Fuel Oil Unloading and Forwarding System Description: I.P.D.C. Project: Shirvan 6×159 M.W. Gas Turbine Power Plant

MINISTRY OF ENERGY
IRAN POWER DEVELOPMENT COMPANY
I.P.D.C. PROJECT : SHIRVAN 6159 M.W. GAS TURBINE POWER PLANT
FUEL OIL UNLOADING AND FORWARDING SYSTEM DESCRIPTION
KHERAD WATER TREATMET COMPANY

B A 0 REV.
As letter No. 20.6367 dated 83.08.05 FIRST ISSUE

DESIGNATION
NOV.2004 AUG.2004
DATE
M.Z. A.Z.
DESIGN
NOV.2004 AUG.2004
DATE
S.H. S.H.
CHKD
NOV.2004 AUG.2004
DATE
E.A. E.A.
APPROV
NOV.2004 AUG.2004
DATE
MAPNA DOC. NO. : MP-SVG-18ID-04-FG0-001 CONTRACT NO. : SV-0602/HA/TL SE CODE : MIR.DOC. NO. 9007
REV. : A
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FILE NAME : FUEL OIL UNLOADING & FORWARDING SYSTEM DESCRIPTION MF CODE: --REV.A
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KHERAD WATER TREATMET COMPANY

B A 0 REV.
As letter No. 20.6367 dated 83.08.05 FIRST ISSUE

DESIGNATION
NOV.2004 AUG.2004
DATE
M.Z. A.Z.
DESIGN
NOV.2004 AUG.2004
DATE
S.H. S.H.
CHKD
NOV.2004 AUG.2004
DATE
E.A. E.A.
APPROV
NOV.2004 AUG.2004
DATE
REV. : A
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CONTENTS
1. General 2. Reference Documents & Drawings 3. Main Equipment 4. Design Data 4.1 Local Conditions 4.2 Gas Oil Specifications 5. Process Description 5.1 Gas Oil Supply 5.2 Unloading Oil Reservoir 5.3 Unloading pumps 5.4 Gas Oil Storage tanks 5.5 Forwarding System
TREATMENT COMPANY
KHERAD WATER
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1-GENERAL
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SHIRVAN Power Plant consists of Six Gas Turbines at 159 MW @ ISO Conditions. The gas turbines will be installed in turbine building. Fuel oil will be utilized as a back up fuel, when natural gas is not available for gas turbines and auxiliary boilers. The fuel oil maximum flow rate at startup for each Gas Turbine is about 63 m3/hr (rev.A), therefore, six sets forwarding pumps, with each capacity 65 m3/hr are considered to pump the fuel oil to the gas turbines. There are two forwarding pumps in each set, which one of them is in service and the other one is as standby. Fuel oil shall be stored in two vertical tanks each with a holding capacity of 20,000 m3. In total, they shall hold approximately 40,000 m3 fuel oil. In this specification the KKS No. of equipment of gas oil unloading system is start with No. (60), and KKS No. of gas oil-forwarding system is start with. No. 61 to 66. The scope of gas oil system includes supplying gas oil for six gas turbines and the auxiliary equipment such as the auxiliary boilers fuel pumps.
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2-REFERENCE DOCUMENTS & DRAWINGS
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2.1-DRAWINGS Fuel oil unloading system P&ID Fuel oil forwarding system P&ID Aux. steam distribution & condensate return system P&ID Fuel oil unloading system PFD Fuel oil forwarding system PFD Aux. steam distribution & condensate return system PFD 2.2- DOCUMENTS Fuel oil system design criteria Aux. steam distribution & condensate return system description
MP-SVG-18IE-02-FG0-001 MP-SVG-18ID-02-FG0-001 MP-SVG-22IE-02-SB0-003 MP-SVG-18ME-02-FG3-001 MP-SVG-18ME-02-FG3-002 MP-SVG-20ME-02-SB3-001 MP-SVG-18ME-04-FG3-001 MP-SVG-22IE-04-SB0-002
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3-MAIN EQUIPMENT
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KKS NUMBER 1- Six unloading station. 2- Fuel oil unloading reservoir (1 set) Capacity : 80 m3 3- Duplex filter for unloading pumps (1 set) 4- Unloading pumps (2 sets) Q= 200 m3/hr H=50 m.w.c. 5- Fuel oil storage tank (2 sets) Capacity : 20000 m3 : 60EGA07 BB001 : 60EGA07 AT001 : 60EGA08/09 AP001 : 60EGB01/02 BB001
6- Duplex filters for forwarding pump (6 sets) : 61EGR01 AT001 : 62EGR01 AT001 : 63EGR01 AT001 : 64EGR01 AT001 : 65EGR01 AT001 : 66EGR01 AT001 7- Forwarding pumps (12 sets) Q= 65 m3/hr H=60m.w.c. : 61EGC02/03 AP001 : 62EGC02/03 AP001 : 63EGC02/03 AP001 : 64EGC02/03 AP001 : 65EGC02/03 AP001 : 66EGC02/03 AP001 : 61EGD03 BB001 : 62EGD03 BB001 : 63EGD03 BB001 : 64EGD03 BB001 : 65EGD03 BB001 : 66EGD03 BB001
8- Accumulator (6 sets)
9- Duplex filters for fuel oil feed pumps of auxiliary boiler (1 set) : 60EGR01 AT001 10- Fuel oil feed pumps of auxiliary boiler (2 sets) Q= 4 m3/hr H=35 m.w.c.
KHERAD WATER
: 60EGC02/03 AP001
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4- DESIGN DATA
4-1 Local Condition

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- Site Altitude: - Max. Ambient Air Temperature: - Min. Ambient Air Temperature : - Design Temperature(rev.A): - Average Humidity: - Design Wind Velocity: - Prevailing Wind Direction:
1115 meter + 42.3 C - 30 C + 15 C 56 % 144 m/s West to East
4-2 Gas oil Specification

CHEM & PHYS. PROPERTIES
Specific gravity Kg/m3 Kinematic viscosity (at 100F) cst Flash point C Pour point Summer C Winter C Total sulfur % Weight max. Carbon Residue % Weight (On 10% Residuum) Ash % Weight Water & Sediment % Vol. Sodium + Potassium p.p.m. Calcium p.p.m. High calorific value KJ/lit Low calorific value KJ/lit Lead p.p.m. Vanadium p.p.m. Rid vapor pressure psia Dust total ppm (wt.) 2<d<10m ppm (wt.) d<10m ppm (wt.) d<25m ppm (wt.) Temp. of fuel oil: Min. 10C above pour point Max. 5C below flash point
Units
Range
(820-860) (2-5.5) Max. 0.1 Max. 0.01 Max. 0.05 Max. 0.4 < 0.5 ppm Less than 2 5 4.5 0.5 -
Design
843.8 3.8 62 -1 -3 1.5 Trace Trace Trace < 0.3 ppm (wt.)ppm <10 (wt.) 38220 36280
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5- PROCESS DESCRIPTION
5.1 Gas Oil Supply

Individual unloading station has been foreseen for delivery of gas oil by road tankers to unloading tank. This station is equipped with six unloading bays, suitable for simultaneous unloading of six road tankers with an approximate capacity of 30 m3. The fuel will be
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discharged from the tanker by gravity and goes through three flexible hoses in to receiving steel pipes. Then fuel from each bay will be collected in to a header and flows in to the 80 m3 fuel oil unloading reservoir (60EGA07 BB001).
5.2 Unloading Oil Reservoir

Unloading tank is underground housed in a pit so, it is placed lower than unloading pumps. The material of unloading tanks is carbon steel and it is covered with soil. The unloading tank (60EGA07 BB001) will be filled via tanker unloading station (rev.A) which is equipped with 18 hoses connection for discharging of six tankers. Unloading tank has been equipped with inlet/outlet isolating valves, drain & vent lines . (rev.A) Also, for preventing to return gas oil to the tank, one check valve (60EGA07 AA100) has been foreseen on the outlet line. A local level indicator (LI 60EGA07 CL501) will be provided on the unloading reservoir which equipped with four positioners. The high high level switch (LSHH 60EGA07 CL001) transmits an alarm signal to unloading station and local control room (rev.A) to inform the operator to stop unloading of the oil tanker, in order to avoid over flow of tank. The high level switch (LSH 60EGA07 CL002) starts one of the unloading pumps automatically. Unless the oil level reaches this level or higher, automatic start of the unloading pump can not be achieved. The low level switch (LSL 60EGA07 CL003) gives an alarm in local control room to announce the operator. The low low level switch (LSLL 60EGA07 CL004) stops the unloading pump to prevent it from dry running and gives an alarm in local control room to announce the operator .
5.3. Unloading Pumps

The fuel oil handing system is designed to transfer gas oil from unloading reservoir to fuel oil storage tank. Fuel oil flows through a DN 250 header from the unloading reservoir to the pumps. The system is equipped with two 100% duty centrifugal unloading pumps (60EGA08/09 AP001) with capacity of 200 m3 /hr and discharge head of 50 m.w.c. One of these pumps will be in service and the other one will be as "standby". The pumps are protected from ingress of particles by duplex filters (60EGA07 AT001) located at the pump suction. For duplex filter one pressure differential indicator switch & alarm ( PDIS 60EGA07 CP001) has been foreseen to notify the operator to change and wash the dirty filter. Low low level switch of unloading reservoir (LSLL 60EGA07 CL003) and high level switch of fuel oil storage tank (LSH 60EGB01/02 CL002) will stop the unloading pumps KHERAD WATER automatically. Also when the level of fuel oil storage tank is at low low level (LSLL TREATMENT COMPANY
MAPNA DOC. NO. : MP-SVG-18ID-04-FG0-001 CONTRACT NO. : SV-0602/HA/TL SE CODE : MIR.DOC. NO. 9007 REV. : A Page 13 of 17 FILE NAME : FUEL OIL UNLOADING & FORWARDING SYSTEM DESCRIPTION MF CODE: --REV.A
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60EGB01/02 CL005) and the manual valves arrangement is in Drainage State(dicharging one storage tank to other one )(rev.A), the unloading pump will be stopped automatically. In addition of automatic start/ stop of pumps, to facilitate the operation, the operator can start / stop the pumps manually by "HS 60 EGA08/09 CH501" (Push buttons from local control boxes when the selector switch is in local position.).Two pressure indicators (PI 60 EGA08/09 CP501)and (PI 60 EGA08/09 CP502) are considered for local pressure indication of suction and discharge of each pump. After passing through a flow meter and totalizer (Local reading) (FIQ 60EGA10 CF501) located in the common discharge of the pumps, the fuel oil flows through a DN 200 line from the unloading pump house to the two storage tanks. Also drainage of gas oil from one storage tank to the second from return lines (60EGA13/14 BR001- GO-250-CL3-F) could be possible with unloading pumps. In this case, the isolating valves should be in their correct position. As mentioned before, unloading tank is underground and its level is lower than unloading pumps, therefore, there is one isolating check valve(60EGA07 AA100), in outlet line of unloading reservoir tank to prevent return of gas oil from storage tank to the unloading tank. The isolating valve on the gas oil return line is normally close but, if it is open, the discharge valve of unloading tank (60EGA07 AA001) should be close. Some of the manual valves which their positions (open/close ) are important equipped with open or close limit switches. Their signals are transferred to the control system. For example on the inlet line of fuel oil to storage tanks there are two manual valves (60 EGA11/12 AA001) which are equipped with limit switches.
5.4 Gas Oil Storage Tanks

There are two above ground storage tanks (60EGB01 BB001 & 60EGB02 BB001) each with a capacity of 20000 m3, which is vertical, cylindrical and fixed supported cone roof type. The fuel oil storage tanks are provided with vents to allow the escape of vapors during temperature rises. One over flow line has been foreseen for each tank. Also each tank is equipped with floating suction device and draw off sumps for drain of tank. In each time, only one fuel oil storage tank is in service and the other one is stand-by then one fuel oil inlet/outlet valve of two storage tanks is in open position. The open or close position of inlet/ outlet isolating valves of storage tanks are selected by operator. Also, when one of storage tanks (60EGB01/02 BB001) should be out of service, because of maintenance, the gas oil should be taken out to the other tanks by unloading pumps from return gas oil lines. Open or close position of related isolating valves on the header return line to unloading pumps (60EGA08/09 AP001) are selected by operator. Each Fuel oil storage tank is equipped with a level instrument with local indication (LI 60EGB01/02 CL501), level transmitter (LT 60EGB01/02 CL103) for remote indication of tank level in central control room and four level switches.
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The high- high level switch (LSHH 60EGB01/02 CL001) will announce alarm in local control room. High level switch (LSH 60EGB01/02 CL002) trip the unloading pumps and will announce alarm in local and central control room. Low level switch (LSL 60EGB01/02 CL004) will announce alarm to local and central control room for providing the fuel oil and increasing the level of gas oil storage tank. Low low level switch (LSLL 60EGB01/02 CL005) will trip the fuel forwarding pumps and announce alarm to local and central control room. Also when the gas oil will be transferred from one storage tank to another one ,if the level of gas oil reaches to low low level in the first storage tank, level switch low low (LSLL 60EGB01/02 CL005) will trip the unloading pumps. In addition, a level indicator (LI 60EGB01/02 CL502) is provided to indicate the fuel oil level locally. (rev.A) Two steam coils are foreseen in each fuel oil storage tank to warm up the gas oil and to bring the temperature of gas oil above the pour point under worst conditions. A motorized valve is installed on the inlet header of steam coils, which is shown in steam & return condensate P&ID. The fuel oil storage tank is provided with a local temperature indication (TI 60EGB01/02 CT501) and two temperature switches high and low (TS 60EGB01/02 CT003/004) for limiting the temperature of storage tank between two points. (For more information refer to aux. steam and return condensate system description Also there is a temperature indicator and transmitter (TIT 60EGB01/02 CT101) on each storage tank, which provides remote indication in LCP and alarms high high and low low in LCP and CR.(rev.A).
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5.5 Forwarding System

The light fuel oil forwarding system supply gas oil from the storage tank (20000m 3) to the gas turbine (GT) injection point at the required pressure and flow rate . Also forwarding system supply the Aux. boilers burners with liquid fuel and control the amount to be injected into the combustion chambers in accordance with the demand at start-up, in operation and while shut down. Two storage tanks are connected to one common header which feeds six branches each for an individual gas turbine. Fuel oil is pumped from the 20000 m3 storage tanks through 12 forwarding pumps, each with capacity of 65 m3/hr. For each turbine, there are two forwarding pumps which one is in service, and the other one is standby. One pressure indicator is foreseen at the suction and discharge of each pump (PI 61 to 66 EGC02/03 CP501), (PI 61 to 66 EGC02/03 CP502) for local pressure indication. One pressure switch low, (PSL 61 to 66EGC02/03 CP001) is provided at the discharge of each forwarding pump. When the pressure is not sufficient and the pressure switch is activated, GT control systems will automatically changeover the pumps. Previously running pump will be tripped and the other forwarding pump will be started. The pumps are protected from ingress of particles by duplex filter(61 to 66EGR01 AT001) (rev. A) located at the suction of each forwarding pump skid. In order to clean one of the filters, a manual changeover valve is included so that a changeover may be performed without interruption of operations. For each duplex filter set one pressure differential indicator and switch (PDIS 61 to 66EGR01 CP001) has been foreseen. The differential pressure across the filter indicates the degree of clogging, locally. If the differential pressure over-runs the predetermined value, the switch will show an alarm in central control room .It inform the operator to change the filter and start washing the dirty filter. There is one accumulator (61 to 66 EGD03 BB001) in gas oil forwarding discharge line of each turbine unit to supply fuel oil during transit time (when the running forwarding pump trips and the stand by pump is not come in to operation) to avoid the trip of GT injection pump. One temperature gauge (61 to 66 EGD03 CT501) has been provided before each accumulator to indicate gas oil temperature locally. A steam heat tracing system and insulation is considered for fuel piping of the forwarding station.The heat tracing shall be sufficient, so that the temperature of gas oil remain above the pour point, even under the worst ambient conditions. At this conditions the formation of wax in the gas oil will be prevented and the viscosity of the fuel at the nozzle will be maintained at the value specified by the GT supplier. To assure satisfactory operation of the combustion system, the fuel temperature should be maintained at 10C during stand-by period. At this temperature the fuel viscosity is good for the GT combustion system at ignition time.
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Two fuel oil feed pumps of auxiliary boiler (2 x 100%) ( 60EGC02/03 AP001) with capacity of 4 m3/hr and 35 meter discharge head are considered for filling the auxiliary boiler's daily tank. This tank equipted with two level switches . Level switches low strarts and level switche high stops the fuel oil feed pumps of auxiliary boiler respectivly. (rev.A) One pressure indicator is foreseen at the suction and discharge of each pump (PI 60 EGC02/03 CP501), (PI 60EGC02/03 CP502) for local pressure indication. As same as forwarding pumps, these pumps are protected from ingress of particles by one duplex filter ( 60EGR01 AT001) (rev.A) set located in the inlet of pump skid. In order to clean one of the filters, a manual changeover valve is included so that a changeover may be performed without interruption of operations. There is two fuel oil return lines (61-66 EGD03-BR004-GO-125-CL3-F) (61-66 EGD03BR005-GO-100-CL3-F) from each gas turbine which one of them will be returned back the excess gas oil and the other line will be combined to return line from three way motorized valve, in the case of system shut down,all of gas oil will be returned back to the fuel oil storage tanks. A three-way motor operated valve (61-66 EGD03 AA701) shall be provided on the discharge line of the pumps of each unit to return gas oil to fuel oil storage tanks. These valves will be located in turbine hall and are controlled by means of GT control logic.(rev.A)
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Fuel Oil Unloading and Forwarding System Description: I.P.D.C. Project: Shirvan 6×159 M.W. Gas Turbine Power Plant

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MINISTRY OF ENERGY

IRAN POWER DEVELOPMENT COMPANY

I.P.D.C. PROJECT : SHIRVAN 6159 M.W. GAS TURBINE POWER PLANT