Professional Documents
Culture Documents
HANDLING
SYSTEM
OPERATION
STAGE I
O &M MANUAL
CHAPTER - I
1.
1.1
the coal mine. Moving coal from Mine to Power station continuously as well
as adequately is the biggest task.
Whether from
1.2.
RECEIVING SYSTEM
lignite.
Con-2 runs between the stock piles No.1 and No.2 . The stacker
moves on the rails and it can feed both stock pile No.1 and No.2. Con-3 is
short length shuttle conveyor. Storage yard consists of stock pile No.1 (4A
side) capacity being 80,000 tones on the southern side of conveyor-2 and
stock pile No.2 (4B side) capacity being 70,000 tones on the northern side of
the conveyor-2.
Stock
meters length. In the closed storage area stacker will have slewing angle of
90 degree only.
It
water drainage during rainy season. Sump pumps are provided on both sides
of stockpiles to pump out water from stock piles.
conveyor-2 is 1450 mts.
1.2.1.
DESCRIPTION OF STACKER
1.
Type
B1800-19.9
2.
Capacity
2800T/Hr(or)3730 M3/Hr
3.
13 Mts
4.
Angle of repose
390 approx.
5.
Rail type
S 54
6.
Slewing angle
1800
7.
Track inclination
0.1 %
8.
Travel speed
6&15 Mts/min.
9.
Hoisting speed
5Mts/min.
10.
Slewing speed
9Mts/min
11.
12.
Drive pulley
1000X2000
mm
No.23148
13.
Tail pulley
14.
15.
16.
Other pulleys
800X2000 mm
17.
Slewing gearbox
Bevel Planetary
18.
Travel drive
4Nos 3KW/7KW
19.
Rail gauge
4m
Brg
1.3.
TRANSFER SYSTEM
1.3.1.
DIRECT LOAD
If lignite is required to be diverted to boiler bunker directly, the
CC-2 can feed to Con-7B by positioning the con-3 at its east extreme called
Direct Load. In this condition con-3 need not run.
1.3.2.
BIFURCATION
A new modification has been introduced in receiving system is
called Bifurcation. In this method the lignite receiving from Mine-II is being
transferred to boiler bunker (60%) and storage yard (40%) In this condition
Con-3 is positioned at bifurcation position. Travel limits are modified for this
purpose. Thus con-3 can be positioned and run as per our requirements.
Con-4A and 4B located along stock pile No.1 and 2 respectively.
Both conveyors 4A and 4B are equipped with reclaimers, one on each.
Reclaimers are mounted over rails of 6.0 meters gauge, Reclaimers can be
slewed to 1800
Conveyors 4A and 4B drive heads are located in transfer tower1
and 2 respectively (TT1 and TT-2). In TT-1 and TT-2 conveyors 6A and 6B are
positioned just below the drive heads of conveyors 4A and 4B respectively
and above conveyors 7A and 7B. Lignite can be fed from Con-4A to either
Con-7A or con-7B by altering the position of the Con-6A if Con-6A is
positioned at extreme right i.e. yard side lignite will be fed to Con-7B and
Con-6A will not run. If Con-6A is positioned at middle, lignite will be fed to
Con-7A. In this position
length of 515 meters and effective travel is 490 meters. Conveyor 4A and
4Bs length is1300 meters. (Each belt length) Belt tension of Conveyors 4A ,
4B and con-2 is adjusted by electrically operated winch.
Magnetic separators are installed above the drive heads of
conveyor CC-2, 4A, 4B, named as MS-1A, 5A, 5B, respectively. Another 2 no.
of Magnetic Separators named MS 7A & 7B are provided across con 7A & 7B
respectively.
1.3.3.
In each
machine contains platform, mast, bucket wheel boom, counter weight boom
and bucket wheel conveyor with transfer point. The slew movements of it
are introduced by two slew assemblies located on the superstructure
platform.
The rotating
connection
and
The bucket wheels with its conveyor area are mounted in the
bucket wheel boom. It can be raised or lowered by a hydraulic cylinder. The
bucket wheel body is of welded design with stiffener ribs welded in place and
with connecting lugs for fixing the buckets. There are 10 fitted buckets. The
buckets are formed by welding side plates, transition plates and welded
together to form a unit. The bottom of the bucket has a mat of chains or
rubber for better bucket emptying. All the buckets are connected to a rim
and which in turn connected to one end of hollow shaft assembly other end is
connected to bucket wheel gear box.
The main drive for bucket wheel is coupled by means of a fluid
coupling. This coupling serves as starting and safety coupling to protect the
drive and reclaimer from detrimental overloading.
The counter weight boom is a torsion resistant truss construction
whose lower fork shaped part is bolt connected to the hinge of pivot point of
the bucket wheel boom. The mass is also similar to counter weight boom
construction and it is also connected to bucket wheel boom.
Bucket wheel boom is buffed by a hydraulic cylinder installed
between bucket wheel boom and superstructure.
1.3.4.
SPECIFICATION OF RECLAIMER
1.
Type
SCH-ss-1000-12.3
2.
Capacity
2200 T /Hr(or)2800M 3
3.
Angle of Repose
39
4.
Slewing angle
180
5.
Bucket capacity
6.
Ring volume
150 ltr.
7.
6.4 RPM.
8.
Travel speed
KW
1.4.
9.
Slewing speed
30 mtrs / min 11 Kw DC
10.
5 mtrs / min
11.
12.
132 KW
13.
Belt
EP 4 / 5 Gr 24
14.
Drive pulley
1000 X 1800 mm
15.
Tail pulley
800 X 180 mm
16.
Travel drive
8 Nos.
17.
Rail gauge
155 KW / 105 KW
6 m.
CRUSHER HOUSE
In this house, lignite is sized and supplied to the units. Facilities
Due to lot of
problem in screen and crusher, and also to avoid single stream in crusher a
new modification has been introduced called SCREEN AND CRUSHER BYPASS. For this purpose travel provision has been made in con-9A. In this
condition con-9A can be traveled and positioned in con-12A bypassing the
screen and crusher.
vertical chute.
1.4.1.
ECCENTRIC SCREEN
Two number eccentric disc screen of Type SRH 25/19 are provided
in the crusher house just below the discharge point of conveyors 9A and 9B.
These eccentric disc screen are designated as 10A and 10Brespecively and
are having 2800 T / Hr. capacity each. They are installed mainly to separate
higher size lignite (more than 80 mm) and to divert these coarser particles to
crushers. Normally maximum lignite size is assumed as 400 mm and corner
to corner size is assumed as 600 mm.
1.4.2.
JUNCTION TOWER
In this place lignite either from mine or from stockyard can
1.4.3.
STAGE I
BUNKER CONVEYORS
1.4.4.
STAGE II
BUNKER CONVEYORS
Conveyors
21C1/D1 fed lignite to unit 4 & 5 and con21C2/D2 feeds to unit-6 & 7. Belt
tension of con-20A/B/C/D and 18C/D is adjusted automatically by the
counterweight provided in these conveyors. Dry fog type dust suppression
system is provided right from TT1 to JT2 at every transfer chutes and at
bunker for dust free atmosphere. Fire protection system is provided along
the 7A/B and 14 A/B galleries.
1.4.5.
Stage-II with this system bunker level can be monitored from control room for
both Stage-I and II.
1.5.
MULSIFIER SYSTEM
Automatic mulsifier system has been provided along con-7A/B
and con-14A/B.
1.6.
to bunker conveyor at every transfer chutes and at all bunkers for dust free
atmosphere.
Automation of boiler bunker filling has been introduced in Stage
I and Stage II. Dry fog type dust suppression system is provided right from
TT-1 to bunker conveyor at every transfer chutes and at all bunkers for dust
free atmosphere.
1.7.
1.7.1.
Executives manning each shift. All the units Stage-I and stage-II are filled
twice in each shift.
bunker for receiving lignite and stacking in the yard. The receiving system
consists of stacker, Conveyor-2, conveyor-3 and MS-1A which can all be
started from control room panel in control room.
The yard is
shed in RA side and to maintain equal loads on both RA and RB sides. Before
asking the stacker operator to start the machine the following points need to
be checked.
1.
2.
3.
4.
5.
executives ask the operator to start stacker. Preceding conveyors are started
from control room. As soon as MS-1A is started, CC-2 operator will get an
indication and will in turn start CC-2 conveyor.
conveyors and preceding conveyors and machines full under the control of
Mine-II.
The
(ii)
(iii)
are as follows.
Position-I 17X positioned to stage-I conveyor idle, chute only
positioned
to
Stage-I,
stream
is
running.
(21B1B2-20B-18B-17X-14B)
Position-II
Position-III
be
idle
condition
(21B1B2-20B-18B-17X-14A)
in
this
configuration
1.7.2.
CRUSHER HOUSE
Shuttle conveyors 12A and 12B can be positioned either in 14A or
14B.
passed and
1.7.3.
TT 1 AND TT 2
The shuttle conveyors 6A and 6B (in TT-1 and TT-2 respectively)
1.8.
MAGNETIC SEPARATOR
Cross belt magnetic separators are fixed in CC-2 (MS-1A) in 7A
and 7B (MS-7A and MS-7B). There is an in line M.S. in 4A and 4B each. The
magnetic materials are separated in the magnetic separator.
1.9.
METAL DETECTORS
The belt conveyor 7A and 7B are provided with metal detectors.
Once any foreign material is sensed, the system trips and a marker bag falls
into the conveyor. The location of the marker is the approximate location of
the foreign material. The unwanted material is removed manually and the
system is restored.
1.10.
CONVEYOR
This is a new addition for handling lorry load. The conveyor has its tail end below the
ramp in which lorries unload the lignite. The drive head is connected to conveyor-2 and material is
stacked using stacker.
Capacity
Belt
width
Troughing
angle
Belt
Speed
Conveyor
length
Motor
rating
Motor
speed
UNIT
tonnes/Hr.
Mm
Degrees
m/sec.
kw
rpm
CON-2
2800
1800
40
4.5
737
2X350
1500
CON-3
2800
1800
2.5
69
120
1500
CON-3.2
2800
1800
40
3.65
24.7
110
1500
CON-4A/B
2800
1800
40
3.59
730
420
1500
CON-6 A/B
2800
2000
15
3.65
13
37
1500
CON-7A/B
2800
1800
40
3.61
431
480
1500
CON-9A/B
2800
2400
15
2.49
30/37
1500
CON-12A/B
2800
2400
15
2.51
18
37
1500
CON-14A/B
2800
1800
40
3.61
344
630
1500
CON-17A/B
2800
1800
30
3.53
12
45
1500
CON-18A/B
2800
1800
40
3.57
81
160
1500
CON-20A/B
2800
1800
40
3.49
88
75
1500
21A1/A2/B1/B1
2800
1800
40
3.57
48
55
1500
CON-18C/D
2800
1800
40
3.57
93.875
160
1500
CON-20C/D
2800
1800
40
3.49
143.4
110
1500
21C1/C2/D1/D2
2800
1800
40
3.57
55.875
75
1500
10A/B
2800
No Idler
32
37
1500
11A/B
2800
No Idler
120/116
2x110
990
Disc screen
&crusher
Disc screen
&crusher
FUEL
HANDLING
SYSTEM
OPERATION
STAGE I
O &M MANUAL
CHAPTER II
CHAPTER II
2.
2.1.
INTRODUCTION
Certain progress has been achieved in efforts to burn pulverized
fuel directly into a cold furnace. But the practice of cold starting with solid
fuels is yet to get established.
Hence,
in
any
pulverized
fuel
firing
system, oil fuel has to be utilized for initial lighting up to achieve gradual
build up of parameters over a time duration, till the furnace becomes warm
enough to sustain ignition and combustion of pulverized fuel as a continuous
reliable process.
In Neyveli Thermal Power Station II steam generators,
provisions have been made in the furnace for firing furnace oil as well as
LSHS (Low Sulphur Heavy Stock) as Auxiliary (Secondary) fuels for initial
lighting up and to stabilize the combustion during fluctuating operating
conditions with the main (Primary) fuel i.e. Lignite. Operation of the boiler
with oil firing system is possible only upto 30 % of boiler load.
The oil fuel has number of favourable factors and hence led to its
easy adoption for the above purposes. They are as under:
1.
Oil can be stored easily for long periods. The storage space
required is also less.
2.
Easy transportation.
3.
4.
The
fuel
can
be prepared
easily
for
proper
combustion.
Easy ignition of fuel. The oil fuel can be ignited even at lower
temperatures.
6.
Easier and finer control of the quantity of fuel input and hence,
the heat liberation rates in the furnace.
7.
The oil fuels have comparatively high heating values and hence,
heat liberation per cubic metre of furnace volume is also high.
8.
9.
10.
11.
12.
Possibilities of ash erosion are very less. The plant also can be
maintained neatly due to the absence of ash.
13.
2.2.
DESCRIPTION
Oil fuels are to be handled carefully not only to achieve efficient
utilization but also to ensure safety against fire hazards and all consequent
losses. Awareness on fuel characteristics and their significance are hence
essential for operation engineers in any thermal power station.
2.3.
2.3.1.
DENSITY
The unit weight of liquid in kilograms per cubic metre (Kg/m 3) is
conversions and vice versa, and is also taken into account in design of oil
vessels, fixing of oil prices etc.
2.3.2.
SPECIFIC GRAVITY
The ratio of density of any liquid to the density of water is the
2.3.3.
API GRAVITY
The oil industry employees the API gravity scale, devised jointly
141.5 - 131.5
2.3.4.
HEATING VALUE
The heating value of a fuel of any type is the amount of heat
liberated by its complete combustion. Two different values for any fuel oil
namely gross (high) heating value and Net (low) heating value are normally
specified. The difference between the gross and the net heating value is the
latent heat of evaporation of the water vapour formed during combustion.
When determining the net heating value, the water remains in the gaseous
state and the latent heat is not recovered because the vapour is not
condensed. Variations in heating values between different fuels may be due
to any of the following factors.
1.
2.
3.
4.
5.
6.
This
2.3.5.
VISCOSITY
The viscosity of an oil is the measure of its resistance to flow.
A greater
timed in seconds. The viscosity gives a good guidance for proper handling
and burning of oil.
of oil
leading to incomplete
combustion.
Apart from
When fuels are heated, vapours are produced which may flash in
the proximity of an external flame at a certain temperature which is known
as the flash point of the oil.
cause a sustained burning and not just a flash. This temperature is called the
fire point.
Generally the light oils have lower flash points except in a few
cases. The flash point may also change due to the blending adopted, the
extent of refining or contamination. A flash point of 50 o C to 60o C at the
preheated stage is a desirable value for any fuel oil. If oil is to be used
without preheating a flash point of 40
point oils, preheating should be regulated with care, since excessive heating
may give rise to the evolution of large volume of vapours within the burner
itself i.e. before the furnace, the tip of the burner nozzle.
2.3.6.
POUR POINT
A disturbing feature of most oils is their ability to get into a
storage tanks, a very low pour point of an oil may not be a problem. Even
when the oil is at the pour point, flow of oil may not be there on a suction line
due to large amount of wax or solidified mass of oil blocking the screen or
strainer. Hence the different conditions that exist in the storage, pipe lines
etc are also the factors to be reckoned regarding the flow of oil.
To ensure satisfactory handling of oil in cold weather, a low pour
point is desirable. Oil of low pour point may also get into a semisolid or solid
state in cold weather. The conditions can be easily overcome if heating coils
are provided. Where they are not provided, air agitation can be adopted as a
means.
Problems created by low pour point are:
1. Inability of the oil to be handled by pumps.
2. Clogged strainers and lines.
3. Spitting and erratic combustion due to the interrupted and
insufficient flow of oil in a random pattern.
4. Smoking in the furnace, carbon deposits at the burners.
FUEL
HANDLING
SYSTEM
STAGE I
O &M MANUAL
OPERATION
CHAPTER III
CHAPTER III
3.
CONSTITUENTS
OF
CHARACTERISTICS
3.1.
CARBON
FUEL
OIL
AND
THEIR
2.
4.
Carbon residue comes under the fourth type. When oil vapour is
evolved, on heating a sample of oil, burnt under prescribed test
conditions, a certain amount of carbonaceous
residue settles
ratio, the problem of carbon residue in combustion does not arise. However
the high carbon residue of a grade of oil or the carbon residue formed on
other conditions may present number of problems as detailed under.
1.
2.
3.
3.2.
HYDROGEN
Hydrogen is a desired element in any fuel since the heating value
3.3.
SULPHUR
Sulphur next to Carbon and Hydrogen comes as the third
The more Sulphur presents in oil the less is its heating value.
3.4.
and
sediment
present
in
oil
causes
the
following
difficulties.
1.
2.
3.
4.
5.
6.
7.
3.5.
ASH
The reactions and effects of the presence of ash in oil are as
under.
1.
2.
3.
is
generally
caused
by
sodium
and
This
vanadium
At
Thermal
Power
Station-II
furnace
oil
of
the
following
specification is used.
3.6.
SPECIFICATION
OF
FURNACE
OIL
(IS:1593
QUALITY)
Carbon
86%
Hydrogen
11-12%
Sulphur
N2 & O2
1% max.
Ash
0.1%
Moisture
Traces
Density at 15o C
0.94
Kinematic viscosity
23 centistokes at 100o
Flash point
66 122o C
Fire point
132o C
Pour point
17 27o C
Sediments
0.25%
Acidity
NIL
10,200 10,280
1%
Kcal/Kg
Water content by volume
FUEL
HANDLING
SYSTEM
OPERATION
STAGE I
O &M MANUAL
CHAPTER IV
DISCRIPTION
OF
OIL HANDLING SYSTEM
CHAPTER IV
4.
2.
The fuel oil received through lorries are transferred to the oil
storage tanks, located outside by the oil pumps in the decanting pump
house. From the above tank, oil is conveyed to the boiler operating floor of
the unit by the pumps in the pressurizing pump house.
4.1.
of the boiler house. A decanting bus (300mm dia) has been erected and has
32 decanting points .
decanting bus is taken through a single line (400mm dia) to the suction
header common for 4 decanting pumps inside the decanting pump house.
The decanting pumps are located at a lower elevation and there
is approximately 2.5 meters head difference between the lorry bottom and
the decanting pump suction line.
decanting pump, facilitating easy charging of the suction side of the pump.
The elevation
difference between this line joining the tank and the decanting pump centre
line is 15.7 mts. All the oil lines have steam tracing provision.
4.2.
inside an earthen bund, with volume equal to the storage capacities of both
the tanks put together(3800 M3). The diameter of the tank is 15 Mts. and the
height is 12.5 Mts. In the bottom of each tank, there are two water drain off
points placed diametrically opposite. Apart from them there is also a drain
provision.
Suction for the fuel oil pressurizing pump is taken off from the
tank at an elevation of 0.5 Mts. from the bottom of the tank and this gives a
positive suction of 1.75 Mts. to the fuel oil pressurizing pumps.
4.3.
provided with floor coil heaters. The floor coil heater is a steam coil heater in
which steam at 16 KSc and 230o C is supplied through tubes of 60 mm
diameter and 6.3 mm thickness. The oil can be heated upto 80 o C in this
heater.
The heater is constructed in four coils with individual support.
Each coil consists of three loops and twelve loops counted from one end to
another covers almost the entire floor area of the tank. The coils are given a
slope that steam entry is at a higher elevation nearer to the centre of the
tank and condensate outlets are at a lower elevation and further from the
centre of the tank.
Steam at 16 KSc pressure and 230 o C temperature is supplied
from a header through a line with isolating valves and pneumatic diaphragm
operated valve. A bypass line with isolating valve is provided for the
pneumatic
valve. This line branches off into four and each branch with its own isolating
valve supplies steam to a coil. The condensate outlets each with a steam
trap and isolation valves and bypass are connected together and taken to a
4.4.
SUCTION HEATER
At the outlet of each oil storage tank, a fuel oil suction heater is
provided. It is horizontally placed on the southern side of the tank. The oil is
heated upto 90o C before it goes to the fuel oil pressurizing pump suction.
This is a shell and tube type heater having 197 U tubes of 19 mm
diameter(Outer) and 14 BWG thickness. Steam at 16 KSc pressure and 230 o
C temperature is passed through the tubes. Oil passes through the 2607 mm
long shell of 731 mm OD and 10 mm thick.
The oil inlet and outlet of the heater are provided with isolation
valves. A bypass line with a valve is there to bypass the heater when it is
isolated. A shell drain and a channel drain are also there for draining the oil
from the heater as and when necessary.
Steam supply to
suction
heater
is
through
pneumatic
steam trap with necessary isolating valves and bypass. A safety valve is
provided in the steam chest on the condensate outlet side.
The oil outlets from both suction heaters join together and go as
a single line to the fuel oil pressurizing pump house.
4.5.
Two pumps each forming a pair is meant for one boiler, out of which one will
be in service and the other standby.
The oil outlet from the suction heaters of both the tanks form a
single line to find its way to the above oil pump house where it forms a
header. The suction lines of the six pumps are connected to the above
header.
A filter is provided in each suction line. Two isolating valves are
provided before and as well as after the filter for isolations of the filter for
cleaning purposes. After this the two suction lines meant for a pair of pumps
of an unit are interconnected. Two more isolation valves are provided in each
suction line after the interconnection. This arrangement facilitates operation
of any of the two pumps and filters in combination thus rendering flexibility,
in the event of failure of either one of the pumps or the filters in the series.
Each filter has an air vent and a drain line.
The fuel oil pump has three screws one above the other. The
drive shaft is connected to the centre screw. The pump is capable of handling
19.4 Kilo Litres of fuel oil per hour and develops a pressure of 35 bar. A relief
valve which can be set to open at a pressure of 40 bar takes care of pressure
surges if any. A drain has been provided in the pump base to collect the
leakage oil if any. This drain is ultimately led to the common drain tank.
Two valves are provided in the delivery of each pump. Discharge
lines of two pumps of one unit join together and three such discharge lines
go towards the valve manifold cluster on the western side of the fuel oil
pressurising pump house. In the valve cluster the three discharge lines from
three pairs of pumps are interconnected by interconnecting lines each with
two valves.
With this combustion arrangement, even if both pumps meant for
one unit fail, oil supply can be maintained to this unit using a pump meant
for any other unit. A recirculation line with a non-return valve and an isolation
valve is also provided in all the three delivery lines. These recirculation lines
join the common return line from the boilers. A main valve is provided after
the above connections and then this main recirculation line divides into two.
Each of the above is provided with three isolation valves one
inside the pump house and the other two near the oil tanks. Two recirculation
line joins the inlet of the suction heater i.e. outside the tank. The three oil
supply lines discharge lines of the pumps one each going to the units, have
been further provided with an isolating valve before they leave the pump
house. The oil lines are led to the secondary heaters at 15 metre level of the
boiler house.
Steam tracing lines are provided for the all oil lines in the pump
house.
The
arrangement.
filters
and pumps
are provided
2.
3.
4.
One pressure tapping in the suction just before the pump for
indication.
5.
4.6
All the drain lines in the fuel oil pressurizing pump house are
connected to a drain oil tank of capacity 3m 3 located at 2.7 Mts. below the
floor of the pump house. A screw pump similar to fuel oil pressurizing pump,
but with a capacity to pump 2.232 tonnes per hour at a pressure of 5 bar
takes suction from the drain oil tank and pumps the oil to the fuel oil storage
tank.
The drain oil tank has an inlet line with two valves.
A level
indicator, a man hole, a drain and an air vent are provided in the tank. The
tank has steam heating provision. In the suction line of the pump a steam
jacketed filter is provided with two isolation valves before it. The discharge
lines of the pump has a non return valve and two isolating valves. It then
divides into two and joins the two fuel oil storage tanks.
FUEL
HANDLING
SYSTEM
OPERATION
STAGE I
O &M MANUAL
CHAPTER V
TECHNICAL DATA
OF
PROCESS EQUIPMENTS & ACCESSORIES
CHAPTER V
5.
TECHNICAL
DATA
OF
PROCESS
EQUIPMENTS
&
ACCESSORIES
5.1
Four
Type
Simplex type
Flow rate
110 M3 /hr
Operating pressure
0.5 Kg/Cm2
Operating Temperature
80o C
Design Pressure
6 Kg/Cm2
Design Temperature.
230o C
Viscosity at Operating
Temperature
750 Centipoise
0.92
Strainer
0.1 Kg/Cm2
Body material
WCB
Screen/basket material
6 Kg/Cm2
3 to 4 Kg/Cm2 &
210o C
& Temperature
Gasket Material
5.2.
10 Kg/Cm2
DECANTING PUMP
Asbestos.
Number of pumps
5.2.1.
5.3.
5.4.
Four
Type
Capacity
Pressure
4 Kg/Cm2
Design Velocity
1000 CST
5.5 MLC
Flow temperature
30o C
Make
Jacketing steam
Type
AMW 2255 4H 1
Voltage
Power
37 KW
Speed
1480 Rpm
Current
63.5 Amps
Make
NGEF, India.
110 M3/hr
DRIVE MOTOR
Two
Capacity
1900 M3
Diameter
15 M
Height
12.5 M
Number of tanks
One
Capacity
100 M3
Diameter
5.0 M
Height
5.4 M
Two
Location
Number of coils
Four
5.5.
5.5.1.
5.5.2.
Heating Steam
75-80o C.
Two
Type
Shell size
Medium in Shell
Fuel oil
Design Pressure
1.5 Kg/Cm2
Design Temperature.
60o C
SHELL SIDE
2.25 Kg/Cm2
Number of passes
One
TUBE SIDE
Number of tube
197
Dia 19 mm x 14 BWG
Number of passes
5.6.
Three
Two
Medium in tubes
Steam
Heating Steam
28.7 M2
22.5 Kg/Cm2
Six
Type
Flow rate
5.6 Kg /Sec
Working pressure
10 bar
Working Temperature
80o C
Jacketing steam
5.7.
50% choked
condition.
Six
Make
Capacity
295-340 Litres/Min.
Delivery Pressure
35 bar
Viscosity
16-850 mm2/Sec
Speed
1450 Rpm
Direction of rotation
2.5 M 16 mm2/Sec
Pump
Motor.
Max Permissible suction lift
5.8.
DRIVE MOTOR:
Type
Voltage
Power
35.5 KW
5.9.
Speed
1470 Rpm
Current
64 Amps
Make
Siemens, Germany.
Capacity
3 M3
Diameter
1.25 M
Length
2.74 M
Operating Temperature
130o C
5.10.
Test Pressure
2 Bar
Heater Type
Heater Size
Make
Wezel,GmbH,Germany
Make
Gmbh,
Germany
Type
Simplex
Working pressure
10 bar
Working Temperature
80o C
Volume
11.5 dm3
Jacketing steam
5.11.
Make
Capacity
40 Litres/Min.
Pressure
3 to 4 bar
Viscosity
16-350-850 mm2/Sec
Speed
1450 Rpm
2.5 M 16 mm2/Sec
Pump
5.11.1.
5.11.2.
Voltage
Power
1.1 KW
Speed
1450 Rpm
Oil Temperature
50 to 90o C
34 bar
DRIVE MOTOR
FUEL
HANDLING
SYSTEM
STAGE I
O &M MANUAL
OPERATION
CHAPTER VI
CHAPTER - VI
6.
Suction
Pressure
Drain Oil
Filter
Filter
Filter
oil
1.
5.6
5.37
0.61
2.
38
3.
Operating Temperature,
80
130
80
4.
0.07
0.1
0.07
0.2
0.22
0.2
6.
0.5
0.3
0.5
7.
Filter Surface, M2
11762
8.
35
5.
Note:
7563
52
2330
15
this value increases the filter must be cleaned. Resistance of the filter will
be checked wice in a shift. It the pressure drop of the filter rapidly increases,
this is the indication of contamination of oil system. When the pressure drop
falls suddenly, the filter is broken through.
6.1.
5. When oil starts coming out in the air vent the air vent should be
closed. Now the filter is in charged condition.
6. Inlet and outlet valves can now be opened fully.
6.2.
must be followed.
6.3.
6. The recirculation valve at the fuel oil pressurising pump house must
be kept opened, when oil is not taken to the boiler house.
7. The pump should be started and the discharge pressure is to be set
at 35 bar adjusting the recirculation valve.
6.4.
2.
3.
4.
6.5.
COMMISSIONING
OF
FUEL
OIL
PRESSURISING
1.
2.
Ensure the power and control supply for oil system and steam
systems of the boiler.
3.
4.
5.
6.
The
operation
of
the
interlocks
and
protections
of
the
The drain oil system in the fuel oil pressurising pump house
as well as in the boiler are to be kept ready.
8.
First the oil lines up to filters are charged from the tank.
Then filters are charged and after that pump is charged.
9.
10.
11.
The oil lines upto boiler house is then charge by slowly opening
the delivery valve in the oil line at pressurising pump house.
12.
Now
the
recirculation
valve
at
14.
15.
and the oil will be under recirculation through the recirculation line before
secondary heaters.
6.6.
ROUTINE
CHECKS
AND
PRECAUTIONS
DURING
NORMAL OPERATION
1.
2.
3.
Temperature
of
the
oil
system
should
be
in
the
range
equipment
in
the
pump
Operation
of
each
and
every
5.
6.
7.
8.
9.
Level of
6.7.
6.8.
1.
The
drain oil
tank
should
2.
The trace heating system of the drain pipings should be put into
operation.
3.
4.
When the pipe drain the trace heating system for that
piping should be shut off.
5.
NOTE
1.
2.
3.
The blowing off hose should be handled with utmost care. Since it
has no insulation and could cause dangerous accidents.
TROUBLE
The pump does
not produce the
design pressure
POSSIBLE CAUSES
REMEDY
Excess
wearing
out
of
the
pump rotor.
2
Oil is solidified in
the oil pipe
Pressure in the
oil system varies.
(a)
Any such opening of valve
should be
located and closed.
(b)
The
should be
6.10.
1.
2.
Draining of the oil from the oil system into open air or rain-water
canal and sewage channel is forbidden, similarly blowing out
pipes into the above places.
3.
Use
of
naked
flame
in
the
oil
supply
rooms
and
its
surroundings is forbidden.
4.
A 0.25M3 vessel fully filled with dry sand along with a spreader
should be kept in every room.
5.
6.
7.
8.
Before doing any repair in the oil system the pressure must be
released from the piping system and from the equipment, then
they shall be drained and blown with steam.
9.
During
repair
the
fire-fighting
regulation
must
be
10.
FUEL
HANDLING
SYSTEM
OPERATION
STAGE II
O &M MANUAL
CHAPTER VII
CHAPTER - 7
7.
7.1.
INTRODUCTION
Acute energy crisis eventually makes enormous trust on efforts to
It has
become a practice to increase the capacity of oil firing system, beyond that
required for coal ignition to a capacity that enables the turbine to be
synchronized on fuel oil alone, as the size of the steam generators has grown
up.
Quick and reliable decanting ability, whenever fuel oil has been
brought to site.
2.
3.
4.
5.
entities in the oil firing system of stage-II steam generators. A separate fuel
oil pump house fort Stage II has been installed behind the stage-II water
treatment plant to handle both fuel oils.
7.2.
FUEL OILS
Fuel oil is rather a complex hydrocarbon mixture containing
India High speed diesel oil & Light diesel oil. The later is a blend distillate
fuel with small proportion of residual fuel oil and it is found most suitable fuel
oil in the coal fired steam generators during start up.
The basic properties and constituents of the fuel oils being used
in stage-II steam generators are detailed as under.
FO
LDO
1.5
4.5
1.8
Ash, % by weight
Traces
0.25
Density, g/ml
0.94 at 25oC
0.
23at 100o C
0.1
0.02
88-92 at 75o C
Flash point,
66 - 122
66
Fire point,
132
130
17 27
12 - 18
Pour point, o C
Sediments, % by weight
7.3.
LDO SYSTEM
7.3.1.
LDO DECANTING
0.25
0.1
Two branches are emanating from the suction header and in each
branch there is an oil filter and a light oil transfer pump.
The oil filter is of simplex type having a screen with 250 microns
perforations. It enables trouble free pumping by separating foreign materials
present in the oil. The accumulation of contaminants in the oil filter can be
monitored with the help of
1. Differential pressure colour indicator and
2. Differential pressure indicator.
The normal colour/differential pressure is white/< 0.05 bar
respectively.
When
the
filter
gets
clogged
(50%
clogging)
the
Two LDO storage tanks are installed in the eastern side of the fuel
oil pump house/
and is capable of storing 100 M3 of oil. The LDO delivery line from LDO
transfer pumps is branched into two lines near the tank and each one is
connected to the LDO storage tank at a higher elevation. A breather is
provided at the top of each tank. In order to ascertain oil level, a level
indicator, a level switch and afloat level indicator are provided in the tank. An
artificial bund (dykes) has been built around the tanks, with a holding
capacity of 200 M3 which is equal to the total capacities of both tanks. This
facility not only contains the oil of any oil leak/tank burst, but also enables
easy extinguishing of fire.
7.3.2.
a hand operated isolation valve is provided. The LDO suction lines emanating
from two tanks are joined to form a single line near the LDO tank area. It is
extended to the pump house, where it is divided into two branches. In each
line a filter and a light oil pressurising pump are installed. Normally out of
two filters and two pumps any one filter and any one pump can be taken into
service. A drain is provided before the filters. It is used in case of doing any
maintenance in the LDO suction line.
The LDO suction filters are of simplex type having screen with 0.
5 mm perforations, to separate any solid contaminants in the oil. The
clogging of the filter can be found out, by checking pressure drop across the
oil filter for which a differential pressure, colour indicator and a differential
pressure
indicator and are installed across each filter. In order to drain as well as
charge the filter, an air vent and a drain are provided at the top and bottom
of the filter respectively. A tray is provided below the filter to collect drained
oil, which can be admitted to the drain oil line. A hand operated isolation
valve is provided, on either side of the filter for isolation purpose.
A line connects the outlet of both filters after their outlet valves
known as interconnection line. It is mainly used to connect any filter to any
pump so that without stopping running pump, reserve filter can be brought
into service. A branch is taken from the middle of the interconnection line to
oil scheme for flushing operation. In addition a drain is provided in this
interconnection line.
LDO pressurizing pumps are screw type pumps (SNH 120 ER 46 D
6.9 W12) having a capacity to discharge oil at the rate of 185 litres per
minute
the
discharge valve. The discharge lines of the pumps are connected as a single
delivery line, carrying light diesel oil to the boiler area.
7.3.3.
bypass line with a hand operated valve is laid for this control valve. After this
arrangement a NRV is provided in the common line.
One pressure indicator, one pressure switch and one pressure
transmitter are provided in the LDO supply line to boilers.
The pressure
transmitter will give necessary signal to the pressure control valve whenever
LDO pressure get varied.
back to the LDO tank.
area, where it branches into two and each line is connected to the tank at a
higher elevation.
NOTE
LDO pressurising pump will not be in service normally. It will be
started as and when it is required.
FUEL
HANDLING
SYSTEM
OPERATION
STAGE II
O &M MANUAL
CHAPTER VIII
CHAPTER - VIII
8.
8.1.
fuel oil pump house. It is common for all seven boilers in TPS-II. But stage-II
fuel oil pump house facilitates pumping of furnace oil to stage-II boilers after
pre-heating. This heating facility ensures free flow of furnace oil from the
tanks to stage-II fuel oil pump house by gravity.
Furnace oil for stage-II boilers is taken from each tank through a
separate suction line.
8.2.
SUCTION HEATER
Suction heater
The oil inlet and outlet of the heater are provided with isolation
valves. A bypass line with a valve is there to bypass the heater, when it is
isolated. A shell drain and a channel drain are also there for draining the oil
from the heater as and when necessary.
Steam supply to
suction
heater
is
through
pneumatic
8.3.
of oil pressurizing pumps. One pair is meant for boilers 4 & 5 and the other
pair for the boiler 6 & 7. Arrangement in both streams are very similar. For a
pair of pump, two separate lines are taken from the suction header. In each
line there is a filter and pump. The filters are of simplex type 6-150 lbs-RF
having perforations of 500 microns. On either side of the pump and filter,
hand operated isolation valves are provided.
An interconnection line is
provided in between the pump and filter connecting both lines of that pair. A
NRV is also provided in the discharge side of the pump. This interconnection
permits the use of any filter for any pump of that pair.
Each pressurizing pump is capable of delivering oil at the rate of
500 lpm at a pressure of 35 bar. The pump is driven by a motor, of three
phase, 415 Volt, 45Kw, 1478 rpm, 82 amps. The following instruments are
provided in the oil scheme.
1.
2.
3.
4.
5.
filters, is branched into two lines. Each line with a hand operated valve is
connected to the interconnection line provided after oil filters.
This is
The discharge lines from the FO oil pumps of the pair, are
connected to form a single delivery line. This line feeds FO to oil preheating
station otherwise known as secondary oil preheating station. A re-circulation
line is taken, before the secondary oil heating station in each stream.
operated isolation valves on either side in the re-circulation line. A line with
a hand operated valve is provided as a bypass for this diaphragm valve. A
NRV is also there in the re-circulation valve after the bypass line connection.
The re-circulation lines of both streams are connected to the return oil line
from the boilers and finally diverted to oil tanks.
8.4.
SECONDARY HEATERS
There are two secondary oil preheaters in each stream, out of
which one will be in service, the other stand by. The pumped oil is preheated
from 85oC to 130oC in the secondary oil preheaters so that
1.
2.
Viscosity
of
oil
gets
reduced
for
better
atomization
and combustion.
Two oil preheaters are arranged in parallel and located one over
the other.
Steam is drawn from steam line taken from the auxiliary steam
interconnecting bus.
heater.
control valve, flanked with hand operated valves. A bypass line with a valve
is also provided for this. After this the steam line is branched off into two and
each line with a hand operated isolating valve is connected to top of one
heater.
2.
3.
Temperature
indicator
and
temperature
element
after
the heater.
4.
5.
6.
7.
The oil line from one pair of oil heaters carries preheated to boiler
4 & 5 and the line from other pair of heaters to boiler 6 & 7. the return oil
lines from all the boilers are connected together and a single line carries
return oil back to Stage II fuel oil pump house. This return oil line is
connected to the recirculation lines of both streams and finally taken to the
oil tanks area, where the oil can be admitted at the inlet of any of the suction
heaters or to any one of oil tanks. Hand operated valves are provided
suitably for the above purpose.
8.5.
FO oil system in order to drain oil from oil lines in case of necessity for
maintenance. The drained oil from oil lines is diverted to a drain oil tank.
Totally there are five drain oil tanks for stage II out of which one is located
in stage II fuel oil pump house. Remaining four are provided at the boiler at
the rate of one per boiler.
The drain oil tank in FOPH is located at - 6.4 ML in the floor of
the pump hose to help effective draining of oil from the lines. All drains
emanating from the oil system at FOPH join a common drain line and this line
with a valve is connected to the drain oil tank. The capacity of drain oil tank
is 1 M3. The tank is of size Dia 1000 mm x 1550 mm. Provision for steam
heating is available to maintain fluidity of oil while it is stored in the steam
pipe of Dia 48..3 x 3.7 mm with an heating area of 0.8 M 2 is fitted inside the
tank for this purpose. The tank is fitted with a level indicator, two level
switches, a man hole, a drain and an air vent.
A drain oil pump is provided to pump the oil back to main tanks.
In the suction of the pump a filter is provided. Isolation valves are provided in
the suction side of the filter discharge side of the pump and also a NRV in the
discharge side of the pump. The drain oil pump has a capacity to deliver the
oil at the rate of 39 Lpm and at a pressure of 4.9 bar which is driven by a
motor of rating 3 phase, 415 V, 1.1 KW, 1415 Rpm, 2.65 Amps.
The discharge line from the pump joins the recirculation line
originating from the secondary heaters which in turn is connected to storage
tanks.
FUEL
HANDLING
SYSTEM
STAGE II
O &M MANUAL
OPERATION
CHAPTER IX
OPERATION
OF
LDO SYSTEM
CHAPTER - IX
9.
9.1.
DECANTING OF LDO
1.
2.
3.
4.
5.
Open the oil supply valve to the tank and ensure that oil supply
valve to the other tank is closed.
6.
7.
8.
9.
10.
11.
Close the air vent as soon as oil flows out from decanting bus.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
9.2.
2.
If the pressure drop exceeds 0.22 bar, the standby pump and
filter is to be started.
3.
4.
5.
6.
7.
Dismantle
cover
of
the
casing
and
remove
the
filter
9.
10.
11.
Close the drain valve and open the air vent of the filter.
12.
Open the inlet valve of the cleaned filter partially and slowly.
13.
Close the filters air vent as soon as oil flows out through it.
14.
15.
2.
3.
Select any one tank and check the oil level in the tank.
4.
Open the tank outlet valve and check for closing of other tank
outlet valve.
5.
6.
7.
If the filter is not already charged, close filter drain, open air
vent.
8.
9.
Close the air vent as soon as oil comes out through it.
10.
11.
12.
Select any one pump and open its suction and discharge valve.
13.
14.
15.
16.
17.
18.
19.
Check the motor for any spark, vibration, unusual noise, etc.
20.
21.
22.
23.
24.
9.4.
Check the colour and differential pressure across the filter which
is in service.
2.
3.
Charge oil to reserve filter and then start the reserve pump.
4.
5.
6.
7.
8.
9.
10.
11.
Open the drain valve and then open air vent of clogged filter.
12.
13.
14.
15.
Close the drain valve and open the air vent of the cleaned filter.
16.
17.
18.
FUEL
HANDLING
SYSTEM
STAGE II
O &M MANUAL
OPERATION
CHAPTER VII
OPERATION
OF
FURNACE OIL SYSTEM
CHAPTER - X
10.
10.1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Open the bypass valve of TCV and admit steam to the heater.
10.
11.
12.
13.
14.
15.
16.
17.
10.2.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
During
running
of
FO
system,
check
the
differential
If differential pressure across the filter is > 0.22 bar, then take
the reserve filter in service.
13.
14.
15.
16.
17.
18.
19.
20.
10.3.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
10.4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Check the pressure of oil at the heater inlet to find the operation
of re-circulation valve
FUEL
HANDLING
SYSTEM
STAGE II
O &M MANUAL
OPERATION
CHAPTER XI
TECHNICAL DATA
OF
PROCESS EQUIPMENTS & ACCESSORIES
CHAPTER - XI
11.
11.1.
11.2.
LDO TANKS
Number of tanks
100m3
Diameter
5.0M
Height
6.0M.
Flow rate
13.5Kl/Hr.
Size
NB 80/250 Microns
Manufacturer
M/s
Sigma
0.05 bar
0.22 bar
Industries,
Bombay
11.3.
Capacity
Delivery pressure
4.5 Kg/Cm2
Type
TS 105/030
Make
TUSHACO Pumps
M/s Delta Corporation, Vapi
Drive
:
3phase,415V,5.5Kw,1430rpm,
11 amps
Make
11.4.
Flow rate
2.85 Kg/sec.
Working Pressure
Working temperature
30oC
Type
2 150lbs RF
Filter size
1.65.1.220.500, Simplex,
500 Microns
Make
0.05 Kg/Cm2
0.22 Kg/Cm2
Body material
Carbon steel
Screen/Basket
Carbon steel/Aluminium
Wiremesh-Stainless
steel
Hydrostatic test pressure
11.5.
13 bar
Screen surface
7563 Cm2
Gasket material
Rubber Viton
Two
Capacity
Discharge pressure
35 bar
Type
Make
Motor
3phase,415V,18.5KW,
2940Rpm, 33 Amps
11.6.
Type
1MJ 6183-2CA90Z-BG180m
Make
Siemens, Germany.
Four
Flow rate
8.5 Kg/Sec
Working pressure
0.5 5 bar
Working temperature
130o C
Type
6150lbsRF1.65.1.4.355.500.6,
Simplex
Differential pressure (Clean) :
0.1 bar
0.25 bar
Filter size
500 microns
Make
Body Material
Carbon Steel
Screen/Basket
C Steel/Alu Wiremesh
Stailess steel
11.7.
13 bar
Screen surface
18575 Cm2
Jacketing steam
10Kg/Cm2
Gasket material
Rubber Viton
Delivery Pressure
35 bar
Type
Screw pump
SMH 660 ER 40 E6.9 Y W 12
TOL 2.
Make
Drive Motor
Type
1 MJ 6253 4 CA90-Z,
BG250m
Make
11.8.
Siemens, Germany
SECONDARY HEATERS
Number of heaters
Manufacturer
Diameter
558.8 x 16mm
Length
7150mm
Number of tubes
Tube Diameter
-----
20 x 2 mm
Volume
900 litres
415 litres
Medium
Steam
Fuel Oil
Design Pressure
25 Ksc
40 Ksc
Design temperature
300oC
150oC
Test Pressure
-----
---6000mm
224
37.5 Ksc
60 Ksc
22 bar
40 bar
Operating Pressure
18 Ksc
35 Ksc
Number of passes
11.9.
Tube Side
Temperature at inlet
230oC
80-85oC
Temperature at outlet
187oC
130oC
Location
11.10.
Capacity
1m3
Size
Heating facility
By using steam
Heating tube
Heating area
0.8 M2
1+4
Flow rate
0.6 Kg/s
Working pressure
10 bar
Working temperature
130oC
Type
1 150 lbs RF
1.65.1.4.160.250 Simplex
Filter size
500 Microns
Make
0.1 bar
0.22 bar
Body Material
Carbon Steel
Screen/Basket
C Steel/Alu Wiremesh
Stailess steel
13 bar
Screen surface
2330 Cm2
Jacketing steam
10 bar
Gasket material
Rubber Viton
11.11.
1+4
0.62 Kg/s
Delivery Pressure
5 bar
Type
Screw pump,
SMH 40 R 46 E6.0 W 72
Make
Drive Motor
3phase,415V,1.1Kw,1450rpm,
2.65 amps.
Type