JOHNEROWN PROCESS ENGINEERING -51-010/1 FUEL SYSTEMS Mar 1993 Page 1 of 8 FUEL SYSTEMS ComTENTS, Introduct fon Fuel Poltey Fuel Coats Operabiiity Start-up Requirements altebiity of Supply Varying Fus) Domne tase of Uae tate Disposal Uiguta Foele Types Ret on} Gas 1 (Otese1) Waste Liguis Fuel fant ing' Systema Fev ont Gas 011 (fee) Wisee Ligue Fuel Fel eas hvturel Gas tre ste as Fuels Eeneral Considerations Energency situa lone Start-Up Formeces FEL SYSTES 1 eTRoouCTTOM Fuel ts used to ratse steam in botlers, fire furnaces and reformers, and power machinery drivers. Fuels such as natural gas or oils may be imported but other fuels may be obtained fram the waste gases and Viguids that are generated as waste products by various processes. In larger complexes, fuel systena may be quite complex. Gases from many different sources and with different conpostt ons may be collected together {nto a comon fuel gas systen. Vaste hydrocarbon Mqutds witl be collected and blended to form « Viquid fuel. Most of the major fuel users will be capable of being Fired by at least two different fuels. Each fuel system must include the facilities required fer collection or import, storage, treatment (if necessary), measurenent and disteibut ton of the fuel 2 FURL POLICY The allocation of particular fuel to a user w117 depend on the fuel policy for the plant. The fuel policy 18 designed to enaure that the plant makes the most econemtc use of the available fuels wht Te ‘ensuring that {t3 operabtlity 1s not impaired. The basic aims of any fuel policy are as set out below. 2.1 Fuel Costs The intent should always be to minimise the average cost per ktlowatt of the energy consumed by the plant as a whole by minimising the use of the most expensive fuels, maximising the use of the less ‘expensive fuels and by the burning of waste liquids and gases. Cost conpartsons should take into account the true value of any material and should include every cost that would be Incurred for disposal wastes by rethods other than by burning, 2.2. Operabt ity The fuel policy should reflect the operat ing requirements of each plant and should take Into fecount the folTowing:~ 2.2.1 St up Requirenents If extensive ute 1s made of waste Tiquids and gases as fuels, then consideration must be given to atart~ up, and alternative fuels provided for each user necessary, 2.2.2 Reltabitity of Supply Vaste streans might be subject to interrupt fon in the event of an item of equipment tripping: this should be taken into consideration in any system esign, and dual Firing provided as necessary. 2.2.3 Varying Fue} Denands Where equipment has varying fuel desands it is best to cater for only part of the load using waste gas fuel since any downturn might require surplus gas to be flared. It ts usually advantageous to split vaste gas fuel between severe] users 20 that its use an be maxinised. 2.2.4 Ease of Use Fuels should be selected to maximise system operability. Unless there are specific reasons, no fuel should be used which requires treatment prior to-use when there are fuels available which do not. 2.3 Waste Disposal Wherever possible conbust ible waste fluids should be burnt as fuels to recover their enersy content. Incineration of some streams may be required in order to destroy constituents that are toxic or hareful to the environment. It 13 sensible to, recover heat from incinerators whenever post ‘to burn waste streams in furnaces or botlers. In the case of waste gas streams tt 1 important to consider the available gas pressure, since it fs tarely economic to reconpress gas for re-use unless it ts available in large quantities.JOHNEROWN LY el H-81-010/1 PROCESS ENGINEERING : Mar 1993 STERS Process | eavelaictie ee TABLE 3.1 Fash Point “¢ Specific Heat (KI/Kg “X) Min Storage Temp “C in Handing Temp Viscosity @ 82°C cP Caloriftc Value Ki/kg: Grose net The use of waste streams my be limited by chemical composition, eg sulphur content which might impact the design of equipment. In such situatfons the costs of upgrading equipment must be balanced aguinat costs of alternative disposal and the cost of additional fuel. It should also be renenbered that tn may cases thetr may not be an alternative disposal method. 3 LiquiD rR 3.1 Types Liquid fuels can be divided into several different classes dependent on the specific gravity (molecular weight) of the material. 3.1.1. Fuel OW This unuelly originates from refining operat ions and {s the residual left after the lighter hydrocarbons have been renoved from crude ofT.” It ts characterised by Its specific gravity, which ts high, and its viscostty whtch is also high. Light rredim and heavy grades are available, typical properties for these grades are given’ in Table 3.1. Because of its high viscosity care must be taken to censure that the of] is stored and used at or above temperature at which it 1s pumpable (see 3.2 later), 3.1.2 Ges 011 (Otese1) Gas of] {2 from the middle dist! Nate range of petroleum fractions.” Diesel fuel ts « typical example of a gtx of]. Typical properties are given ‘n Teble 3.1. 3.1.3 Maste Liquid Fuels The character and composition of waste Tiquid fuels ‘xIT1 depend on the nature of the processes from which they originate. Typically they consist of the “heavies” left after product purifteat ion and often have a specific name such as "fuse? of" (methanol plants) or “green oi 1” (ethylene plants). 3.2 Handing System 3.2.1 Fuel 17 The fuel of] systema are designed to ensure & constant, regulated supply of of1 to the burners of ‘the boilers and process users. A typical system 1s, shown in Figure 3.1. The system hes often to cater for situations when the fuel of7 is not punpable at ambient temperatures and must. Include complete - facilities to maintain the of] in @ pumpable condition 1 Storage The capacity of storage systems will depend on the nature and source of the fuel being stored, and the 2 of consimpt fon. For large systens the use of two tanks 18 not uncommon since it aTlows for one tank to be available for f111ing and blending and possibly dewatering. If fuel of7 1s being brought tn by sea, then the storage mist be capable of receiving a tanker parcel ‘size. This parcel size will depend on the size of ‘the ships to be employed, but a mininun would be of ‘the order of 1000 tonnes. The tankage capacity should be either two tanks of capactty equal to the ‘minimum parcel stze, of one tank with capactty equal to the parcel size plus 7-10 days of] usage. The total volume of the tank should not be less than 35-40 days usage. This allows for one delivery per fsonth with @ margin to cater for late arrival of tankers.JOHNBROWN od PROCESS ENGINEERING H-51-010/1 FUEL SYSTEKS Mar 1993 a TYPICAL SYSTEM FOR HEAVY FUEL OIL ica —— © g =[ [ES on re 1 COMDENEATE, Ao To evans Gg 4 2 ) $e © 8 3 4) FIGURE 31 Vnere fuel of1 12 produced on site the fuel of1 tank should have at least 24 hours capacity or sufficient Yolume to cater for short term loss of the fuel of] Tanks are generally cone roofed to API 650 or ite equivalent and are fitted with heating cots. For high viscosity ofTs the tanks will also be Fittes with outflow heaters (Figure 3-1). Norma} tank fittings will include roof and shell access ways, vent, gauge hatch, level indicator, temperature’ indicator, and water draw-off facilities. Where water can be present the tanks should not be maintained at temperatures close to 100°C in order to prevent possible botl-over situations. Tanks can be maintained at above 126°C to prevent any water collecting tn the tanks and thus avoiding the problem. Tanks held at temperatures above the flash point should have pressure/vacuum relief in place of vents. 2 Pumping and Oistribut fon The fuel of1 must be maintained to « suitable temperature to ensure that it is pumpable. Temperature is also important at the burners where the various types of burner wil] each have viscosity imitations. The off ts thus preheated at the storage tank to ensure 1t flows to the pump and thereafter {t 1s heated to a controlled temperature. The of] 2 supplied to the users via a ring main whitch returns to the storage tank. This eystem helps contre! the temperature at a constant level in all parts of the fuel ot} network and allows the pressure to be raintained in each part of the system by utilising ‘the pressure control valve at or near the furthest part of the loop. ‘The pumps should be rotary or gear type and be rated for a minieun of 125% of the design flow to allow for recirculation to be maintained. ATI heaters should be rated for the pump capacity. The pump pressure will depend on the pressure required at the burners which my be 10 barg or higher for pressure atomizing type. An allowance of up to 308 of Tine ‘osses must be made for the main fuel control valve, Coarse strainers (1.5 ma) should be provided at the amp suction. Finer strainers may be required by the vendors upstream of the burners. 3 Pipework Pump suction lines should be sized for a maximum of 0.07 bar/100n (0.3 psi/100 ft). The auction pipework should ba designed to sult the KPSH requirenents of the fuel of pump. The recirculation pipework should have a pressure drop of 0.22-0.45 bar/100m (1-2 pai/100 ft). ANT ptpes are traced and insulated.¥-51-010/1 PROCESS ENGINEERING Mar 1993 FUEL SYSTEMS Page 4 of 8 TYPICAL DIESEL STORAGE SYSTEM Said EE u coe 3.2.2 Gas O11 (Oteset) Thia is usually used for firing gas turbines or diesel engines although it can be used to fire botlers and heaters in certain situations. 1 Storage Diesel engines and gas turbines are generally provided with local tanks with sufficient fuel for ‘24 hour operation and referred to as “day tank”. These are filled frou a central bulk storage as shown in Figure 3.2. ‘The bulk tanks should be stzed to receive a minimum of one tanker load (road tankers) plus 7 days consumption. If diesel ts brought’ in by sea then ‘the sume cons derat ions apply as for fuel of (3.2.1, para i above). Diesel bulk tanks should be provided with water drw-off facilities. Diesel day tanks would normally be elevated to provide « positive pressure at the engine fue) pumps. 2 Pumping and Treatnent It 1s comon practice to provide f1Tler/coalescer units to treat diesel before distribution. These are usually purchased a8 standard packages and provide fl lItrat on down to 1-5 micron and remove water dom to 3-5 ppm. here a constant pressure ts Tequired-at the users a ring main systen may be required. 3.2.3 Waste Liquids Fuel Waste quis fuel 1s generaTly used to fire furnaces or bot lers. 1 Storage Where waste liquids derive from several sources it ts important to ensure that adequate blending takes place. Quantities are often too small to warrant the provision of two tanks to assist blending, 20 this should be achteved by the use of collect ion drums on-plot where mixing can occur and/or the provision of adequate mixing in the storage tank, by use of pump rectreulation.a i os PROCESS ENGINEERING M-51-010/1 FUEL SYSTEMS Mar 1993 Page 5 of 8 NATURAL GAS RECEIVING STATION CONNECTIONS oN Tankage should be provided with blanket ing, water Graw-off, level and temperature indication as appropria 2 Pumping and Treatment: Pumping and treatment of waste Iiquid fuels is similar to that of gas of]. Depending on the liquid sources it may be possible to use it without any treatment or in som cases filtration and coalescence may be required. A rectreulatton ring main may be required to ensble pressure control atthe users to be achieved or when Flowrates are variable. 4 FIL es. 4.1 Natural Gas Natural gas supplied as feed stock or as a fuel in a Process plant 1s usually of good quality and does Not require any on-site treatment to renove Tiquids for solids. In some cases, however, residual hhydrogen sulphide in the gas can lead to the formation of ferric sulphide dust in the pipeline which mst be renoved {f the gas {8 to undergo Compression as it enters the process. For fuel gas use, treatment may or may not be required depending fon the users. Gas turbines w111 normally require ood quality fuel gas. The dust can be removed by the provision of cyclones or filters in the incoming gas Tine. A typteal natural gas receiving station 1s show in Figure ur 42 U6 LPG 1s sometimes used as a supplementary or start fuel supplied from battles or bullets. Propane. ts normally selected since its vapour pressure (7.25 barg at 20°C) allows for alr to be used as heat seurce for the evaporation process. Figure 4.2 shows a typical system for propane evaporation. Tt 1s advisable to electrically trace ines down stream of the knock-out pot to prevent Tiquids condensing and collecting. 4.3, Waste Gas Fuels Most plants are provided with systens to collect. surplus hydrocarbon gases from around a plant and tse them a3 fuel. The most important consideration in any waste gas systen 1s that the gos 13 supplied to the users at & steady pressure and at a constant calorific value. If the calorific value canot be kept constant, then ‘any variations should be kept smooth and step-less.N-51-010/1 PROCESS ENGINEERING Mar 1993 FUEL SYSTEMS Page 6 of 8 TYPICAL LPG VAPOR! SER ro Fue. cs FIGURE 4 v A typical aystem {2 shown in Figure 4.3. The waste gases from the process unit are collected in @ header system and fed into a mixing drum held at constant pressure. Natural gaz or LPG can be added to the drun to maintain the pressure or boost calorific value (using flow fraction contret). The drum may be fitted with quid level control or, {f the Tiquid collection rate is expected to be small, the base of the dru can be traced to ‘evaporate any Tiguids that my collect. Re- ‘evaporation should only be considered for condensate formed by cooling of the gas and not for liquid carryover from upstream separators. ‘The mixed gas 1s distributed to users at a controled pressure, any surplus ges 1s vented to the flare system. Host gases are required by the burners at pressures of up to 4.0 barg and can be ccammodated with the range of waste gas pressures avai Gas turbines require fuel gas pressures up to 30 barg and are normally fed by natural gas directly. A booster compressor ts used when the fuel gas pressure ts too low to be used directly. but tt should only be used when the cost can be shown to be recoverable The fuel gas mixing drum 1s designed to take waste gases from a plant to ensure sufficient mixing 20 ‘that sudden changes in composition and/or heating value are avoided. The normal knock-out drum sizing formuta should be used. —— ay 18 the Tiquid density kg/m 18 the oun deaity tg? K 1s the sizing factor (= 0.05) Ve $8 the eritical velocity, where Q we 3 a Were Q 18 the gas flow m/s and d ts the dram dlaneterJOHNBROWN ia PROCESS ENGINEERING M-51-010/1 FUEL SYSTEMS Mar 1993, Serr Page 7 of 8 TYPIeAL FUEL GAS SySTEM i —e vara _ 4 7 = } ieetees) eee FIGURE 4.3 It has been found by experience that if the dram is § GENERAL GIMSIDERATIONS Sized at a kotoouk Gram ft will ensure adequate stxing, Oruna can be fitted with mizing baffies if 5.1. Emargeey Sttuat fone there is wide variation in the composition of the gases to be mixed (say syn-gas and butane), or if 928 production is cyclic, but it 1s not normally considered necessary. These baffles may be of disc- doughnut or segment type. The drum can be expected to collect some Viquid particularly if the gas has been cooled by expansion to below its dew point. If a lot of Tquld ts predicted this must be level controled fron the rum and disposed of to a waste liquids tank: small amounts of Tiquid can be accomodated by tracing the dru and evaporating the condensate, It 1s considered good practice in any fuel gas system to provide knockout pots in the fuel gas Vines at the inlets to each process area close to users. The purpose of such pots is collect Condensate formed due to cooling by thermodynamic effects or cold anbient temperatures and to cater for the Tiquid slug which may arise if condensate ‘can collect at a Tow point over & long period. ines downstream of the drum may traced and tn critical situations, the gas may be heated at the drum out et to prevent further condensat fon. Vendors require knock-out pots and filters in the the fuel 988 inlet pipework of gas turbines and wil1 normally provide them as part of their package. There is a sense in which fuel Vines can be considered as conveying hazardous material into closed systems. ATI fuel lines must be fitted with automatic trip valves which can be actuated in the event of fire or energency situation and thus Prevent more conbustible material from entering the system, 5.2 Start-up The start-up procedure of any equipment where conbustion takes place must Include & sequence to purge out the fuel systen between the fuel stop valve and the burner. The fuel system design must cater for this and allow for adequate vent ing and catch pots as required, 5.3 Furnaces Furnaces my be fired by Tiquid or gaseous fuels. ‘The gases and Tiquid fuels may be Fired a2 alternatives or fired together. A simplified bot ler control achene 13 shom in figure 5.1. The following points are worthy of note. 1) AN fue] ines must be provided with ‘solation valves located a minim of 15.00 ‘rom the furnace.-51-010/1 PROCESS ENGINEERING Mar 1993 FUEL SYSTEMS Page 8 of 8 2 2 Dy 3) JOHN BROWN TYPICAL FURNACE CONTROL & SAFETY SCHEME FIGURE 54 ANI fuel lines to be provided with ‘independent trip valves, ATL gas lines to be vented to atmosphere at ‘safe location in the event of a trip. Liquid fuel 1s flow controled to the burners, whtle the Flow of gas ts controlled by regulation ‘of the burner inlet pressure. The control system should be designed for the snaximan burner turn down, which may be §:1 for Mquids or larger for gases. Some burner designs utilise steam to atanize the fuel ot) tn the burner. This enables larger fuel fT Flow ranges to be accommodated than for burners which rely on uti ising the of] pressure to do. the Atomising. The rate of steam required ts about 0.2 to 1.0 kg of steam per kg of of! assuming a st pressure of 12.0 barg, The design of the atomising steam supply Tine should ‘ne lude a non-return valve to prevent of1 from entering the steam system and a steam trap to tscharge any condensate that may collect at the low point between valve and burner. Traps downstream of tthe non-return valve should discharge to drain and not te the condensate collection system. ave 1 Ea nar 1995 rode by_| ¢ 1 preston epproved ty | 0 4 ALFORD BS-AC nae 1998 W Text file refit: \P2I0\EOWP\ECOPTWOTO_1F.51 > Graphics refi 1O\EMONUPAELEDPTAWPG\FUELSX-y..by Fig ro. Distribution: Process Engineering Manual (code PS)