Beruflich Dokumente
Kultur Dokumente
For
LDO SYSTEM
Of
AT
CHAPTER NO TITLE
1 SALIENT INFORMATION
2 CONTROL PHILOSOPHY
4 COMMISSIONING / OPERATING
PROCEDURES
5 PG TEST PROCEDURE
7 LIST OF ENCLOSURES.
System Designed and Supplied by : M/s FUTECH PROJECTS (I) PVT LTD,
Regd Office : 105, SHOPPING CENTRE, POCKET J,
SARITA VIHAR, NEW DELHI 110 076
1. INTRODUCTION
This document contains the salient features of the LDO unloading & storage
system proposed at 3x18MW Coal fired Power Plant at Sangatta, Indonesia
for PT. CITRA KUSUMA PERDANA , INDONESIA.
The LDO system basically consists of the following:
i LDO Unloading and storage system.
Ii Fuel oil Drain system.
iii Oily Water Collection system.
4. Reference drawings :
O-1404-PID-01 P & I DIAGRAM FOR LDO UNLOADING SYSTEM
One cone Roof tank is provided for storage of LDO Oil unloaded. The tank is
of 3.25 m diameter and 3.75 m High with a capacity of 25 KL. The LDO Tank
is located in the Fuel oil Dyke Area.
When the oil hoses are connected to the tanker and the tapping valves opened ,
LDO will flow into the unloading station piping and specialties , open the vent
valve of the strainer in line at that time to escape the air. When the unloading
station suction piping is filled with LDO, oil will flow out from vent valve
close the vent valve. The unloading pump now shall be started manually either
from MCC or from Local Push Button station.
At the suction of each LDO Oil Unloading Pump set, one duplex strainer is
provided of capacity 25cum/hr.
High Differential Pressure across the strainer will indicate that the strainer is
choked and the switch will trip the pump.
LDO unloading pump discharge line is provided with one pressure gauge and
one pressure switch.
Pressure gauge will indicate the discharge pressure where as if there is low
pressure means high differential pressure across strainer shall be sensed by
Pressure switch , at low pressure signal the unloading pump shall be tripped.
Further one pressure transmitter is mounted on the common discharge header
of both the pumps , which will start the stand by pump automatically after
sensing the low pressure in discharge header.
The setting and action of all the instruments are indicated in the document
named Instrument Schedule (O-1404-C&I-02)
The unloaded LDO oil is sent to the LDO Storage tank (cap 25KL) , prior to
tank fill a flow meter with transmitter is provided . The flow meter shall
provide indication of flow data on the meter and same shall be transmitted to
relay base panel.
CHAPTER-1
CONTROL PHILOSOPHY
The drain oil tank is provided with one no. Drain oil pump set (Single screw
positive displacement) mounted on the tank. The pump set is 2cum/hr capacity
with a head of 2 kg/sqcm(g).
In draining operation, the equipment vent valves are opened and then the drain
valves are opened. The drain oil will lead to the drain oil tank. When the oil
reaches a high level then the drain operation is stopped.
The drain oil pump can be manually started from local push button station or
MCC. If it is kept in auto mode then at high level it will start automatically
and low level it will stop automatically.
One pressure switch is provided on the discharge header of drain oil pump
which will sense the low pressure and trip the drain oil pump.
The pit is provided with one no pump set of capacity 2.0cum/hr and 15.6 mtr head.
This pump can be started manually either from MCC or from Local Push button
station, to transfer the oily water to Plant ETP. Where it will be further processed and
dispose of as per plant requirement by other.
A top mounted level indicator is provided on the oily water collection pit to check the
liquid level inside the pit.
CHAPTER-3
PRE COMMISSIONING CHECKS
1.0 Systems
2.1 Mechanical
Check physically all systems with approved and final P&I diagrams,
layout drawings, fabrications drawings and Engineering change notices, if
any, issued post approval of drawings / documents.
All concerned persons of various agencies involved shall sign the Design
Compliance Report*.
Check physically all systems with approved and final Single line
diagrams, layout drawings, Panel drawings, cable schedule and
Engineering change notices, if any, issued post approval of drawings /
documents.
All concerned persons of various agencies involved shall sign the Design
Compliance Report.
3.1 Pumps
3.2 Tanks
Once it is established and verified that all pipe lines (all systems) have been hydro-
tested at required pressure and all pre-commissioning checks mentioned above have
been carried out, these lines are ready for flushing.
It is important that all the instruments including the flow meters etc, are
isolated by closing the root valves before the pipe lines are flushed with
RESPECTIVE media such as water, air, LDO AS THE CASE MAY BE
Close the valves including motor operated valves on all the nozzles of all
tanks.
Close all the vent and drain valves of pipe lines and all equipment such
as pumps, filter, line heaters etc
It shall be ensured that none of the pipe lines is spared from flushing.
All pipe lines shall be flushed with compressed air after these lines are
flushed with water.
Now the pipe lines are ready for flushing with LDO.
Caution: Since the pressure inside the line is high, air will come out with
force which can be FATAL. HENCE ENSURE NO BODY IS EXPOSED
TO HIGH PRESSURE AIR.
After flushing of lines, the clean the filter elements of all filters manually.
All the root valves and isolation valves for all instruments shall be
opened.
S No Title
1 P&I Diagram for LDO Unloading system
2 Instruments Schedule
3 Junction box interconnection diagram
4 Instrumentation cable schedule
5 Input / Output list
6 Operation manual of unloading pumps
7 Operation manual of instruments
8 ...and following instructions
5.0 Input
Futech shall make available the O&M manuals for all major
equipment and instruments as received from the manufacturers.
1.5 Utilities
Following utilities are required for Commissioning of the system. The Owner
is required to make these utilities available before commissioning.
6.1 Open all the valves except those valves which are supposed to be normally
closed such as filter / pump drain valves, valves meant for flushing, line drain
and vent valves, by pass valve to flow meter etc.
6.3 Note down the level indicator's reading on LDO storage tank as well as that
of level transmitter on DCS.
6.4 Select the working pump from MCC and accordingly the filter. Close the
upstream valve of non-working filter.
6.5 Place the LDO road tankers (Capacity: 12/20 kl each) on the unloading
platform as per the layout drawings. Connect the road tanker outlet valve with
unloading header's inlet valve by means of unloading hose. Open the outlet
valve of the tankers.
6.6 Open the vent valves on the unloading header / filter and let the air escape
from the piping and filter before the pump is started.
6.7 Switch on the working pump from local push button / MCC.
6.8 Partially close the discharge valve of the pump so that the pressure gauge on
discharge of pump shows the duty point pressure of pump (2 kg/cm2).
CHAPTER-4
COMMISSIONING / OPERATING PROCEDURES
6.9 Since the duty point flow rate of pump is 25 cum/hr and pump working at duty
point, 2 nos road tankers of 12 cum each shall be unloaded in 60 minutes
approximately.
6.10 Check the readings of flow meters and level of tank to ensure that 24 cum is
unloaded.
6.11 Once all the tankers are emptied, the sound of pump shall change. Stop the
pump. The screw pumps shall not be run on dry condition for more than
maximum 3-5 minutes. THIS IS VERY IMPORTANT.
6.12 Check physically the road tankers, if they are emptied completely.
6.13 Disconnect the hoses from the road tankers, Lift this end of hose so that the
oil inside the hose finds way to unloading header and rest the hose on hose
stand.
Differential pressure high across filter. It will trip the unloading pump.
If this happens, isolate this filter and pump and bring the standby
filter and pump in operation. Choked filter shall be cleaned and
refitted.
High High level in storage tank will close the inlet motorized Valve to
the Tank.
6.16 Following readings should be noted before and after every unloading
operation:
Flow meter
Level indicator on tank
Level in tank (Level transmitter)
CHAPTER-4
COMMISSIONING / OPERATING PROCEDURES
Differential pressure indicator across the filter should not exceed the
set pressure.
6.18 Following parameters shall be monitored in DCS which are being repeated
from the Local control panel.
Pump running status of LDO unloading, Drain Oil Pump and Oily
water transfer pump.
Repeat signal of Level transmitter
Repeat signal of Pressure transmitter
Repeat signal of Flow transmitter
7.1 Drain oil tank (DOT) of 2 Kl capacity is kept inside the pit in the pump house.
The drain from Strainers and pumps flow into the drain oil tank by gravity
after opening the drain valves.
7.2 The DOT is provided with a top mounting level switch and incase If the tank
level is high, transfer the drain oil to LDO storage tank through drain oil pump
(DOP) either in manual mode or in auto mode as the case may be.
7.3 During transfer of oil in DOT to LDO tank, low level once reached in DOT
shall trip the DOP. Once low level is reached. Open the inlet valve and let
LDO fill the DOT again.
7.4 In case of low pressure in discharge of DOP sensed by a pressure switch will
trip the DOP.
CHAPTER-4
COMMISSIONING / OPERATING PROCEDURES
8.1 Oily water shall be collected through civil drains from various areas in the Oil
water collection pit.
8.2 The oily water so collected shall be pumped to ETP by starting the pump
from either Local push button or from Local control Panel.
8.3 This is entirely a manual operation. The pump discharge valve shall be kept
open.
8.4 A level indicator provide on the pit will indicate the level in the pit.
CHAPTER-5
PG TEST PROCEDURES