done by steam tapped off from the to either of the HFO/LSHS/HPS storage tanks.

5 The drain oil tank is auxiliary steam header. insulated and provided with steam coil heater to maintain the The unloading of oil rake is done in about 8 hours duration (wagon temperature for flow-ability inside the tank as required for those of placement, heating & pumping). Suitable unloading headers, about HFO/LSHS/HPS storage tanks. Dirty oil spillage/ floor wash from 700 meter long covering entire length of the rake, along the railway unloading area and unloading/transfer pump house is collected in an tracks are envisaged for quick unloading. This process involves use of oily sump. unloading pumps for transferring the fuel oil to the storage tanks. In cases where coal transportation is not by rail, HFO unloading by Methodology of FOHS. road is preferred to eliminate the need of laying a railway track and Project Reference associated marshalling facilities. The unloading of LDO is done by This report is prepared based on the specification of Indiabulls for road only.

6 Amravati TPP 5 x 270 MW[1] [2]. As such this report covers the scope Fuel Oil Storage and Transfer to Day Tanks of work and system design inline with the specification requirement. The heavy fuel oil is stored in the storage tanks. These tanks are Overview of Process heated to maintain a suitable temperature by supplying steam through The project comprises of setting up new storage and handling facilities floor coil heaters. Heavy fuel oil tanks are also provided with suction for Heavy Fuel Oil (HFO) and Light Diesel Oil (LDO). Light Diesel heaters with steam as the heating source to heat the oil before sending Oil (LDO) is used for initial start up while heavy fuel oil (HFO) is it to transfer pumps. The fuel oil unloaded into main storage tanks is used for flame stabilization, mill change over and during low load transferred to the day oil tanks for sending it to oil pressurizing station operation of boilers.

7 From where it is sent to the burners, as and when required. The oil is Description Of Fuel Oil System transferred from main oil tank to Day oil tank using the transfer The fuel oil system will comprise of the following sub system: pumps. During this process the fuel is freed from mechanical 1. HFO System impurities by means of filters. The provision of day tank may not be 2. LDO System required where fuel oil tanks are located close to boilers. 3. Drain System LDO Storage and Transfer to Day Tanks HFO System The light diesel oil is stored in the storage tanks. LDO is further HFO unloading accessories such as Neoprene rubber hoses, quick transferred to the day oil tanks for sending it to oil pressurizing station coupling, etc. for unloading Railway wagons and road tankers. from where it is sent to the burners, as and when required. The oil is Heating steam accessories such as metallic hoses, quick couplings, transferred from main oil tank to day oil tank using the transfer etc.

8 For unloading Railway wagons and road tankers. Condensate *Corresponding Author, accessories such as metallic hoses, quick couplings, etc. for unloading E-mail: Railway wagons and road tankers. Six (6) nos. (4 x 150 + 2x 25. All rights reserved: m3/hr) of HFO unloading pumps, positive displacement type screw pumps with electric tracing, simplex strainer in the individual pump 290. IJARI. Volume 5 Issue 2 (2017) 290-292 ISSN 2347 - 3258. International Journal of Advance Research and Innovation suction. Two (2) nos. of vertical fixed cone roof HFO storage tanks , Two (2) nos. (1w + 1s) oily water sump pump of vertical, single minimum effective capacity of 2000 m3 with thermal insulation up to screw type of capacity 1 m3/hr for Oil water collection sump in 2m from the bottom of the tank. Dyke area. Floor coil heater at the bottom of each HFO storage tank Two (2) nos. (1w + 1s) recovery oil pump of vertical, single screw Fuel oil suction heater at the outlet of each HFO storage tank Pressure type of capacity 1 m3/hr for Oil water separator in HFO railway reducing station for auxiliary steam system.

9 All piping, valves and wagon unloading area. instruments as indicated in the P&ID for HFO system, All field Two (2) nos. (1w + 1s) recovery oil pump of vertical, single screw instruments including pressure gauges, temperature element with type of capacity 1 m3/hr for Oil water separator in Dyke area. transmitter, temperature indicator, level gauges, level transmitters, Two (2) nos. (1w + 1s) vertical centrifugal type pump of capacity 2. differential pressure switches, differential pressure gauge, pressure m3/hr for Recovered water in OWS of railway wagon unloading switch, level switch along with necessary accessories like isolating area. valves, pulsation dampeners , nipples, piping etc. Two (2) nos. (1w + 1s) vertical centrifugal type pump of capacity Drive motors suitable for operation on 415 Volts with space heaters, 2m3/hr for Recovered water in OWS of tank farm area. complete with all standard accessories including motor terminal box Two (2) nos.

10 Oil water separator. and cable glands for HFO unloading pumps & inline with electrical All field instruments including level switch, pressure gauges along specification requirement. Local Emergency Push Button for the with necessary accessories like isolating valves, pulsation dampeners, operation of Motors shall be routed through MCC. nipples, piping etc. Temperature control valves self-actuating on/off type for floor coil Drive motors suitable for operation on 415 Volts with space heaters, heater and suction heater along with I/P converters, air filter complete with all standard accessories including motor terminal box regulators, copper tubing etc. and cable glands for LDO unloading pumps & inline with electrical Common PLC based control Panel for HFO & LDO System with two specification requirement. Local Emergency Push Button for the (02) No. operator cum engineering work station located in control operation of Motors shall be routed through MCC.