OPERATION & MAINTENANCE MANUAL

For

LDO SYSTEM

Of

PT.CITRA KUSUMA PERDANA, INDONESIA,

AT

3 X 18 MW COAL FIRED POWER PLANT AT SANGATTA

BOP EPC CONTRACTOR : PT.PUNJ LLOYD INDONESIA

DESIGNED AND SUPPLIED BY

FUTECH PROJECTS (INDIA) PVT LTD

105, SHOPPING CENTRE, POCKET J, SARITA VIHAR, NEW DELHI 110 076
Phones: 2694 7948 /2694 0429 Fax : 2694 2613
 OPERATION & MAINTENANCE MANUAL
CONTENTS

CHAPTER NO TITLE

1 SALIENT INFORMATION

2 CONTROL PHILOSOPHY

3 PRE COMMISSIONING CHECKS

4 COMMISSIONING / OPERATING
PROCEDURES

5 PG TEST PROCEDURE

6 PREVENTIVE MAINTENANCE SCHEDULE

7 LIST OF ENCLOSURES.

DESIGNED AND SUPPLIED BY

FUTECH PROJECTS (INDIA) PVT LTD

105, SHOPPING CENTRE, POCKET J, SARITA VIHAR, NEW DELHI 110 076
Phones: 2694 7948 / 2694 0429 Fax : 2694 2613
 CHAPTER-1
SALIENT INFORMATION

Name of the Owner : PT.CITRA KUSUMA PERDANA,

SANGATTA , INDONESIA

Type Of Industry : 3 X 18 MW COAL FIRED POWER PLANT

Owners Consultants : FICHTNER CONSULTING ENGINEERS

(INDIA) PVT LTD,

BOP EPC CONTRACTTOR : PT.PUNJ LLOYD, INDONESIA

BOP EPC Contractor`s Consultant : CETHAR CONSULTING ENGINEERS,

CHENNAI

PACKAGE : LDO SYSTEM

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

Corporate Office : C-28, Sector-65, NOIDA-201301.U.P.INDIA

Contact Person : Mr.K.L.NARSIMHAN / Mr.S.S.AHMAD

Phone nos : 91 (0120) 4655900

Fax : 91 (0120) 4655901
E Mail : projects@futechgroup.com
 CHAPTER-2
CONTROL PHILOSOPHY

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.

2. Geographical data at Plant Site:

Design Ambient Temperature : 40 deg C
Elevation above MSL : 500 meters (FGL)
Max. Recorded Rainfall on any day : 198 mm
Average monthly relative humidity : 90%
Max. Recorded wind speed at 10m
Above ground level : 35 m/sec and terrain cat-2
Seismic Zone : III (As per SNI 1726-2002 &
MAP OF
INDONESIA Y 2010)/ AS 1170.4
3. Fuels :
LDO : Light diesel Oil

4. Reference drawings :
O-1404-PID-01 P & I DIAGRAM FOR LDO UNLOADING SYSTEM

5. SYSTEM DESCRIPTION LDO UNLOADING &

STORAGE
LDO will be brought to site in road tanker, each of capacity 12/20 KL. The
system is designed to unload 2nos. Road tanker at a time.

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.

The Unloading header is designed for connecting 2Nos unloading tappings

each with one hose and manually operated valve.

Two(2)nos. LDO unloading Pumps sets (Horizontal twin screw positive

displacement) are provided (1 working + 1 stand by). Each Pump is rated for
25cum/hr at 2 kg/sqcm(g) discharge head.
 CHAPTER-1
CONTROL PHILOSOPHY

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.

The unloading pump shall be started after checking:

i) LDO unloading station valves are open, valves are not provided with
limit switches.
ii) Motor operated valve fitted before tank inlet is open.
iii) The correct working station pump is selected by the selector switch on
MCC.
iv) MCC healthy.

The LDO unloading rate is 25cum/hr.

At the suction of each LDO Oil Unloading Pump set, one duplex strainer is
provided of capacity 25cum/hr.

Each strainer is provided with a differential pressure indicator and differential

pressure switch.

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 LDO storage tank (FO-TK-01) is provided with the following

instruments:
i) One Radar type level transmitter whose signals are provided to Local
control Panel. The following signals and interlocks are provided :
a) Low level in tank - indication and to trip the transfer pump(by
other) only contacts shall be provided in the panel further scheme
shall be developed by transfer pump supplier.
b) High level in tank indication and to trip the unloading pump
c) High High level in tank Indication and to close the motor
operated valve installed at the inlet of tank.
ii) One mechanical float operated level indicator to check the levels of
LDO inside the tank.
iii) One flame arrestor is provided for safety purposes on the tank vent.
iv) Tank outlet valve is provided with limit switch to indicate the position
of the valve as open or close. The close position is start permissive for
motor operated valve provided at tank inlet

6. DRAIN OIL COLLECTION, STORAGE AND TRANSFER

SYSTEM:
The fuel oil facility is provided with a manual drain oil collection facility for
unloading equipment provided in Pumping shed. Each strainer and pump is
provided with a drain connection with an isolating valve. The drain connection
are connected to the drain oil piping leading to the drain oil tank (FO-TK-02)
OF 2.0KL capacity; 1.25x1.25x1.5mtr high rectangular tank.

The tank is provided with :

i) One top mounted displacer type level switch for high level and low
level alarm and interlock.
ii) One gauge glass type level indicator for local indication.
iii) One flame arrestor for safety purposes on the tank vent.

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 level switch signal is processed at relay base panel.

 CHAPTER-1
CONTROL PHILOSOPHY

The drain oil pumps shall be started after checking:

i) Drain oil pump discharge valves are open
ii) Tank inlet valves are open
iii) Oil level in storage tank is not high
iv) MCC healthy

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.

7. TANK FARM AREA AND OTHER AREAS OF OIL

FACILITY : OIL TRAPPING AND TRANSFER SYSTEM:
The fuel oil facility is provided with spill oil collection, and disposal system. This is a
manual system in which the dyke area / unloading area and pump shed area drains are
brought to an oily water collection pit.

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.

The OWS SUMP Pump shall be started after checking:

i) Is it safe to discharge liquid?
ii) OWS SUMP pump discharge valves are open.
iii) MCC healthy.

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

PRE-COMMISSIONING CHECKS & FLUSHING OF LINES

1.0 Systems

1.1 Light Diesel Oil (LDO)

1.2 Drain Oil (DO)
1.3 Oily Water Pit

2.0 Design Verification

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*.

Any deviation from approved drawings / documents shall be highlighted

and shall be validated before pre-commissioning / commissioning of the
systems.

2.2 Electrical / Control & Instrumentation

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.

Any deviation from approved drawings / documents shall be highlighted

and shall be validated before pre-commissioning / commissioning of the
systems

3.0 Physical Completeness of the system

3.1 Pumps

Ensure pumps are installed as per manufacturer's recommendations.

Ensure pumps are properly aligned and have been tested for vibration
and noise.
Ensure pumps are properly coupled and that the fasteners are
adequately tight.
 CHAPTER-3
PRE COMMISSIONING CHECKS

Ensure pumps are lubricated as per requirement.

Ensure motors are properly earthed.
Pumps are drained through drain valves.
Ensure Inlet / outlet nozzle flanges are adequately tight.
Check rotation of pumps on no load for few seconds.

3.2 Tanks

Ensure tanks are clean & dry from inside.

Ensure all accessories / instruments / valves are fitted on the tanks /
tanks' nozzles as per drawings.
Ensure that the mesh on the vent / flame arrestor is clean for free flow of
vapours / air.
Ensure that the levels of level switches are as per drawings / documents.
Ensure tanks are painted as per specs.
Ensure no welding work is required to be done on the tanks.
Ensure that the nozzle flanges are adequately tight.
Ensure that the tanks are properly earthed.

3.3 Piping & Valves

Ensure that the piping is complete as per drawings.

Ensure all flanged joints are adequately tight.
Ensure all blind plates used during hydro-testing are replaced with
flanges and blind flanges as per drawings.
Ensure all sockets used for hydro-testing are provided with plugs / valves
as per drawings.
Ensure vent valves / drain valves are provided on highest and lowest
points of piping as per drawings. Ensure all these valves are closed.
Ensure that the tracer lines on HFO lines are complete. They are
equipped with isolation valves and the steam traps. Ensure all the valves
are open.
Ensure that valves are opened or closed as per drawings. Normally
closed valves shall remain closed.
Ensure that the pipes are adequately supported as per drawings.
Ensure that the supports are properly finished. Look for temporary
welding of pipe shoes with supporting members and remove, if found.
Ensure that the isolation valves are open or closed as per drawings.
Ensure that the baskets of the filters are clean.
Ensure that the filters are drained through drain valves.
Ensure that the vent and drain valves are normally closed.
 CHAPTER-3
PRE COMMISSIONING CHECKS

4.0 Flushing of pipe lines

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.

Following procedure for flushing shall be adopted:

4.1 Isolate all instruments

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

4.2 Isolate all tanks

Close the valves including motor operated valves on all the nozzles of all
tanks.

4.3 Vent and drain valve

Close all the vent and drain valves of pipe lines and all equipment such
as pumps, filter, line heaters etc

4.4 Open all other valves

Except as mentioned above, open all other valves fully.

4.5 Flushing media and sequence

ALL LINES WERE FLUSHED WITH WATER TO REMOVE ALL SOLID

PARTICLES ,SLAGS ETC AND THEN HYDROTEST WAS CARRIED OUT.
AFTER SUCCESSFUL HYDROTEST DRAIN OUT THE WATER AND THEN
FLUSH WITH COMP AIR AFTER BLOCKING THE END WITH CARD
BOARD SO THAT ONCE THE PRESSURE INSIDE IS BUILT UP THE
CARD BOARD WILL BREAK ON ITS OWN TO ALLOW THE PARTICLES IS
ANY INSIDE TO COME OUT OF THE PIPING. FOLLOW THIS
PROCEDURE TILL CLEAN AIR COMES OUT.

LDO lines shall be flushed with compressed air .

Adequate quantity of flusing media shall be made available by Owner at

site for flushing of pipe lines.

Following pressures (approximate) shall be used of various flushing

media:

* Compressed air 5bars

 CHAPTER-3
PRE COMMISSIONING CHECKS

4.6 Flushing in sections

Flushing of lines in sections shall be easier and should be adopted. For

example: Section 1 could be from LDO unloading header to storage
tanks, Section 2 could be from HFO tanks to pressurizing pumps, Section
3 could be from pressurizing pumps to battery limit near boiler house and
so on.

These sections, however, shall be decided at site as per the convenience

of commissioning team and also as per the flushing connections provided
in the system as per the drawings.

It shall be ensured that none of the pipe lines is spared from flushing.

4.7 Flushing with air

All pipe lines shall be flushed with compressed air after these lines are
flushed with water.

Flush the lines as per clause 4.5 above

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.

4.8 After Flushing

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.

All valves shall be opened or closed as per normal operation of the

system. All drain and vent valves are closed. All bypass valves are
closed.

The system is ready for commissioning.

 CHAPTER-4
COMMISSIONING / OPERATING PROCEDURES

COMMISSIONG PROCEDURE FOR LDO SYSTEM

Once Pre-Commissioning checks are carried out and pipe lines are flushed as mentioned in
Pre-Commissioning Checks, the system is ready for Commissioning trials.
Essential readings
Following documents should be read thoroughly by the Commissioning Team and should be
kept handy during commissioning trials.

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

1.1 Commissioning Team

The commissioning team shall consist of following from Owner,

Owner's Consultant, EPC Contractor, Sub Contractor
PLL shall designate one Team Leader.
Minimum one representative for each discipline (Mechanical /
Electrical / C&I) from each company.
A gang of Electrician, Fitter, Welder, Rigger and Helper.

It is suggested that the Plant Operation Team is also part of this

commissioning team.

1.2 O&M Manuals and Pre-Commissioning Meeting

Futech shall make available the O&M manuals for all major
equipment and instruments as received from the manufacturers.

All members of the commissioning team should read these manuals

before going for commissioning.

It is advised that major points are discussed in a "Pre-Commissioning

Meeting" among the commissioning team members to conclude the
commissioning procedure so that the difference of opinion is not
there while actual procedure.

1.3 Tools & Tackles

Erection Tools & Tackles

Measuring instruments
 CHAPTER-4
COMMISSIONING / OPERATING PROCEDURES
1.4 Safety Equipment

First aid box

Portable fire extinguishers as per CCE norms shall be in position.
Fixed fire fighting system shall be in operation
Owner shall arrange for an Ambulance

1.5 Utilities
Following utilities are required for Commissioning of the system. The Owner
is required to make these utilities available before commissioning.

Illumination in all areas

Functional Earthing grid / Earthing pits
Three phase / Single phase power to MCC / Control panels / Other
panels as required
DC power as required
Service water
Service air / Instrument air at required pressure and flow
LDO in road tankers for unloading operation

6.0 LDO Unloading Operation

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.

6.2 Open the root valves of all instruments.

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.

6.14 Avoid spilling of oil through hose.

6.15 During unloading operation, following interlocking are possible:

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 level in storage tank. It will trip the unloading pump

automatically.

High High level in storage tank will close the inlet motorized Valve to
the Tank.

Low pressure in pump discharge sensed by a pressure switch

located in the discharge line will also trip the unloading pump.

In such an event, the pressure transmitter on the common discharge

header will start the standby pump automatically.

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

6.17 Observe the following during unloading operation:

Pressure gauge on discharge of pump should show the pump's duty

point pressure.

Differential pressure indicator across the filter should not exceed the
set pressure.

Abnormal sound (Dry running) of pump.

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

6.19 Following parameters shall be monitored in Local control panel :

Differential pressure across filter 1 on unloading pump 1

Differential pressure across filter 2 on unloading pump 2
High level in LDO tank
High-high level in LDO tank
Low level in LDO Tank
Motorized valve feed back

7.0 LDO Draining Operation

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

8.0 Oily Water Separator

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

REFER PG TEST PROCEDURES ATTACHED AS ANNEXURE - 5

 CHAPTER-6
PREVENTIVE MAINTENANCE SCHEDULE

REFER PREVENTIVE MAINTENANCE SCHEDULE ATTACHED

AS ANNEXURE - 6
 CHAPTER-7
LIST OF ENCLOSURES

1. LIST OF DRAWING & DOCUMENTS - ANNEXURE - 1

2. LIST OF DATA SHEETS - ANNEXURE - 2

3. TEST CERTIFICATE SCHEDULE - ANNEXURE - 3

4. LIST OF SUPPLIERS O&M MANUALS - ANNEXURE - 4

5. PG TEST PROCEDURE - ANNEXURE - 5

6. PREVENTIVE MAINTENANCE SCHEDULE - ANNEXURE - 6

7. LIST OF SPARES FOR SCREW PUMPS - ANNEXURE - 7