Fuel system of HFO Plant

How the HFO fuel system is working and design criteria for 100 MW Engine based Power plant.

1. By Md. Abu Sufiyan Sr. Engineer ECPV Chittagong Ltd FUEL OIL SYSTEM

2. LIGHT FUEL OIL ( lFo ) Heavy FUEL OIL (HFO) Fuel Oil Used In ECPVCL

3. Properties of Fuel Oil Properties Light Fuel Oil Heavy Fuel Oil Sulphur (%) 1.8 3.5 (Max) Ash Content (%) 0.02 0.1 Relative Density at 15 ͦ C 0.86-0.90 0.991 Pour Point ͦ C (Min) 3 (win)/15(Sum) 24 Kinematic Viscosity (Centistokes) 2.5 to 15.7 (@38 ͦ C) 180 Water Volume (%) 0.1 0.5 Gross Calorific Value 10600 Kcal/Kg, Av 39000 Kj /Kg (Min) Flash Point ( ͦ C min) 66 60

4. Fuel Oil Handing System HFO Unloading System Storing In Storage Tank Transfer to Day Tank LFO Unloading System

5. Storage System Transfer System HFO Storage Tank Total No s : 2 (101/102) Capacity : 5000/ 5000 KL Diameter : 8498 / 23986 mm Height : 10090/ 12070 mm LFO Service Tank Total No s : 1 (201) Capacity : 500 KL Diameter : 8497 mm Height : 10070 mm HFO Service Tank Total No s : 1 (103) Capacity : 5229117 liter Diameter : 8497 mm Height : 10070 mm HFO Separator Total No s : 2 Capacity : 31.5 m з /hr Transfer Pump Total No :2 RPM :1450 Fuel Oil Handing System

6. Fuel Oil Handing System

7. Fuel Oil Handing System

8. Fuel Oil Handling System LFO Unloading System and Storage system Unloading System Total Pump No s : 2 RPM : 1450 Filter No s : 2 LFO Service or Storage Tank Total No s : 1 (201) Capacity : 500 KL Diameter : 8497 mm Height : 10070 mm

9. Fuel Oil System HFO Feeding and Boosting system LFO Feeding & Boosting System Engine Fuel Feed System HFO Treatment system

10. HFO Feeding System The engine fuel supply system is equipped with fuel feeder units which take suction from HFO day tanks or LFO day tank as selected by the change over valve and delivers to fuel booster unit. Feeder units are fitted with an inter-connection valve for emergency use. HFO feeders pump Module: Feeder Pumps (1w+1 st .by), Filters / Strainer PRV. Local alarms. Quick Shut Off Valve Manual Fuel Change Over Valve Pressure Transmitter / Pressure gauge. Individual pump suction and delivery valves Suction valve for HFO and LFO with change over arrangement HFO Feeding and Boosting System

11. HFO Feeding and Boosting System

12. HFO Feeding and Boosting System

13. HFO Feeding and Boosting System

14. HFO Feeding and Boosting System The suction from HFO day tanks or LFO day tank as selected by the change over valve (vo1) and delivers to fuel Feeder unit. Feeder units are fitted with an inter-connection valve for emergency use.

15. HFO Feeding System Quick Shut off valve Quick Shut Off Valve Air Torque Feeder unit pumps and quick closing valves are controlled from a common control panel for feeder. 13.2 Nm to 10 Nm. Control Air 5.5 to 7 bar. 24VDC signal. Up to +150 ͦ C. HFO Feeding and Boosting System

16. Suction Valve Strainer HFO Feeding and Boosting System

17. HFO Feeding and Boosting System HFO Feeding System: The feeder units which take suction from HFO day tanks Discharge to line common or header. Feeder Pump AURU MARINE (FINLAND) Type: Feeder Unit AMF-120-HFO/LFO Serial No : 11510 Pump Capacity : 31.4 m з /hr RPM : 1460 Manufacturing Year :2012 H  YER MOTORS HFO Designation: M001 Motor :11.0 KW TYPE :Y2E2 160M-4 Serial No :SH533533-175

18. Suction Pressure Feeder Pressure HFO Feeding and Boosting System

19. HFO Feeding and Boosting System Alarm list

20. HFO Feeding and Boosting System The main function of Feeder and Booster unit is to provide the engine(s) with fuel oil of correct flow, pressure, viscosity and degree of purity. Our power plant is designed for using Heavy Fuel Oil (HFO) as the main fuel. Light Fuel oil (LFO) is used as back-up fuel. The feeder unit feeds HFO and LFO from the fuel tanks to the fuel circulation system. The feeder unit has separate lines for HFO and LFO. The unit includes two feed pumps for HFO and Two feed pump for LFO. One of the HFO pumps is normally in operation, while the other one is on standby. The feed pumps are electrically driven screw pumps equipped with suction strainers and built-in safety valves. Each pump motor is equipped with a cooling fan. The pumps are controlled by frequency converters. The frequency converter regulates the speed of the feed pump to maintain the pressure in the outlet line. To prevent under pressure or overpressure in the system at sudden changes in the fuel consumption, the feeder unit is equipped with overflow valves. The feeder unit includes equipment for monitoring the pressure in the system. A pressure switch at the outlet of the HFO pumps enables the standby pump to be started automatically when required.

21. HFO Feeding and Boosting System Booster Operation Open the HFO day tank outlet valve. Keep the manually operated HFO change over valve in position for HFO . Open the inlet valve for feeder pump Open the outlet valve for feeder pump Check that the pneumatic valve for are open. Open the inlet and outlet valves for booster pumps . Open the inlet and outlet valves for fuel oil heater. Open steam inlet valves and condensate outlet valve. Open the inlet and outlet valves for auto filter. When the auto filter is in operation, the inlet and outlet valves for manual filter will remain closed. Open the inlet and outlet valves for the viscometer. Open the instrument air supply valve Check that all the valves of pump & filter unit are in open positions. Start the Feeder pump following the operation schedule & check that the fuel pressure is 4.0 bar. Start the Booster pump following the operation schedule & check that the fuel pressure is 6.0 bar. Set the fuel oil temp. corresponding to 12-14 cSt and keep the controller auto mode. Switch on the auto filter, flush frequency monitor and viscometer. When required temperature is reached, change over the controller to “viscosity control” mode.

22. HFO Feeding and Boosting System HFO Common Header

23. HFO Feeding and Boosting System Heavy Fuel Oil Booster Unit: The purpose of the module is to boost up HFO pressure with the defined viscosity and control fuel temperature. In this plant its suck HFO from Common Header of feeder outlet and delivering regulated fuel to a Ring main which is common for every four engines. Booster Module Specification: Brand of Module : AURU MARINE (FINLAND) Type : Booster AMB-L-50-SS Serial No. : 11506,11507,11508,11509 HFO Booster pump Module: Booster Pumps (1w+1 st .by), Auto Filters / Manual Filter Local alarms. Mixing Tank. Heat Exchanger

24. HFO Feeding and Boosting System General arrangement

25. HFO Feeding and Boosting System P&DI

26. Overview of assembly groups (exterior view I) 1 Air tank 2 Pressure gauge 3 Safety valve 4 Pressure controller 5 Solenoid valve (flushing valve) 6 Ball valve 7 One-way restrictor valve 8 Flushing valve 9 Draining 10 Type plate 11 Terminal box (optional) 12 Pressure gauge (optional) 13 3-way ball valve (optional) 14 Differential pressure monitoring system HFO Feeding and Boosting System Combination Filter

27. Overview of assembly groups 1 Filter housing 2 Cam disc 3 Limit switch 4 Solenoid valve (pivoting actuator) 5 Pivoting actuator (pneumatic) 6 Upper section of housing 7 Lower section of housing (optional) 8 Shut-off valve HFO Feeding and Boosting System Combination Filter

28. Overview of assembly groups (cross sectional view) HFO Feeding and Boosting System Combination Filter 1 Vent (automatic) 2 Filter candle 3 Valve tappet 4 Candle holder 5 Plug valve 6 Change-over housing cover 7 Spacer N1 Filter inlet N2 Filter outlet N3 Flushing oil outlet N4 Heating medium inlet N5 Heating medium outlet

29. Overview of assembly groups (view I)) HFO Feeding and Boosting System Combination Filter 1 Wrench 2 Spring-type dowel pin 3 Cover (Bypass filter) 4 Housing cover safety device including vent 5 Seal 6 Filter element 7 Seal 8 Plug valve 9 Housing 10 Drain valve (partial draining) 11 Element support 12 Drain valve (final draining) 13 Filter heating (optional) 14 Shut-off valve N1 Inlet N2 Outlet N4 Heating medium inlet N5 Heating medium outlet

30. HFO Feeding and Boosting System Controller Differential Pressure Monitoring system Filter candles Pivoting actuator Flushing valves. The controller regulates and monitors all automatic filter functions. The differential pressure monitoring system measures the differential pressure between the filter inlet and filter outlet. As the soiling increases, the differential pressure in the filter also increases. The controller processes the electrical signals from the differential pressure monitoring system and triggers a backflushing process when the set maximum value is reached. The filter candles are cleaned automatically so that the plant does not have to be switched off for cleaning. The pivoting actuator turns the plug valve so that the flow to the soiled filter chambers is shut off and, at the same time, the stand-by filter chamber is activated. If the plug valve reaches the filter chamber which is to be cleaned, the pivoting movement is stopped. The pivoting actuator is actuated by a solenoid valve (pivoting actuator). The limit switch monitors the position of the plug valve. The pneumatically actuated flushing valve opens and closes the flushing oil outlet at the start and end of the backflushing phases respectively.

31. HFO Feeding and Boosting System Automatic filter with bypass filter: for removing impurities from fuel oil and indication of failures in purification system. Mixing tank: for mixing the return fuel from the engines with fresh fuel and for compensating for temperature and pressure changes. Booster pumps : for further pressurizing and circulating fuel to the engines, equipped with an automatic. Fuel heaters: for heating the fuel oil to injection viscosity, controlled by a viscometer. Viscosity control system: for measuring the fuel viscosity and controlling the power of the heaters to maintain constant injection viscosity, secured by a temperature controller

32. HFO Feeding and Boosting System Booster pumps : for further pressurizing and circulating fuel to the engines, equipped with an automatic. Total Nos : 2 Specification: 25.5 m3/h, 4/8 bar, 20 cSt , fixed speed 2900 rpm. 11 kW,

33. HFO Feeding and Boosting System Fuel heaters: for heating the fuel oil to injection viscosity, controlled by a viscometer. Technical Data: 2x100 % steam heaters of tube type, based on steam temperature /pressure 148 °C / 3.5 bar g. Heat exchanged 246 kW. Steam consumption max. 430 kg/h 4 Flange gaskets 5 Tube insert 6 In and outlet flange gaskets 7 Steam and condens flange gaskets

34. HFO Feeding and Boosting System Viscosity control system: for measuring the fuel viscosity and controlling the power of the heaters to maintain constant injection viscosity, secured by a temperature controller.

35. HFO Feeding and Boosting System Quick start guide . Activating pump shaft seal lubrication by Grease. Inspecting fuel valve positions. Venting suction filters. Inspecting instrument valves. Activating fuses and thermal relays. Starting feeder/supply pumps. Venting the deaeration tank. Checking suction and feed pressure. Starting the booster/circulation pump. Checking booster/circulation and outlet pressure gauges. Adjusting viscosity Checking the steam regulator valve Testing equipment and alarms Starting and running the engine on HFO

36. HFO Feeding and Boosting System Quick start guide . Activating pump shaft seal lubrication by Grease • Ensure that pump has a functional grease. • Activate the pump lubricator 24 hours before starting for the first time by turning the switch. If Grease is not activated in time, it may cause the pump shaft seals to leak.

37. HFO Feeding and Boosting System Quick start guide . Inspecting fuel valve positions • Ensure that the heating media is not turned on. • Open the required fuel valves according to the PI diagram.

38. HFO Feeding and Boosting System Quick start guide . Venting suction filters • Open the venting screw and ensure that the oil is flowing. • The suction pressure gauge should read > 4 bar (usually 03 –04 bar). Remember to vent all suction filters and then close them after venting.

39. HFO Feeding and Boosting System Quick start guide . Inspecting instrument valves • Open the air valves and ensure that there is adequate air pressure . • Check the automatic filter air pressure gauge to see whether the air pressure rises to approximately 4 bar. (Note! Not all filter models come with a pressure gauge.)

40. HFO Feeding and Boosting System Quick start guide . Activating CB and thermal relays • Ensure that the main switches are set to zero – otherwise, the cabinets will not open. • Activate the electrical cabinet fuses and thermal relays . • Ensure that the drive switches are set to zero . • Turn on the power with the main switch. • Reset the alarms. Ensure that all drive switches are set to zero before switching on the main power. After resetting, one of the alarms may still be active – this is normal. The lights should go off when the unit is started.

41. HFO Feeding and Boosting System Quick start guide . Starting Feeder Pump. Ensure that HFO is flowing into the pump. • Test run the electric pumps. Ensure that the motors are rotating in the right direction. If the rotation direction is wrong, contact an electrician. • If the rotation direction is right, leave one of the pumps running. Ensure that the electric motor is rotating in the right direction (always clockwise). Never run the pump ”dry”.

42. HFO Feeding and Boosting System Quick start guide . Venting the deaeration tank.

43. HFO Feeding and Boosting System Quick start guide . Checking suction and feed pressure • Bleed all gauges by turning the yellow tip. • The suction side pressure should drop to approx. 0 bar (Figure 1). • The feed pressure should rise to 3 – 5 bar (Figure 2). • If the connections are wrong, the feed pressure gauge (Figure 2) will not display any values.

44. HFO Feeding and Boosting System Quick start guide . Starting the booster/circulation pump. • Ensure that oil return circulation is allowed to the unit deaeration tank. • Test run the electric pumps. Ensure that the motors are rotating in the right direction. If the rotation direction is wrong, contact an electrician. • If the rotation directions are right, leave one of the pumps running. Ensure that the electric motor is rotating in the right direction.

45. HFO Feeding and Boosting System Quick start guide . Checking booster/circulation and outlet pressure gauges. • Vent the unit’s external fuel system. • The ship’s diesel engine fuel feed pressure should be the same as the unit’s outlet pressure. • Also ensure that the fuel flow returns to the unit. Outlet pressure is adjusted with the pressure regulator valve located outside the unit, not the pump relief valves! Turn the switches for feeder and booster pumps being shut down to the standby position.

46. HFO Feeding and Boosting System Quick start guide . Adjusting viscosity • Activate the viscometer on the control panel (1) and select Adjust viscosity (2).Also turn on the automatic filter (3). • Check the display to ensure that the viscosity is 13 cSt . There is a 5 – 15 min time delay between manual flushing of the automatic filter!

47. HFO Feeding and Boosting System Quick start guide . Checking the steam regulator valve • Ensure that the steam regulator valve is closed or the electric heaters are switched off. • Ensure that the heat tracing valves are closed or electric tracing is shut off. • If the regulator valve is open, contact an electrician, who will switch the feed phases. • Temperature regulation is a safety function, which is only available with HFO. Heat tracing must not be on

48. HFO Feeding and Boosting System Quick start guide . Testing equipment and alarms. • Test equipment and alarms. • Test functions according to the alarm panel; also test remote control. • Also ensure that the alarms are being sent to the engine control room.

49. HFO Feeding and Boosting System Quick start guide . Starting and running the Heat Tracing Ensure that heat tracing is on for unit outlet and inlet pipelines.

50. HFO Feeding and Boosting System

51. LFO Feeding and Boosting System A common module of two different units, one for Feeding HFO and other for Feeding LFO from Service tank to Common Header. It can maintain desire pressure and flow at delivery with sufficient protection. Plant emergency shutdown system included with this unit. LFO Feeder Module Specification: Brand of Module : AURU MARINE (FINLAND) Type : Feeder Unit, AMF-120-HFO/LFO Serial No. : 11510 Manufacturing Year : 2012 Pump details (LFO) : Brand : H  YER MOTORS LFO Designation : M005 & M006 Type : MS 132S2-2 Serial No. : SH530289526 & SH530289531 Power ratings : 7.5KW, 415V, 50Hz, 2900rpm.

52. Engine Fuel Feed System Fuel Feed System for Individual Engine Fuel Change-Over Module The purpose of the module is to interchange engine inlet fuel in between Diesel and HFO. The process of this changing is fully automatic. The unit is consist of following items-   Change Over Unit -005-HFO: Type : MS-90L-2 Power : 3p, 2.2KW, 440V, 50Hz. Ins. Class : F IP : 55 HFO pump capacity 6,05 m3/h, 5/8 bar, 12 cSt Manuf. Year : 2011 Weight : 16.2 Kg Electric motor 2,2 kW, 2900 rpm Bearings : D.E-6206 , NDE- 6204 Change Over Unit -006-LFO: Type : M6906-2 Phase : 3p, 1.5KW, 2780rpm. Ins. Class : F IP : 55 DFO pump capacity 7,41 m3/h, 5/8 bar, 7 cSt Manuf. Year : 2011 Electric motor 1,5 kW, 2900 rpm Weight : 16.2 Kg Bearings : D.E-6206 , NDE- 6204

53. Engine Fuel Feed System Quick start guide . Fuel Change-Over Module . P&ID

54. Engine Fuel Feed System Fuel Change-Over Module . Section View of Screw Pump.

55. Engine Fuel Feed System Flow Meter Each Revolution of wheel oval displaces a precisely know as volume of liquid through the meter, from inlet to outlet. The number of revolutions therefore is directly proportional to the measured volume. During operation the sensor generate and transmit pulse signal to indicates etc.

56. Engine Fuel Feed System Fuel Fine Filter The Fuel fine filter is duplex type with a manual change over valve. Depth type filter cartridge, 7-10 micron nominal. Specification: Type : HFO/LFO Duplex fine filter 709152 FF-10 Manuf. Year : 2012 Type/Drawing : 1027643 Press. max./min. : 16/0 bar Test Pressure : 24 bar Temperature max./min. : 150°C Volume : 220 Ltr . Manufacturer : Pumplohja Corporation

57. Engine Fuel Feed System Fuel Injection Pump Cleaning System Nozzle Temperature control system 104 DO Valve FIPCS: The function of the unit is to clean the fuel injection pumps. The control sleeves/racks are washed with diesel oil at regular intervals, to prevent sticking. Including air driven pump, solenoid valve and air filter.  NTC: Nozzle temperature control system: The nozzle temperature control excluding tanks system is an internal system on the Engines. 104 DO valve: The purpose of the three way valve is to restrict the mixed oil (HFO+LDO) from entering into Diesel Service tank during engine fuel changeover process.

58. Whole Plant Fuel System P&ID

59. HFO Treatment system HFO treatment plant comprises of fully automatic, self cleaning centrifuge system. It is suitable for treatment Heavy fuel of viscosity up to 180cst at 50°C and density 0.96 at 15°C. The unit collect raw oil from storage tank and deliver treated oil to service/day tank. Specification of HFO Separator Number of Unit : 2 Nos Separator type : S 986 Serial no : 4211076 & 4211077 Year : 2011 Product No : 881207-06-01 Inlet and outlet : 564743-01 Bowl : 593650-01 Machine bottom part : 595374-01 Designation : PX213UFT-21 Belt driving device : 566201-01 Max. Speed : 5270 rpm Direction of Rotation : Counter-clockwise. Speed motor shaft : 3000 /min El. Current frequency : 50 Hz Rated motor power : 31 KW Max. Density of feed : 1100 Kg/m3 Max. Density of sediment : 2014 kg/m3 Max. Density of liquid : 1000 kg/m3 Process temp. min/max : 0/100 ◦C  

60. Question