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.

OPERATION & MAINTENANCE MANUAL

TURBINE
1.

VOLUME A

TURBINE OPERATION.

(STAGE I)
2.

VOLUME B

TURBINE OPERATION.

TURBINE MAINTENANCE.

(STAGE II)
3.

VOLUME C

III.

OPERATION & MAINTENANCE MANUAL

ELECTRICAL
1.

VOLUME A

2.

VOLUME B

ELECTRICAL OPERATION.
-

ELECTRICAL

MAINTENANCE.

IV.

OPERATION & MAINTENANCE MANUAL

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