Chapter I Fhs

FUEL
HANDLING
O &M
SYSTEM
MANUAL
STAGE I &II
Thermal Power Station II (7 x 210 MW)
ISO 9001, 14001 and OHSAS 18001 certified Company
Neyveli Lignite Corporation Limited

(A Govt. of India Mini Ratna Enterprise)
NEYVELI.
Obelisk to mark the

commencement of
Thermal Power Station -II
NEYVELI LIGINITE CORPORATION

Vision
To emerge as a leading Mining and Power
Company, Continue to be a socially responsible
company and strive for operational excellence
in Mining and Exploration.
Mission
Strive towards greater cost competitiveness
and work towards continued financial strength.
Continually imbibe best practices from the
best Indian and International Organizations
engaged in Power Generation and Mining.
Be
attractive
preferred
avenues
employer
of
career
by
offering
growth
and
excellent work environment and by developing

human
resources
standards.
to
match
international
Play
an
active
role
in
society
and
be
sensitive to emerging environmental issues
NEYVELI LIGINITE CORPORATION

Quality & Environment Policy
NLC, Thermal Power Stations (Neyveli), affirm
our commitment to produce power with focus
on customer satisfaction, pollution prevention
and continual improvement.
We are committed to:
Setting
and
periodically
reviewing
the
Quality and environmental objectives and

targets
Supply quality power
as
per
committed
schedules
Incorporate
Quality
assurance
in
all
activities of our power generation

Optimal
utilization
and
conservation
of
resources such as water, fuel and auxiliary

power
Comply with all applicable legal & other
requirements with respect to Environment
Achieve
Excellence
management
by
in
environmental
elimination/reduction
of
environmental pollution
Enhance
Quality
awareness
and
among
all
Environmental
employees
and
contract workers, to promote Quality and

Environmental management
Promote new, innovative ideas on Quality
and Environment and fix benchmarks.
INDEX TO VOLUMES
I.
OPERATION & MAINTENANCE MANUAL
BOILER
1.
VOLUME A
2.
VOLUME B
BOILER OPERATION. (STAGE I)

-
BOILER OPERATION
(STAGE II)
3.
II.
VOLUME C
BOILER MAINTENANCE.
TURBINE
1.
VOLUME A
TURBINE OPERATION.
(STAGE I)
2.
VOLUME B
TURBINE OPERATION.
TURBINE MAINTENANCE.
(STAGE II)
3.
VOLUME C
III.
ELECTRICAL
1.
VOLUME A
2.
VOLUME B
ELECTRICAL OPERATION.
-
ELECTRICAL
MAINTENANCE.
IV.
PERIPHERALS
1.
VOLUME A
LIGNITE HANDLING SYSTEM.

WATER CHEMICAL TREATMENT
PLANT.
CIVIL MAINTENANCE.
SERVICES MAINTENANCE
CONTROLS &
INSTRUMENTATION.
INTRODUCTION ABOUT THERMAL
POWER STATION II
Thermal Power Station II has a total installed capacity of 1470

MW
(7 units of each 210 MW capacity). The station
was constructed in two stages: Stage I comprising the first phase of

three units and stage-II comprising the second phase of four units.
The total cost of the project including IDC worked out to 2011.26
crores. The project is constructed on an area of 207 hectares.
The Steam Generators and the Turbo Generators of Phase I were

supplied by Transelektro, Hungary in collaboration with EVT,
Germany and FrancoTosi, Italy respectively. All equipments of Phase
II are of indigenous make except the Milling and Firing Technology
for Steam Generators from EVT, Germany. The power station is
equipped with a sophisticated instrumentation system. The salient
features of Thermal Power Station II are given in Annexure-I.
The salient features of the Boiler, Turbine and generator are tabled
in the Annexure II.
The power station has been awarded the ISO 9001 : 2000
certificate of approval for Quality Management System and the ISO
14001 : 1996 for Environmental Management System by the Indian
Register Quality Systems (IRQS) in 2004.
As a Central Power Generating System, the station caters to the

power needs of the Southern Region. The power allocation from the
station to the Southern states of
Tamil Nadu, Andhra Pradesh,
Karnataka, Kerala and Pondichery and to NLC Mines is based on GOI

guidelines with changes in actual share notified from time to time.
The fixed share of the beneficiaries are as follows. The actual share
will vary depending on the pattern of distribution of the unallocated

part among the beneficiaries based on their requisitioning.
Andhra Pradesh
18.84%
Karnataka
13.54%
Kerala
10.41%
Tamil Nadu
30%
Pondicherry
5.44%
NLC Mines
6.8%
Unallocated:
14.97%
ACKNOWLEDGEMENT
PREFACE / FORWARD
WATER CHEMICAL TREATAMENT PLANT

OPERATION MANUAL
CONTENTS:
STAGE -I
CHAPTER I
Lignite Handling System (LHS)
CHAPTER II
Oil Handling System
CHAPTER III
Constituents Of Fuel Oil And Their
Characteristics
CHAPTER IV
Description of Oil Handling System
CHAPTER V
Technical Data Of Process Equipments &

Accessories
CHAPTER VI
Fuel Oil Filters

STAGE - II
CHAPTER VII
Fuel Oil Handling System /LDO & FO
CHAPTER VIII
Furnace Oil Systems
CHAPTER IX
Operation of LDO System
CHAPTER X
Operation of Furnace Oil System
CHAPTER XI
Technical Data Process Equipments &

Accessories
FUEL
HANDLING
SYSTEM
OPERATION
STAGE I
INDEX
Sl.No.
TOPIC
PAGE No.
CHAPTER - I
1.
Lignite Handling System (LHS) Stage I
1.1.
General Description
1.2.
Receiving System
1.3.
Transfer System
1.4.
Crusher House
1.5.
Mulsifier system
11
1.6.
Dust Suppression System
11
1.7.
Lignite Handling System (LHS) Operation
1.8.
Magnetic Separator
15
1.9.
Metal Detectors
15
1.10. Conveyor
12
16
CHAPTER II
2.
Oil Handling System
19
2.1.
Introduction
19
2.2.
Description
2.3.
Characteristics of fuel oil
Sl.No.
21
21
TOPIC
PAGE No.
CHAPTER III
3.
Constituents of fuel oil and their characteristics
28
3.1.
Carbon
28
3.2.
Hydrogen
29
3.3.
Sulphur
29
3.4.
Water and Sediment
30
3.5.
Ash
30
3.6.
Specification of furnace oil (IS:1593 Quality)
31
CHAPTER IV
4.
Description of oil handling system
33
4.1.
Decanting pump house
33
4.2.
Fuel oil tanks
4.3.
Floor coil heater in fuel oil tank
4.4.
Suction Heater
4.5.
Pressurising Pump House
4.6
Drain tank and Drain pump
35
35
36
37
39
CHAPTER V
5.
Technical data of process equipments & Accessories 41
5.1
Decanting pump suction strainer
41
5.2.
Decanting pump
42
5.3.
Fuel oil storage tanks
42
5.4.
Floor coil heater
43
5.5.
Fuel oil suction heater
43
5.6.
Fuel oil suction filters
44
Sl.No.
TOPIC
PAGE No.
5.7.
Fuel oil pressurising pump
5.8.
Drive motor
5.9.
Drain oil tank
44
45
45
5.10. Filter before drain pump

5.11. Drain oil pump
45
46
CHAPTER - VI
6.
Fuel oil filters
48
6.1.
Putting the filter in to service
6.2.
Filter cleaning procedure
49
6.3.
Starting of pressurising oil pumps
49
6.4.
Stopping of the fuel oil pressurising pump
48
50
6.5.
Commissioning of fuel oil pressurising
50
pumps Oil lines

6.6.
Routine checks and precautions during
52
normal operation
6.7.
Decommissioning of the oil system
53
6.8.
Emptying the oil pipes
54
6.9.
Trouble shooting
55
6.10. Measure of safety precautions for accident
57
prevention
FUEL
HANDLING
SYSTEM
OPERATION
STAGE II
INDEX
Sl.No.
TOPIC
PAGE No.
CHAPTER - 7
7.
Fuel Oil Handling System / LDO & FO
60
7.1.
Introduction
60
7.2.
Fuel oils
61
7.3.
LDO System
62
CHAPTER - VIII
8.
Furnace oil systems
68
8.1.
Furnace oil decanting
68
8.2.
Suction Heater
68
8.3.
Oil Pressurising Pumps
70
8.4.
Secondary Heaters
71
8.5.
Drain Oil System
73
CHAPTER - IX
9.
Operation of LDO System
76
9.1.
Decanting of LDO
76
9.2.
Operation of LDO suction filter
77
9.3.
Operation of LDO pressuring pump
78
9.4.
Operation of LOD pressuring pump filter
79
Sl.No.
TOPIC
PAGE No.
CHAPTER - X
10.
Operation of furnace oil system
81
10.1. Operation of suction water
81
10.2. Operation of suction filter
82
10.4. Operation of secondary heaters
83
10.3. Operation of fuel oil pressuring pumps
83
CHAPTER - XI
11.
Technical data process equipments & Accessories
11.1. LDO tanks
85
85
11.2. LDO decanting pump suction filter

11.3. LDO decanting pumps
11.4.
LDO pressurizing pumps suction filter
85
85
86
11.5. LDO pressurising pumps
86
11.6. Fuel oil pressurising pump suction filter
87
11.7. Fuel oil pressurizing pumps
88
11.8. Secondary heaters
88
11.9. Drain oil tank
89
11.10.
Drain oil pump filter
89
11.11.
Drain oil pumps
90

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FUEL

Neyveli Lignite Corporation Limited

Obelisk to mark the

NEYVELI LIGINITE CORPORATION

excellent work environment and by developing

sensitive to emerging environmental issues

NEYVELI LIGINITE CORPORATION

Quality and environmental objectives and

activities of our power generation

resources such as water, fuel and auxiliary

contract workers, to promote Quality and

OPERATION & MAINTENANCE MANUAL

BOILER OPERATION. (STAGE I)

OPERATION & MAINTENANCE MANUAL

OPERATION & MAINTENANCE MANUAL

OPERATION & MAINTENANCE MANUAL

LIGNITE HANDLING SYSTEM.

INTRODUCTION ABOUT THERMAL

Thermal Power Station II has a total installed capacity of 1470

(7 units of each 210 MW capacity). The station

was constructed in two stages: Stage I comprising the first phase of

The Steam Generators and the Turbo Generators of Phase I were

As a Central Power Generating System, the station caters to the

Tamil Nadu, Andhra Pradesh,

Karnataka, Kerala and Pondichery and to NLC Mines is based on GOI

will vary depending on the pattern of distribution of the unallocated

WATER CHEMICAL TREATAMENT PLANT

Lignite Handling System (LHS)

Oil Handling System

Constituents Of Fuel Oil And Their

Description of Oil Handling System

Technical Data Of Process Equipments &

Fuel Oil Filters

Fuel Oil Handling System /LDO & FO

Furnace Oil Systems

Operation of LDO System

Operation of Furnace Oil System

Technical Data Process Equipments &

Lignite Handling System (LHS) Stage I

Dust Suppression System

Lignite Handling System (LHS) Operation

Oil Handling System

Characteristics of fuel oil

Constituents of fuel oil and their characteristics

Water and Sediment

Specification of furnace oil (IS:1593 Quality)

Description of oil handling system

Decanting pump house

Fuel oil tanks

Floor coil heater in fuel oil tank

Pressurising Pump House

Drain tank and Drain pump

Technical data of process equipments & Accessories 41

Decanting pump suction strainer

Fuel oil storage tanks

Floor coil heater

Fuel oil suction heater

Fuel oil suction filters