Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) STANDARD DESIGN CRITERIA/GUIDELINES FOR BALANCE OF PLANT OF THERMAL POWER PROJECT 2x (500MW OR ABOVE) SECTION-4 : FUEL OIL HANDLING SYSTEM 41 42 INTRODUCTION ‘The fuel oil handling and storage system in a thermal power station covers unloading of the fuel oil, its storage and transfer to the day oil tanks. Heavy Fuel oil (FO/LSHS/HPS) are generally used for the initial start up of the boiler and upto a load of 30% MCR. Fuel oil is also used for coal flame stabilization upto 40- 50% MCR of the steam generator. In addition to above, light diesel oil (DO) system, of, 7.5% MCR capacity, is also provided to start the unit from cold condition when steam is, not available for HFO heating. Light Diesel Oil (DO) is also_used for auxiliary boiler (if envisaged) the fuel oil may be received in a power station by rail tankers or by road tankers or by ships for coastal plants depending on the logistics. Based on the kind of tankers received the unloading facilities are planned. SYSTEM DESCRIPTION ‘The Fuel Oil Handling system of a power station essentially consists of the following: Fuel oil unloading system Heavy Fuel oil (HFO/LSHS/HPS) is generally unloaded by rail tankers. Till recently, oil rake consisted of 80 wagons (TOH/TORX type) of 22.3 KL each. Currently rakes consisting of 48 wagons (BIPN type) of about 58 kL each are also being received. Unloading system involves heating of high viscosity fuels such as furnace oil, LSHS & HPS. The heating is normally done by steam tapped off from the auxiliary steam header. ‘The unloading of oil rake is done in about 8 hours duration (wagon placement, heating & pumping). Suitable unloading headers, about 700 meter long covering entire length of the rake, along the railway tracks are envisaged for quick unloading. This process involves use of unloading pumps for transferring the fuel oil to the storage tanks. In cases where coal transportation is not by rail, HFO unloading by road is preferred to climinate the need of laying a railway track and associated marshalling facilities. The unloading of LDO is done by road only.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) 422 424 428 Fuel oil storage and transfer to day tanks The heavy fuel oil is stored in the storage tanks. These tanks are heated to maintain a suitable temperature by supplying steam through floor coil heaters. Heavy fuel oil tanks are also provided with suction heaters with steam as the heating source to heat the oil before sending it to transfer pumps. ‘The fuel oil unloaded into main storage tanks is transferred to the day oil tanks for sending it to oil pressurizing station from where it is sent to the bumers, as and when required. The oil is transferred from main oil tank to day oil tank using the transfer pumps. During this process the fuel is freed from mechanical impurities by means of filters. ‘The provision of day tank may not be required where fuel oil tanks are located close to boilers. LDO storage and transfer to day tanks ‘The light diesel oil is stored in the storage tanks. LDO is further transferred to the day oil tanks for sending it to oil pressurizing station from where it is sent to the burners, as and ‘when required. The oil is transferred from main oil tank to day oil tank using the transfer pumps. During this process the fuel is freed from mechanical impurities by means of filters. The provision of day tank may not be required where LDO tanks are located close to boilers. The LDO day tank is also provided for auxiliary boiler, if envisaged ‘Steam and Condensate system ‘The heating steam required for floor heater and suction heater in HFO/LSHS/HPS storage tanks, HFO/LSHS/HPS unloading headers, piping and pumps is supplied at about 16 kg/cm’ (a) at saturated condition from auxiliary steam header. Steam pressure is reduced to 4 kg/m (a) through a pressure reducing station, located near the fuel oil tank farm area, and distributed to the following heating applications: a) HFO/LSHS/HPS unloading header and piping b)HFO/LSHS/HPS railway wagons. ©) HFO/LSHS/HPS unloading and transfer pumps and valves. 4) HFO/LSHS/HPS storage tank floor heaters and suction heaters. e) HFO/LSHS/HPS unloading and transfer piping upto the day tank. 1) Drain oil tank at main tank farm area, Drain oil system Clean oil spillage from unloading and transfer pumps in pump house is collected in a Grain oil tank. This drain oil tank is located in the unloading pump house area. Drain oil pumps transfer the drained oil to either of the HFO/LSHS/HPS storage tanks. The drain oil tank is insulated and provided with steam coil heater to maintain the temperature for flow-ability inside the tank as required for those of HFO/LSHS/HPS storage tanks. Dirty oil spillage/ floor wash from unloading area and unloading/transfer pump house is collected in an oily sump.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) 42.6 43 43.1 ‘Typical scope of work for 2x500 MW thermal power project is attached at Annexure 4A, ‘Typical flow diagrams (as listed below) of fuel oil handling system for 2 x 500 MW are enclosed Drawing no: CEA-TETD-FO-001 (Typical flow diagram - Fuel Oil unloading, Storage and Handling (HFO) for 2x500 MW coal based Thermal power plant) 2. Drawing no: CEA-TETD-FO-002 (Typical flow diagram — Fuel Oil unloading, Storage and Handling (LDO) for 2x500 MW coal based Thermal power plant) DESIGN CRITERIA AND BROAD FEATURES Capacity of Fuel Oil Handling System and Major Equipment i) The following shall be considered while sizing the plant: a) Heavy fuel oil unloading system shall handle one full rake of HFO/LSHS/HPS at a time. The unloading time shall be 8 hours (wagon placement, heating and pumping). b) LDO unloading system shall handle 8 road tankers (max) at a time. The capacity of each tanker is 9.9m’, ‘The unloading time shall be 4 hours (pumping & tanker placement), ©) Capacity of HFO/ LSHS/ HPS storage tanks shall be maximum of the following: * To store one full rake of wagons * 2.0 ml/kWh of HFO/LSHS/HPS for one months’ requirement. * Minimum no. of tanks shall be two of capacity 2000 kl each 4) For LDO storage, minimum two tanks of 500 kl each shall be provided.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) ii) Typically for a2 x 500 MW power station the system capacities are given below: ‘SINo Equipment No. of Typical rated equipment | capacity of each equipment for 2x500 MW plant 1 | HFO/ LSHS/ HPS Unloading | 5 100 m'/hr Pump 2 [EDO Unloading Pump (for | 2 30m The road tanker) 3 | HPO? LSHS/ HPS Transfer | 2 50 Thr Pump (if required) 4 [CDO Transfer Pump Gf |2 5mm 7hr 5 [EDO ‘Transfer Pump for | 2 5mn7hr auxiliary boiler day tank (if required) 6 | HFO/LSHS/HPS Tanks 2 2000 KI 7 | EDO Tank 2 300 KI 8 | HFO/LSHS/HPS Day Tank | 2 TOOKI (if required) 9 | EDO Day Tank 2 100K (if required) 10 [LDO Day tank for Auxiliary | 1 TOOK boiler (if required) TT [Sump pumps in Unloading | 1 (W)=1 (S) TO mybr pump house 12 [Sump pumps in Oil water | 1 (WI (S) TO mybr separator 13 _ | Drain oil pumps TOTS) Sma Thr 44Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) 432 D Requirements 4.3.2.1 Mechanical Equipment / Systems General i. Typical Fuel Oil Characteristics Light Diesel Oil (1S:1460-1974) ‘Sulfur 18% Ash 0.02% Relative density at 15°C 0.86 — 0.90 Pour Point (°C max.) 18, ‘Kinematic viscosity at 38°C 15.7 centistokes Water (Volume percent) 0.10 Gross Calorific Value (Keal/kg, avg) 10,600 Flash point °C min) 66 B. Heavy fuel Oil SIN, | Characteristics Heavy Tow sulphur | Heavy Fumace oil | Heavy stock | Petroleum Grade «LsHis) stock (HPS) 18-1593 | IS-11489- | 1S-11489- 1992 1985 1985 I Total sulphur content 4.5% Max. | 1.0% Max. | 4.5% Max. 2. Gross calorific value (Keal/kg) | 10280 of the order — | of the order (Typical) | of 11,000 _| of 10,000 3 Flash point (Min) 66 degC | 66degC | T2deg C 4 ‘Water content by volume 1.0% 1.0% 1.0% (max) 3. Sediment by weight (max) | 0.25% 0.25% 025% 6 ‘Asphaltene content by weight | 2.5% 2.5% 2.5% (max) T Kinematic viscosity in 370 100 100 centristrokes at (max) S0degC | 100 degC _| 100 deg C 8 ‘Ash content by weight (max) | 0.1% 0.1% 0.1% 9. Acidity (inorganic) Nil Nil Nil 10. | Pour point (max) Source Source Source specific __| specific specific Ti. | Sodium content = = 100 ppm 12.__| Vanadium content 25 ppm__| 25ppm 25ppmStandard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) ii. ili iv. vii. ix, xii ‘The unloading system shall be compatible with the latest designs of fuel oil wagons as indicated by RDSO. In case due (o layout constraint for placing of 650 meter long rake for unloading is not possible then the rake can be unloaded by splitting in two parts and the unloading header shall then be located in between the two tracks designated for unloading of oil rake. In case of multiple tanks for fuel storage, tank transfer lines with NRV (non return valve) shall be provided using the unloading pumps. Dyke size shall be as per OISD-118 guide lines. ‘The temperature to be maintained for handling the oil shall be 10 deg. C above its pour point except for HFO which shall be handled at 50 deg. C. 100% capacity of the pressure reducing station shall correspond to the maximum steam requirement under the worst (lowest temperature) ambient condition for the following conditions put together: a) Unloading of one full rake of railway wagons. b) One heavy oil storage tank in heating mode ©) One heavy oil storage tank in Maintain’ temperature mode. 4) One suction heater in operation. ‘Steam condition after pressure reducing station shall be 4 kg/cm’ The system layout should meet the requirements of Indian Explosive Acts and approval in this regard shall be taken from Chief Controller of Explosives. Pumps HFO/LSHS/HPS unloading pumps shall be of steam jacketed, positive displacement twin-screw (ype. LDO unloading pumps and LDO transfer pumps shall be of positive displacement twin- screw type, Drain oil pumps shall be of vertical centrifugal type. “The pumps shall be capable of operation in parallel Material of construction for major components will preferably be as below: a Pump casing: Cast iron grade IS 210 FG 260, b. Screws: 13% Chrome Steel ©. Rotors: AISI 431 or equivalentStandard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) xvii. xviii xix, xxi d. Shaft: Stainless steel €. Shaft seal: 30% Chrome steel mechanical seal Fuel oil tanks Fuel oil storage and day tanks shall be of Cone roof, vertical cylindrical, atmospheric pressure welded steel tanks, conforming to IS:2062 Gr.B or approved equal welded construction designed, fabricated and installed in accordance with IS:803. The tanks shall have sloping bottom 1 in 100 towards an adequately sized sump inside the tank to enable complete draining of the contents. Sufficient number of plugged holes shall be provided in the bottom plate of the tanks for bottom testing as per IS:803. HFO & LDO tanks shall be provided with spiral staircase conforming to the relevant standards. The tanks shall be provided with level indicators, level switches, level transmitters and other instruments to make the system complete. Proper earthing shall be provided for these tanks. Conical roof with a slope of not less than 1 in 16 to ensure drainage of rain water. Al shell course plates shall be accurately bent at required radius, Care shall be taken uring bending to prevent plate skewing. For butt-weld joints, edges shall be prepared ‘which shall be uniform and smooth throughout. Shell plates in each course width shall be so arranged that all vertical joints are staggered having a minimum of 600 mm stagger. HFO/LSHS/HPS tanks shall be provided with floor coil heater and suction heaters. The tanks shall be insulated with minimum 40 mm thick mineral fibre blocks for personnel protection and heat conservation purposes Strainers For oil strainers, the open area ratio (i.e. straining area to the inlet area ratio) shall be 6:1 ‘The strainer shall have screen of stainless steel (AISI-304) construction with wire diameter of about 0.01 inch. and open area of about 50%. Strainer screen in unloading, line shall be of 40 mesh & that in pressurising side shall be of 80 mesh, Strainer body shall be made of mild steel. No cast iron component shall be used in strainers for F.O, system, Insulation and cladding Insulation materials shall be inhibited and of a low halogen content Insulation materials shall contain no asbestos.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) xxiv. All heavy fuel oil, steam & condensate piping and heavy fuel oil tanks shall be insulated with lightly resin bonded mineral wool insulation. There shall be full insulation on tank except the roof top. xxv. Equipment and piping operating at elevated temperatures shall be insulated with rock ‘wool mattress conforming to IS:8183 and have a density of 100 kg/m? xxvi. Thickness of aluminum lagging shall be 20 SWG (0.911 mm) for piping and all equipment having outside diameter over 450 mm and above. Thickness of lagging shall be 22 SWG (0.711 mm) for piping having outside diameter including insulation less than 450 mm. Emissivity of cladding material shall be considered as 0.2. 4.3.2.2 Electrical System For design requirements of Electrical System, Section -8 of this document may be referred to. 43.2.3 Control and Instrumentation System For design requirements of Control and Instrumentation System, Section -8 of this document may be referred to. Civil Works For design requirements of Civil works, Section 9 of this document may be referred to, 4.3.2.5 Layout and Maintenance requirements |. While deciding the layout of buildings namely Fuel Oil Pump House building the Bidder shall consider the following parameters, a) Minimum clear working space around the equipment shall be 1200 mm b)_ In case of space provided is acting as the handling space for the equipment by overhead crane the space shall be maximum size of equipment being handled plus the clearance of 500 mm minimum on either side with the stationary equipment. ©) Withdrawal spaces of equipment. fi, One maintenance bay of 6m x the width of the building shall be provided.Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) 44 i) ii) iii) iv) » 45 PERFORMANCE REQUIREMENTS. Performance Guarantee Tests shall include: Fall load power measurement of motor for various pumps, Capacity of the HFO unloading & transfer pumps Capacity of the LDO unloading (road and rail) & transfer pumps Capacity of the Drain oil pumps Demonstration of steam system parameters CODES AND STANDARDS The design, manufacture, inspection and testing of the Fuel Oil Handling System shall comply with all the currently applicable statues, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall confirm to the latest edition of the following standards & codes. Other internationally acceptable standards/codes, which ensure equal or higher performance, shall also be accepted. OISD 118 Layouts for Oil and Gas Installations including tank farm for storage of crude / products. Is 1593 Code for Heavy fuel Oil (HFO) IS 1460 Code for light Diesel Oil (LDO) 1S 817 Code of practice for training & testing of metal are welders. IS 823 Code of procedure for manual metal arc welding of mild steel API 620 Recommended rules for design and construction of large welded low pressure storage tanks API 650 Welded steel tank for oil storage ASME Boiler & Pressure Vessel (B & PV) Code : Section VILL, Division I, Pressure Vessel. ASME Boiler & Pressure Vessel (B & PV) Code : Section IX, Welding & Brazing qualification. APL 12D Large welded production tanks IS 803 Code of practice for design, fabrication and erection of vertical mild steel cylindrical welded oil storage tank 18 816 Code of practice for use of metal arc welding for general construction in mild steel. 1S 4503 Code for design & manufacture of Heater ANSIB31.1 Design of power piping system API 600 Code for design & construction of gate valve for sizes 50 NB or above APT 602 Code for design & construction of gate valve for sizes below 50 NB 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 599 Code for design & testing of plug valve 49Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) IS 8183 Group 4 1S 9842 Group 3 Specification for Preformed Fibrous Pipe Insulation 18277 Specification for Galvanised Stee! Sheet 1s 7413 Code of practice for the Application and Finishing of Thermal Insulating Materials at temperatures between 40 Deg.C and 700 Deg.CTYPICAL SCOPE OF WORKS FOR BALANCI 4AL1 4A12 ii) iit) iv) vi) vii) Standard Design Criteria/Guidelines for Balance of Plant of Thermal Power Project 2x (SOOMW or above) Section- 4 (Fuel Oil Handling System) ANNEXURE 4A OF PLANT OF THERMAL POWER PROJECT (2x500MW): FUEL OIL HANDLING SYSTEM SCOPE OF WORK ‘The scope of fuel oil handling system typically covers the design, engineering, ‘manufacture, supply, assembly and testing at manufacturer's works, inspection, packing, forwarding, delivery FOR site and handling with storage at site (Je. taking delivery of ‘materials from carriers, transportation to site), fabrication (as needed), erection, trial run, testing and commissioning including painting protection of fuel oil handling system. ‘The statutory approval for fuel oil unloading, transfer and storage system from Chief Controller of Explosives shall be obtained by the bidder. ‘Typical scope of work for 2x500 MW thermal power project includes: Mechanical One (1) no. 400 NB (min.) heavy fuel oil unloading manifold, 686 meter length, complete with eighty (80) stand pipes with flexible hoses of 8 m length, with tank heating arrangement, One (1) no, 200 NB LDO unloading manifold completed with eight (8) stand pipes with flexible hoses of 8 M length for connecting to road tankers. Five (5) nos. 100 m’ per hour capacity, 4 kg/m? (g)* discharge pressure, AC driven horizontal twin screw type steam jacketed heavy fuel oil unloading pump sets. Two (2) nos. 50m’ per hour capacity, 4 kg/m? (g)* discharge pressure, AC driven horizontal twin serew type LDO unloading pump sets for unloading road tankers, Two (2) nos. 25 m° per hour capacity and 4 kg/em2(g)* horizontal twin screw type pumpset for transferring HFO from storage tank to day tank, if required. ‘Two (2) nos. 25 m’ per hour capacity, 4 kg/em2(g)* horizontal twin screw type pumpsets for transferring LDO from storage tank to day tank, if required. ‘Two (2) nos. 25 m’ per hour capacity, 4 kg/cm2(g)* horizontal twin screw type pumpsets for transferring LDO from storage tank to day tank for auxiliary boiler.