Professional Documents
Culture Documents
Distribution
March 6, 2012
NJ ASHRAE Chapter Meeting
Presented By:
Ed Twiss, PE
Analytical and Combustion Systems
www.acs-ny.com
1
Fuel Oil Handling Overview
Fuel Oil System Layout
Unit Conversions/Pump Terminology
Pressure, Vacuum and NPSH
Fuel Oil Pumping Basics
Pump Types & Characteristics, Pump Slip
Fuel Oil Systems Application Examples
Emergency Generator and Burner Loop Examples
Pump Set Selection
Selecting the appropriate pump according to system requirements
Fuel System Design
Control Strategy, Fuel Oil Specialties and System Piping
NYC Caveats (handout)
Long Term Storage of Fuel Oils-Special Considerations
2
Fuel Oil System Layout
3
Unit Conversion
Pressure
1 psi = 2.31 feet of water
1 psi = 2.6 feet of #2 oil
Vacuum
1” Hg = 1.28 feet of #2 oil
1” Hg = 1.13 feet of water
1” Hg = 0.49 psi
-29.92” Hg = perfect vacuum
4
Pump Terminology
NPSHa: Net Positive Suction Head Available.
NPSHa is the absolute pressure available at the suction port of the pump
Function of the “SYSTEM”
NPSHr: Net Positive Suction Head Required.
NPSHr is the minimum pressure required to keep the fluid in the pump from
boiling/flashing/causing cavitation.
Function of the “PUMP”
Operating Pump Suction
The total summation of all losses encountered on the suction side of the pump
while running.
Priming Pump Suction:
This value takes into account the vertical lift of a dry system
Often referred to as the priming static lift.
5
NPSH and Cavitation
High velocity/low pressure at the suction side of a pump can cause
the fluid to start boiling with
reduced efficiency
cavitation
damage
Boiling/cavitation starts when the pressure in the liquid is reduced to
the vapor pressure of the fluid at the actual temperature.
To prevent cavitation of the pump, NPSHa MUST always be greater
than NPSHr.
6
NPSH and Cavitation
7
NPSH and Cavitation
Pump Location
Pump Location
8
Positive Displacement Pumps
For most practical purposes:
Able to pump viscous liquids
Positive displacement pumps are self priming
» Able to lift fluid/operate in vacuum on suction side
Discharge flow relatively constant over range of operating pressures
and viscosities
Can develop high discharge pressure
» when discharge flow is blocked, something could break
9
Pump Comparison
Positive Displacement Versus Centrifugal
10
Internal Gear Pumps
• Two meshed gears, one
driven, one idling
• Outer/driven gear has
internal teeth, inner is a spur
gear/external teeth
• In general
• Flow rates up to 1500 gpm
• Pressures up to 250 psig
11
External/Spur Gear Pump
12
Screw Pumps
• More Costly
• Higher Pressure
• Can Handle some solids
13
Pump Slip
14
Fuel Oil Systems Applications
Boiler Loops
Generator Systems (Day Tanks/Headers)
Most common is duplex pump set
two 100% pumps, one for backup
Triplex pump sets for large plants
three 50% pumps allow for one spare
two 100% “winter pumps” - one 50% “summer pump”
Other systems available
Thermo-Pump Sets (Outdoor Tanks)
Jockey Pumps (tank to tank transfer)
Day tank return pumps
15
Boiler Supply Loop Systems
Most burners have a supply and return line
Burners pump more oil than they burn
5 gph burner might pump 45 gph
100 gph burner might pump 150 gph
Burners may be piped in parallel or series
Pump set might provide atomizing pressure (high pressure
loop)
Pump set floods the burner loop (low pressure)
16
Example – Atomizing Air Burner
#2 Fuel Oil Train
17
Example – Burner Fuel Oil Pump Capacities
18
Piping and Flow for Single Burner
Return line at Higher
elevation and full size,
could use BPRV
19
Burners in a Series Loop
“Low Pressure Loop”
Return line must be piped to the bottom of the tank to prevent foaming, air
entrainment and possible loss of prime during off cycles.
22
Day Tank Systems
Day tanks are used for remote inventory for:
diesel generators
small burners and/or boilers on higher floors
Protects pump seals on burner or engine pump
Day tank provides a period of operation without power
Precautions needed to prevent foam problems
Overflow from day tanks are costly mishaps
In critical applications design should include a means to
test fuel pump set and suction line integrity
Supply/Return lines at opposite ends of tank
23
Generator/Day Tank Considerations
Each 100 kw of generator capacity will consume ~ 7 gallons per hour.
Diesel generators use fuel oil for combustion and engine cooling – there is a
large difference between the generator “burn” rate versus actual pumping rate.
When the Emergency Generators unburned fuel is returned to the day tank,
size pump set to meet generator burn rate
When the Emergency Generators unburned fuel is returned to the main
storage tank, size pump set to meet generators total pump capacity
Generator fuel oil return piping configuration
Day tank versus Main tank
Generator fuel oil return temperature determines the fuel oil return path.
If too hot?
Return main tank
Install fuel oil cooling radiator to prevent day tank overheating
Increase day tank capacity
25
Pump Set Suction Line Integrity Test
26
Day Tank Controls
Vent
Multi-Point level controller To System
• Tank Level Controls
Weighted
• High & Low Level Alarms Emergency Vent*
• Fill Control
• Pump On/Off Control
• Fill Valve On/Off Control
• Fuel Temperature Monitoring
• Secondary Containment Leak
Detection From
Main
• Motor controls on tanks with Pumpset
return pumps
Rupture Basin Leak Switch
27
Generators with a Header System
Greater than 330 gallons
of total volume requires
variance in NYC
28
Pump Set Design Summary
Determining Pump Capacity
For day tank systems
Rate of use + safety factor/duty-cycle determines pump flow
Length of time without power or local code determines day tank size
E-Gen sets – “RULE of THUMB” 7 GPH / 100kw
E-Gen/Day tank - “RULE of THUMB” 4:1 duty cycle
For burner systems
parallel loop, total burner(s) pumping rate X 2
series loop, 2 X (total required flow rate)
Pick pump-motor pair with next greater flow rate
29
Pump Inlet Suction Guidelines
30
Determining Inlet Suction
Determine gravity head in feet oil
Determine loss through suction piping
Figure static lift from bottom of tank
convert fittings, valves, etc. to equivalent feet
add total length of pipe to equivalent for fittings
add loss through strainer
Increase pipe size or lower pump flow to suit
31
Discharge Piping
Pressure at pump discharge =
pressure needed at point of use plus:
32
Fuel Oil Sizing Program
33
Pump Set Components
Flow Switch
Strainer DP
Switch/Gauge
34
Miscellaneous Cautions
Beware of entrained air
locate return and supply at opposite ends of tank
Pipe return line to bottom of tank
Avoid high lifts and “traps”
Allow for easy priming of pumps
Provide adequate vent lines
Provide properly sized day tank overflow lines
Design the system so it can be tested regularly
35
Fuel System Design
Select The Appropriate Pump Size & Type
Flow, Pressure and Supply Voltage Required
36
Control System Considerations
Starting and stopping pumps automatically
Call for operation is typical for boiler loops
intermittent operation typical for day tanks/level systems
Lead/Lag and alternating schemes
Sequencing for filling multiple day/main tanks
Motorized ball valves with end switches
Provision for automatic pump back-up
based on flow or pressure at pump discharge
flow switch
Alarms on malfunction
Automatic testing
Pump started on weekly basis for testing
System safety shutdowns
37
Fuel
Management
Systems
38
Typical FOS Alarms
Failure of a pump to provide flow
Failure of both pumps to provide flow
Low level in a day tank
High pressure in system
High level in a day tank
Leak in a day tank or pump set containment
Leak in double wall piping
Dirt buildup in strainers and filters
PLC Failure
39
Typical Shutdown Conditions
Leak in riser piping*
Leak in containment piping
Leak in day tank*
Leak in pump set
Low level in main tank
Loss of flow in pump, to protect pump
Day tank high level*
Oil in day tank vent line
*NYC Code requirements
40
Control System Summary
Different applications need different strategies
Control system is as important as the pumps
Custom design is key to a reliable fuel system
PLC allows monitoring of many points
System may interface with a building management system
41
Long Term Storage Of Fuel Oils
Special Considerations
Diesel Fuel is an organic product that begins to decay as
soon as it is refined.
Emergency generator fuel may store for 10 years
Diesel fuel is prone to degradation
moisture accumulates in fuel, corroding injectors and/or
seizing valves
bacteria grow in fuel, clogging filters and injectors
Sludge builds up
43
Fuel Maintenance
Filtration systems are recommended for diesel generator
systems where the fuel is likely to sit for long periods of time.
A typical system will:
44
Emergency Fuel Life Extension
Filtration to 5 microns
Water removal
Chemical treatment
Automatic controls
Doubles fuel life
Engines start reliably
Mutli-tank sequencing
Inventory determines system
design
45
NYC Fuel Oil Code Caveats
Day tanks above lowest floor
Must have 200% containment
330 gallons maximum fuel oil storage per floor
Vent lines must be piped back to main tank
46
Summary
We discussed...
Rules of thumb/conversion and NYC caveats
Positive displacement pumps
How to determine the required oil flow
How to determine the required oil pressure
Selecting the appropriate pump size and type
Sizing suction and discharge piping
Selection of control strategy
Problems with long term storage of fuel oils
47