FOHS

INTRODUCTION
Fuel Oil:
Fuel oil is a fraction obtained from petroleum distillation, either as a
distillate or a residue. Broadly speaking, fuel oil is an liquid petroleum product that is
burned in a furnace or boiler for the generation of heat or used in an engine for the
generation of power, except oils having a flash point of approximately +40 °C (104 °F)
and oils burned in cotton or wool-wick burners. In this sense, diesel is a type of fuel oil.
Fuel oil is made of long hydrocarbon chains, particularly alkanes, cycloalkanes and
aromatics. The term fuel oil is also used in a stricter sense to refer only to the heaviest
commercial fuel that can be obtained from crude oil, heavier than gasoline and naphtha.
Fuel oil in the United States is classified into six classes, according to its
boiling temperature, composition and purpose. The boiling point, ranging from 175 to
600 °C, and carbon chain length, 20 to 70 atoms, of the fuel increases with number.
Viscosity also increases with fuel oil number and the heaviest oil has to be heated to get it
to flow. Price usually decreases as the fuel number increases.
Some commonly used fuel oils are

• High Speed Diesel
• Light Furnace Oil
• Heavy Furnace Oil
• Light Diesel Oil
Properties of Fuel Oil:

Some of the important properties of fuel oil are
1. Viscosity: Viscosity is a measure of the resistance of a fluid to being deformed by
either shear stress or extensional stress. It is commonly perceived as "thickness",
or resistance to flow. Viscosity describes a fluid's internal resistance to flow and
may be thought of as a measure of fluid friction.
2. Flash Point: The flash point of a flammable liquid is the lowest temperature at
which it can form an ignitable mixture in air. At this temperature the vapor may
cease to burn when the source of ignition is removed. The flash point is often used
as one descriptive characteristic of liquid fuel, but it is also used to describe
liquids that are not used intentionally as fuels.
3. Pour Point: The pour point of a liquid is the lowest temperature at which it will
pour or flow under prescribed conditions. It is a rough indication of the lowest
temperature at which oil is ready to pump. Also, the pour point can be defined as
the minimum temperature of a liquid, particularly a lubricant, after which, on
decreasing the temperature, the liquid ceases to flow.
4. Density: The density of fuel oil is an important factor in the design of the fuel oil
handling system. Density greatly depends on the temperature of the fuel oil and in
turn will determine the viscosity and the power required for pumping it.
Uses of Fuel Oil:
1. Fuels are used in house hold purpose, Industrial purpose and transportation
purpose etc.
2. Electricity power can also produced by diesel generators but it is very pollutant
and it is not economical to use the power continuously.
3. In power plants Fuel oils are very useful to produce steam by heating up the water
to convert into Electric power
4. Heavy fuel oils continue to be used in the boiler "lighting up" facility in every
coal-fired power plant. It is analogous to lighting kindling to start a fire - without
performing this simple function it is difficult to begin the large-scale combustion
process.
Fuel Oil Handling System:
A fuel oil handling system is a system which
is used to supply the fuel oil to the boiler/furnace/plant. The basic functions which a fuel
oil handling system must perform in order to achieve this are
1. Filtration
2. Heating
3. Pumping
4. Storage and
5. Transfer of the fuel oil.
A schematic diagram of a general fuel oil handling system is as shown in the

given figure
Fig.1 Fuel Oil Handling System

Applications of Fuel Oil Handling System:
1. Used in thermal power plants for storage and supply of fuel to boilers.
2. Used in manufacturing industries for the firing of oil furnaces.
3. Used at fuel processing and petroleum refining industries.
4. Used for handling of various types of oils in food processing, transportation and
petroleum industries.
5. It is generally used wherever heavy fuel oil is used.
Components of Fuel Oil Handling System:
The main components of a fuel oil handling system as illustrated in

the figure are
1. Skids
2. Storage Tanks
3. Industrial Heaters
4. Piping
5. Day Tank
The fuel oil handling system is designed according to the specifications of the customer
as well as the standards of the American Petroleum Institute.
The various components listed above will now be discussed in brief
Skids:
A skid is basically an assembly of various components such as
• Frame: The frame is constructed using steel beams and fabricated using arc
welding. All the main components of the skid such as pumps, piping, etc are
supported by the frame.
• Pumps: Generally three types of pumps are used for pumping of fuel oil according
to the discharge and pressure requirements. They are
1. Centrifugal Pump: For high discharge and high pressure heads.

2. Screw Pump: For low discharge and high pressures.
3. Gear pump: For medium discharges and pressures.
Here we use mainly Gear pump to pump the oil from Supplier tank to
Storage tank and from Storage tank to Boiler.
GEAR PUMP:
A gear pump uses the meshing of gears to pump fluid by
displacement. They are one of the most common types of pumps for hydraulic fluid
power applications. Gear pumps however are also widely used in chemical installations
to pump fluid with a certain viscosity. Gear pumps are fixed displacement, meaning they
pump a constant amount of fluid for each revolution. Some gear pumps are designed to
function as either a motor or pump.
Theory of operation
As the gears rotate they separate on the intake side of the pump,
creating a void and suction which is filled by fluid. The fluid is carried by the gears to the
discharge side of the pump, where the meshing of the gears displaces the fluid. The
mechanical clearances are small—on the order of a thousandth of an inch (micrometers).
The tight clearances, along with the speed of rotation, effectively prevent the fluid from
leaking backwards.
The rigid design of the gears and housing allow for very high pressures and the ability to
pump highly viscous fluids.
Many variations exist, including; helical and herringbone gear sets (instead of spur
gears), lobe shaped rotors similar to Roots Blowers (commonly used as superchargers),
and mechanical designs that allow the stacking of pumps. The most common variations
are shown below (the drive gear is shown blue and the idler is shown purple).
Gear pump design for hydraulic

power applications.
Suction and pressure ports need to interface where the gears mesh (shown as dim gray
lines in the internal pump images). Some internal gear pumps have an additional, crescent
shaped seal (shown above, right).
• Piping: All the piping of the skid is as per IS 2062 material standard and is
designed for the required discharge and pressure.
• Valves: Various types of valves are used in the skids such as flow control valves,
pressure relief valves, non return valves, etc.
• Meters: Different types of measuring instruments such as a thermometer, pressure

gauge, flow meter and viscometer are used in order to measure the temperature,
pressure, rate of flow and viscosity of the fluid.
• Heaters: Sometimes an In-line heater is used on the skid if the fuel oil is very
viscous and the surrounding temperature does not allow for the smooth flow of
the oil.
• Filters : Filters are used in the skids to filter the fuel oil as per the requirement.
They are made of MS Fabricated basket with flange connection. Filters are
generally of two types. They are
1. Simplex Filter
2. Duplex Filter (combination of two simplex filters connected with two
3-way interconnecting ball valves).
Fig.2 Duplex Filter
Simplex and duplex filters contain a stainless steel mesh backed with MS
perforated sheet. They are provided on the unloading skid with 500microns of
filtration and on the transfer skid with 250microns of filtration.
Docking ports
Pressure Gauge
Frame
Fig.3 Front View of a Skid
Duplex Filter
Gear Pumps
Fig.4 Rear View of a Skid

Skids are used to transfer fuel oil from one point to another.
They are divided into two types based on their function. They are
1. Unloading Skid: which is used to unload fuel from the tanker and supply it
to the storage tank. This has a filtration of about 500microns in order to
remove the sediments from the fuel oil before being pumped to the storage
tank.
2. Transfer Skid: This is used to transfer fuel oil from the storage tank to the
day tank. It has a filtration of around 250microns before being pumped to
the day tank and then to the furnace.
Design Considerations: The skid is designed based on the specifications of the customer
such as the number of unloading ports, rate of discharge of the fuel oil, number of pumps,
etc.
Storage Tanks:
These are basically large tanks which are used to store fuel oil in
bulk for later use in the plant. The capacity of these tanks usually varies from a few kl
(kilo liters) to sometimes up to 4000kl depending upon the customer’s specifications.
There are generally two types of storage tanks
1. Horizontal Storage Tank

2. Vertical Storage Tank
Components of a Storage Tank: The following are the basic components of a storage
tank. They are
• Air vent: This vent is provided in order to relieve the build up of internal pressure
inside the storage tank due to the heating of the fuel oil.
• Drain vent: It is provided in order to drain the storage tank during regular
maintenance and repair work.
• Inlet nozzle: The fuel oil is pumped into the storage through the inlet nozzle
which is usually located radially near the top of the tank.
• Outlet nozzle: This nozzle is also positioned radially but near the bottom of the
storage tank.
• Manhole: It is basically an opening in the storage tank through which the repair
and maintenance worker can climb into the tank and is usually located at the top
of the tank on its roof.
• Level indicator: The level indicator is basically an arrow and scale type of a
measuring device which is used to determine the level of fluid in the storage tank.
• Spare nozzle: A couple of spare nozzles are provided on the storage tank in case
the primary nozzles do not work or need maintenance and repair work.
• Heaters: Industrial heaters of the immersion or outflow type are used in the
storage tank in order to heat the fuel oil to its required temperature.
Fig.5 Vertical Cylindrical Storage Tank
Design Considerations: The storage tanks are designed as per the standards of the
American Petroleum Institute (API 650) or Indian Standards (IS 803) and the given
specifications of the customer. The design is based upon the estimated or required
capacity of the tank as well as the space conditions.
Industrial Heaters:
There are Electrical heaters and Steam traced heaters which
are used to heat the fuel oil in order to decrease its viscosity and to increase its flow. We
are mainly concentrated on the Steam traced heaters which use steam for heating and are
specified according to the Surface area of the heater. There are three types of heaters.
They are
1. Floor coil Heater: This type of heater is used inside the storage tank and is
submerged in the fuel oil, below the outlet nozzle of the tank. These are usually
high capacity heaters.
2. Outflow Heater: This type of heater is used in the outlet nozzle of the tank to
heat the fuel oil uniformly when it leaves the storage tank. This type of heater
differs from the floor coil type in the way that these are usually low capacity
heaters and is used if the fuel oil is not so viscous and can be easily made to flow
with the addition of only a small amount of heat.
Outlet
Fig.8 Outflow Heaters

Inlet to Fuel Oil
Storage Tank
Inlet Nozzle
Outflow heater
Outlet Nozzle
Fig.9 Outflow heater
3. In-line Heater: These type of heaters are used in-line with the pipeline and are
used for pre-heating the fuel oil at regular intervals in the course of the piping.
Fuel Oil Out

Fuel Oil In
Heating Elements
Heater Shell
Fig.10 In-line Heater
Design Considerations: The industrial heaters are designed based upon the type of fuel
oil, its viscosity, its flash point and pour point, the flow rate required and the required
temperature.
Day Tanks:
These are basically smaller capacity tanks which are used for supplying
the fuel oil to the furnace/boiler/plant according to the running capacity of the plant per
day. The capacity of the day tank usually lies between a few kl (kilo liters).
Fig.11 Day Tank

Design Considerations: These tanks are designed as per the standards of the American
Petroleum Institute and the given specifications of the customer. Heaters of smaller
capacities are provided in order to heat the fuel oil.
Other Equipment Used:
• 3 way ball valve

• 2 way ball valve
• Non return valves
• L-port valve
• Pressure relief valve
• Flow meters
• Pressure gauges
• Viscosity meter
• Temperature gauges
• Insulation (wool blanket covered with Aluminum sheet)
• Heating jackets
• Level indicators
• Level switches
• Thermostats
• Control panels
DESIGN CALCULATIONS OF FUEL HANDLING SYSTEM
`The fuel handling system is the system is used to supply the fuel from the
supplier tank to the storage tank and from storage tank to the boiler. The components
which we have to design in the fuel handling system are
a. Unloading Skid :
 Pipe for guide the fuel from supplier tank to the storage tank
 Strainer for filtering the oil
 Pump for pressurized the oil from supplier tank to the storage tank
 Storage tank to store the oil for further use
 Floor coil heater to raise the temperature of the oil up to its pour
point temperature
b. Transport Skid :
 Pipe for guide the fuel from the storage tank to the Boiler
 Strainer for filtering the oil
 Pump for pressurized the oil from Storage tank to the Boiler
c. Total steam requirement :
 Steam requirement for across the Fuel Handling System to raise

the temperature of the fuel to its Pour point temperature.
Design of the above mentioned components are calculated by using the

inputs given by the customer according to his plant requirement. Our main intension is to
Design the components involve in the fuel handling system up to the satisfaction of the
customer requirement.
Input data given by the customer to design the Fuel handling system to
there plant are :
UNLOADING SKID :
I. PIPE AND PUMP

Required Discharge (Q) = 10 m3 / h
Velocity of flow at the suction side of the Gear pump (V1) = 0.9 m / sec
Vapour head of the oil (Vh) = 0.2 mwc
Level of the supplier tank outlet w.r.t 0.0 m = 1.3 m
Level of the pump suction w.r.t 0.0 m = 0.6 m
Suction head = (1.3 – 0.6) = 0.7mwc
Level of Pump discharge w.r.t 0.0m = 0.6 m
Level of Tank inlet w.r.t 0.0m = 11.9 m
Static head = (11.9 – 0.6) = 11.3
Design Viscosity (K) at 50ºC = 180 centi strokes
Velocity of flow at the delivery side of the Gear pump (V2) = 1.5 m / sec
II. STORAGE TANK

No. of Storage tank = 1
Diameter of the Storage tank (D) = 10 m
Height of the Storage tank (H) = 8.5 m
Net Design Liquid Height (He) = 8m
Effective Capacity, (Q1) = 628 m3
Design Specific Gravity (G) = 1
Design Density of liquid (ρ) = 1000 kg / m3
Design Temperature, (T) = 120 0 c
Corrosion Allowance for Roof Plate, (C) = 1 mm
Corrosion Allowance for Bottom & Shell plate, (C) = 2 mm
Material of Construction = IS 2062 Gr. B
Maximum Allowable working Stress, = 165 MPa
Width of Shell Plates, (Ws) = 1.5
III. FLOOR COIL HEATER
Operating Pressure = 4.5 ata

Pressure at inlet of Floor coil heater = 4.5 ata
Satruated Temp. at 4.5 ata = 138 0 c
Latent heat at inlet pressure of 4.5 ata (hf) = 512.89 Kcal / kg.
Type of Oil = HFO
Maxi Density, (D1) = 875 Kg / m3
Specific heat, (Cp) = 0.46 Kcal / kg 0 c
Initial Temperature, (T1) = 12 0 c
Final Temperature (T2) = 55 0 c
TRANSFER SKID :
IV. PIPE AND PUMP

Length of the pipe = 12 m
According to the plot plan and the input data given by the customer we
have to draw a “PROCESS AND INSTRUMENTATION DIAGRAM” and send to the
customer for corrections. After refering of our “PROCESS AND INSTRUMENTATION
DIAGRAM” if there is any correction they will correct on the “P &ID” and send to us to
Design according to that corrections.
The “P & ID” according to the above information
After corrections we have start design the components according to the input data given
by the customer.
UNLOADING SKID :
Pipe Design:
All the piping used in the fuel oil handling system is made of material SA 106 Grade B.
The required data to design the pipe is :
Required Discharge (Q) = 0.002 m3 / sec

Q = AxV
A = Q/V
= 0.002 / 0.9
= 0.003
d = [(0.003 x 4) / 3.12] 1/2
= 0.061 m
Inner diameter of the pipe = 0.061m

Length of the pipe = According to the plot plan.
PIPE THICKNESS
We have calculate the pipe thickness according to the internal

pressure of the steam which flow under the pipe.
T = ( P x D) / [2((S x E) + (P x Y))] + CA
Where
Pressure (P) = 3.5 Kg / cm2
Diameter(D) = 6.1 cm
Allowable Stress (S) = 1680 Kg / cm2
Joint efficiency = 0.7
Wall thickness factor (y) = 0.04
T = ( P x D) / [2((S x E) + (P x Y))] + CA
= (3.5 x 6.1) / [ 2((1680 x 0.7) + (3.5 x 0.04))] + CA
= 0.029 cm
Thickness of the Pipe is equal to 0.00029m

FILTER CALCULATIONS
The volume of the basket = 10 x diameter of the pipe (As

per
Customer)
= 10 x 0.061
= 0.61 m
The filtration Capacity is 1000 microns
1 micron = 10-6 m
1000 micron = 1000 x 10-6
= 0.001 m
= 1 mm
PUMP SELECTION:
Usually, Gear pumps are used for pumping fuel oil in most of the fuel oil
handling systems since they require lesser maintenance than other type of pumps and also
they are used for medium pressures and discharges.
P = Q x [(NPSH) + (DH)] / (270 x η)
P = power of pump in (HP)

Q = discharge of pump in (m3/sec)
NPSH = Net Positive Suction Head (m)
DH = Discharge Head (m)
η = efficiency of pump=0.5
Net Positive Suction Head :
The head of the fuel at the suction valve of the pump is known as the Net
Positive Suction Head.
NPSH = (Atm. head + Suction head) - (Friction head + Vapour head)
Required Input data :

Atm. Head = 10.3 mwc
Suction head = (1.3 – 0.6) = 0.7mwc
Now we have to find the Friction head loss by using the “DARCESE FORMULA”
H = (4fLV2) / (2gd)
Where,
H = head loss in m =?
f = friction factor =?
L = Overall length of the pipe and fittings =?
V = Velocity of fluid in m/sec = 0.9m/sec
G = acceleration due to gravity = 9.8m/sec2
d = dia. of pipe in m = 0.061m
Overall length of the pipe and fittings before suction valve of the pump(L)
= [(length of the suction pipe) + (2 x length of the 900bend)
0
+ (length of the non return value) + ( length of the 45
bend) + (length of the ball valve)]
According to Standards of Pipe Fittings :
45º Elbow (Le/D=15.75)

Tee (Le/D=45)
Gate Valve (Le/D=7.65)
Globe Valve (Le/D=270)
Ball Valve (Le/D=2.25)
Plug valve (Le/D=7.65)
Non return Valve (Le/D=90)
Overall length (L) = 30 + (2 x 1.23) + (5.49) + (0.96) + (0.13)
= 40 m
Friction Coefficient (f) = 16 / Re (When Re <= 2100, if Re > 2100 we have

to find the “f” by modi diagram)
Reynolds number = VD / Design viscosity
= (0.9 x 0.061) / (180 x 10 -6 )
= 305
Friction Coefficient (f) = 16 / Re = 16 / 305 = 0.05
By substituting the values of Overall length and Friction Coefficient in the

Friction head loss formula we can find the Friction head.
H = (4fLV2) / (2gd)
Friction head loss ( H ) = (4 x 0.05 x 40 x 0.92) / (2 x 9.81 x 0.061)
= 5.4m

= (10.3 + 0.7 ) - (5.4 + 0.2 )
= 5.4 mwc
DELIVERY HEAD = (STATIC HEAD LOSS) + (FRICTION HEAD LOSS)

Required input data :
Level of Pump discharge w.r.t 0.0m = 0.6 m

Level of Tank inlet w.r.t 0.0m = 11.9 m
Static head = (11.9 – 0.6) = 11.3
For Friction Head Loss
H = (4fLV2) / (2gd)
Where,
= [(length of the delivery pipe) + (2 x length of the
900bend) + (length of the ball valve)]
Overall length (L) = 40 + (2 x 0.83) + (0.092)

= 42 m

Reynolds number = VD / kinematic viscosity
= (1.5 x 0.041) / (180 x 10 -6 )
= 341

H = (4fLV2) / (2gd)
= 18.79m
DELIVERY HEAD = (STATIC HEAD LOSS) + (FRICTION HEAD LOSS)
= (11.3 + 18.79)
= 30 m
P = Q x [(NPSH) + (DH)] / (270 x η)

= 10 x [5.4 + 30] / (270 x 0.5)
= 2.62 H.P
We require 2.62 Horse Power motor to pump the oil from the supplier tank to the storage
tank.
FLOOR COIL HEATER
The Floor Coil Heater is used to raise and maintain the pour point
temperature of the oil, which stored in the storage tank for further use. This heater is
arranged at the bottom of the Storage tank which transfer heat from the steam to the oil.
Floor Coil Heater is just like a shell and tube type Heat Exchanger that the steam is flow
through the tubes and the oil which we want to boil is stored in the shell.
To design the Floor Coil Heater we have to calculate
 The heat load taken by the oil for initial heating

 The heat loss through Tank shell, Bottom & Roof during initial heating
 The heat loss through Tank shell, Bottom & Roof during maintaining heating
 The heat load taken by the storage tank material
To calculate above heat loads and heat losses the required input data is
Inner Diameter of the Storage tank (d) = 10 m
Outer Diameter of the Storage tank without insulation (d1) = 10.016 m
Outer Diameter of the Storage tank with insulation (d2) = 10.09 m
Height of the Storage tank (h) = 8.5 m
Operating Pressure (P) = 4.5 ata
Pressure at inlet of Floor coil heater = 4.5 ata
Satruated Temp. at 4.5 ata (T) = 138 0 c
Latent heat at inlet pressure of 4.5 ata (hf) = 512.89 Kcal / kg.
Type of Oil = HFO
Maxi Density, (D1) = 980 Kg / m3
Specific heat, (Cp) = 0.44 Kcal / kg 0 c
Initial Temperature, (T1) = 12 0 c
Final Temperature (T2) = 55 0 c
Average Temperature (Tavg) = (55 +12) / 2 = 33.50c
Heating time (Ht) = 72 hours (Assumed)
THE HEAT LOAD TAKEN BY THE OIL DURING INITIAL HEATING (Q1)
The heat load taken by the oil during initial heating (Q1) = [m Cp(T2 - T1)] / Ht
Mass(m) = Volume x density

= [(3.14 / 4) x d1 x h] x 980
= 615752 kg
Q1 = [m Cp(T2 - T1)] / Ht
= [ 615752 x 0.44 x (55 – 12)] / (72)
= 161805 Kcal / hr.
THE HEAT LOSS THROUGH SHELL, ROOF AND BOTTOM PLATES

DURING INITIAL HEATING :
HEAT LOSS THROUGH SHELL OF THE TANK :
The heat loss through the shell during initial heating (Q2)
Q2 = (Tavg – T1) / [(d1 / 2k) x (ln(d2 / d1)) + (d1 / fd2)]
Film Coefficient (f ) = (f) convection + (f) radiation
(f) convection = 1.957x(T3-T1)^0.25 x (2.857xV+1)^0.5

(f) radiation = 5.755 x 10^-8 x E x (T34-T14)/(T3-T1)
Where
Outside surface temp. of insulation, T3 (Consider Max. Outside Temp. As 50ºC) = 323
Ambient Air Temp, T1 = 273 k
Average wind speed, V = 50 m / sec
By substituting all the above values in the (f) convection and (f) radiation and by
summing them we get Film Coefficient value as given below
Film Coefficient = 17.46 kcal / hr.m2 oc
Q2 = (Tavg – T1) / [(d1 / 2k) x (ln(d2 / d1)) + (d1 / fd2)]
= (33.5 – 12) / [( 10.016 / 0.088) x (ln(10.9 / 10.016) ) + (10.016 / (17.46 x 10.09))
= 24.03 Kcal / hr m2
Surface area (A) = (3.14 / 4) x d x h
= (3.14 / 4) x 10.016 x 8.5
= 67 m2
Heat loss through tank shell = Q2 x A
= 24.03 X 67
= 1606 Kcal / hr.
HEAT LOSS THROUGH ROOF PLATE :
Rate of heat loss through Roof plate(Q3) = (Tavg – T1) / [(L /k) + (1 / f)]
= 21.5 / [(0.04 / 0.044) + (1 / 17.46)]
= 22.25 Kcal / hr m2
Surface area (A) = (3.14 / 4) x d2

= (3.14 / 4) x 10.112
= 80.27 m2
Heat loss through Roof plate = Q3 x A
= 22.23 x 80.27
= 1806 Kcal / hr.
HEAT LOSS THROUGH BOTTOM PLATE :
Heat loss through Bottom plate(Q4) = KA (Tavg – T1)

= 0.86 x [(3.14 / 4) x (10)2] (33.5)
= 1417 Kcal / hr.
THE HEAT LOSS THROUGH SHELL, ROOF AND BOTTOM PLATES

DURING MAINTAINING HEAT :
HEAT LOSS THROUGH SHELL OF THE TANK :

Rate of heat loss through the shell during maintaining heat (Q5)
Q5 = (T2 – T1) / [(d1 / 2k) x (ln(d2 / d1)) + (d1 / fd2)]
Film Coefficient (f ) = (f) convection + (f) radiation
(f) convection = 1.957x(T3-T1)^0.25 x (2.857xV+1)^0.5

(f) radiation = 5.755 x 10^-8 x E x (T34-T14)/(T3-T1)
Where
Outside surface temp. of insulation, T3 (Consider Max. Outside Temp. As 50ºC) = 323
Ambient Air Temp, T1 = 273 k
Average wind speed, V = 50 m / sec
By substituting all the above values in the (f) convection and (f) radiation and by
summing them we get Film Coefficient value as given below
Film Coefficient = 17.46 kcal / hr.m2 oc
Q5 = (T2 – T1) / [(d1 / 2k) x (ln(d2 / d1)) + (d1 / fd2)]
= (55 – 12) / [( 10.016 / 0.088) x (ln(10.9 / 10.016) ) + (10.016 / (17.46 x 10.09))
= 48.31 Kcal / hr m2
Surface area (A) = (3.14 / 4) x d x h
= (3.14 / 4) x 10.016 x 8.5
= 67 m2
Heat loss through tank shell = Q5 x A
= 48.31 X 67
= 3236 Kcal / hr.
HEAT LOSS THROUGH ROOF PLATE :
Rate of heat loss through Roof plate = (T2 – T1) / [(L /k) + (1 / f)]
= 43 / [(0.04 / 0.044) + (1 / 17.46)]
= 44.51 Kcal / hr m2
Surface area (A) = (3.14 / 4) x d2

= (3.14 / 4) x 10.112
= 80.27 m2
Heat loss through Roof plate (Q6) = Q3 x A
= 44.51 x 80.27
= 3572 Kcal / hr.
HEAT LOSS THROUGH BOTTOM PLATE :
Heat loss through Bottom plate(Q7) = KA (Tavg – T1)

= 0.86 x [(3.14 / 4) x (10)2] (43)
= 2902 Kcal / hr.
Heat load taken by the material of the tank = m Cp (T1 – T2) / Ht

= [(3.14 / 4) x d2 x h] x 7850
= 5240569 kg
Q8 = [m Cp(T2 - T1)] / Ht
= [ 5240569 x 0.52 x (55 – 12)] / (72)
= 1721381 Kcal / hr.
TOTAL HEAT LOAD PER HOUR
Initial Heat load consider 10 % Marjin (Q1) = (Q1 + Q2 + Q3 + Q4 + Q8) x 1.1

= 2076816 Kcal / hr.
Maintain heat load consider10 % Marjin(Q2)= (Q5 + Q6 + Q7 ) x 1.1

= 9710 Kcal / hr.
HEAT TRANSFER AREA OF THE FLOOR COIL HEATER
Heat transfer area required for floor coil heater(a) = (Q1) / {K x [T sat - (T1 + T2) / 2])
= (2076816) / {75 x 114.42)
= 242 m2
LENGTH OF THE FLOOR COIL HEATER
Actual Length of Floor Coil pipe required = Heat transfer area / Area of pipe per
meter length
Floor Coil Pipe considered is 50NB Seamless Carbon Steel to ASTM A-106, Gr.B, Sch-
40
Surface area of 50NB Pipe per meter, a4 = 0.189 m2 / m
Length of Pipe required (L) = 242 / 0.189
= 1280 m
DESIGN OF THE STORAGE TANK
The main components which involve in the construction of the storage

tank that which we are going to design are
 Shell Courses
 Rafters
 Center column
SHELL COURSES :
Shell courses are the structural steel plates conforming to the material standard IS 2062
which are rolled and welded to form a cylindrical shape according to our requirement and
are generally available in the market in standard dimensions, i.e. 1.25x6.3m and
1.5x6.3m of variable thicknesses. Therefore, according to the required dimensions of the
tank, plates of optimum dimensions have to be chosen in order to minimize the waste.
RAFTER :
Rafter is a structural beam which is used to support the roof of the tank. It is generally in
“I” section and one end of the section is supported by the Center column and other is
supported by the shell courses.
CENTER COLUMN:
Center column is a structural Column which is used to support the Rafter.
Requied input data for design
No. of Storage tank = 1

Diameter of the Storage tank (D) = 10 m
Height of the Storage tank (H) = 8.5 m
Effective Capacity, (Q1) = 628 m3
Design Specific Gravity (G) = 1
Design Density of liquid (ρ) = 1000 kg / m3
Design Temperature, (T) = 120 0 c
Corrosion Allowance for Roof Plate, (C) = 1 mm
Corrosion Allowance for Bottom & Shell plate, (C) = 2 mm
Maximum Allowable working Stress, (Sd) = 165 MPa
Maximum Allowable Hydrostatic Stress, (St) = 175.7 MPa
Width of Shell Plates, (Ws) = 1.5
Density of material (ρ1) = 7850 kg / m3
SHELL COURSES
No of shell courses required to construct the require storage tank = H / Ws

= 8.5 / 1.5
= 6 Nos.
Thickness of the Courses
Thickness of 1st Course :
Thickness of the 1st course = (4.9xGxDx(Hc1-0.3)/Sd) + C
Where
Hc1 = Ht - ((n-1) x Ws)
Because it is 1st course n = 1
Therefore
Hc1 = 8.5 m
Thickness of the 1st course according to Maximum Allowable working stress = 4.44 mm
Thickness of the 1st course = (4.9xGxDx(Hc1-0.3)/St) + C

Where
Hc1 = Ht - ((n-1) x Ws)
Because it is 1st course n = 1
Therefore
Hc1 = 8.5 m
Thickness of the 1st course according to Maximum Hydrostatic stress = 3.87 mm
Thickness of 2nd Course :
Thickness of the 2nd course = (4.9xGxDx(Hc1-0.3)/Sd) + C

Where
Hc2 = Ht - ((n-1) x Ws)
Because it is 2nd course n = 2
Therefore
Hc2 = 7m
Thickness of the 2nd course according to Maximum Allowable working stress = 3.99 mm
Thickness of the 2nd course according to Maximum Hydrostatic stress = 3.53 mm
Thickness of 3rd Course :
Thickness of the 3rd course = (4.9xGxDx(Hc1-0.3)/Sd) + C

Where
Hc3 = Ht - ((n-1) x Ws)
Because it is 3rd course n = 3
Therefore
Hc3 = 5.5 m
Thickness of the 3rd course according to Maximum Allowable working stress = 3.33 mm
Thickness of the 3rd course according to Maximum Hydrostatic stress = 3.18 mm
Thickness of 4th Course :
Thickness of the 4th course = (4.9xGxDx(Hc1-0.3)/Sd) + C

Where
Hc4 = Ht - ((n-1) x Ws)
Because it is 4th course n = 4
Therefore
Hc4 = 4m
Thickness of the 4th course according to Maximum Allowable working stress = 3.1 mm
Thickness of the 4th course according to Maximum Hydrostatic stress = 2.84 mm

Where
Hc5 = Ht - ((n-1) x Ws)
Therefore
Hc5 = 2.25 m

Where
Hc6 = Ht - ((n-1) x Ws)
Therefore
Hc6 = 1m
As per Cl.3.6.1.1, of API 650, Refer page 3-6:

For < 15m nominal tank diameter, nominal plate thickness is 8 mm. The thickness of all
the shell courses are less than 5mm, So we can take the shell thickness as
Thickness of the shell of the storage tank = 8 mm
THICKNESS OF BOTTOM PLATE

As per Clause No.5.5.3,Table 5-1, Page 5-10 of API 650, 2007; Bottom plate thickness
required is 6mm exclusive of Corrosion Allowance. Hence Thickness of bottom plate
provided is 8 mm.
THICKNESS OF ROOF PLATE

As per Clause No. 5.10.2.2, Page 5-60 of API 650, 2007; Roof plate shall have a
minimum nominal thickness of 4 mm, Also Corrosion Allowance (2mm) shall be added
for the plates of supported roofs, Hence the thickness of roof plate provided is 6 m.
By the above calculations we came to known that the

No of Shell courses required = 6
Thickness of shell courses = 8 mm
Thickness of Bottom plate = 8 mm
Thickness of Roof plate = 6 mm
DESIGN OF RAFTER
Design of Rafter for roof with slope 1:16.
Slant length of the roof (l) = [ DO2 + (DO /16)2] 1/2
DO = outer radius with insulation of tank
= [5.0082 + 0.3132] ½ = = 5.02 m
Thickness of the roof plate (t ) = 6mm

Weight of the roof (w) = Volume x Density
= [(3.14 / 4) x (2 x l)2 x t] x 7850
= 3728 kg
Roof Area of Tank, (Ar) = Π x (D/2) x l = 78.7 m2
Dead Weight of the roof per area(Wd) = w / Ar

= 3728 / 78.7
= 47.31 Kg /m2
Live load on the roof (Assumed)(Wl) = 150 Kg / m2
As per Cl. 5.10.4.4, Rafters shall be spaced so that, in the outer ring, their centers shall
not be more than 0.6Π m i.e 1.884 m, apart measured along the circumference of the
tank.
No. of rafters required = (3.14 x D) / 2

= 17
We should always take even number rafters. So the No. of rafters(n) = 18 Nos
Max. Distance between two adjacent Rafter, (Xmax) = (3.14*D*100)/18

= 174.5 cm
Min. Distance between two adjacent Rafter, (XMIN) = (3.14*d) / 18

Where d = dia of the crown plate = 63
= 11cm
Length of the rafter (Lr) = (Slant length of the roof) – (dia of crown)
= 5.008 - 0.63
= 437 cm
Average width of Roof Area supported by individual Rafter, b = (Xmax + Xmin)/2

= (174.5 + 11) / 2
= 92.75 cm
Dead weight on each rafter(Wd) = (Wd / 104) x b
= 47.31 x 92.75
= 0.43 Kg / cm
Live weight on each rafter(Wl) = (Wl / 104) x b
= (150 / 104) x 92.75
= 1.39 Kg / cm
Total weight on each rafter (Wr) = (Wd) + (Wl)

= 0.43 +1.39
= 1.82 Kg / cm
Loading on Rafter member is considered as Simply Supported beam with uniform

loading,
Therefore
Max. Bending Moment, (Mmax) = (Wr x Lr2)/8

= (1.82 x 190969) / 8
= 43445.45 Kg-cm
Section Modulus (Z) = Mmax / Sd

= 43445.45 / 1682.54
= 25.82 cm3
So ISMC 150 member is Considered as a member for the above Rafter.

Deflection Checking for Rafter
Uniform load on Rafter, Wr = 1.82 Kg / cm

Maximum length of Rafter, L = 437 cm
Moment of Inertia for Rafter i.e. ISMC 150, I = 779.4 cm4
Youngs Modulus of Elasticity, E = 200000 MPa
= 2039432 Kg/cm2
Max. Vertical Deflection for Rafter, δ = (5 x WrL4)/(384E x I)

= (5 x 1.82 x 4374) / (384 x
2039432 x 779)
= 0.54 cm
Limiting Vertical Deflection for Rafter, δl = L/325

= 437 / 325
= 1.34 cm
Max. Deflection is under permissible limit, Hence member considered for Rafter i.e.
ISMC 150 is Safe Under loading and deflection.
DESIGN OF CENTER COLUMN
Considering Center Column configuration as a composite section of ISMC of ISMC 250

&200
Slenderness Ratio is the ration of Length of the Column to the least radius of gyration.
When Slenderness ratio is Less then the column strength is high and if the Slederness
ratio is high then the column strength is less.
As per above configuration least radius of gyration, Rm = 10.26 cm
Length of Centre Column considered, Lcc = 1232.81 cm
Induced Slenderness Ratio, λ = Lcc/Rm
= 1232.81 / 10.26
= 120.16
Induced Slenderness ratio is less than Max. Permissible, Hence satisfactory
Allowable Stress in compression, σac = 652.62 Kg / cm2

Induced Compressive stress, σic = Total compressive load(Wc)/Cross Sectional
Area of centre column(Ac)
So we have to find Total compressive load and Cross sectional Area of center
column(Ac)
Total load of each Rafter = (Length of rafter x Weight on rafter) / 2

= ( 437 x 1.82 ) / 2
= 398 Kg
Total Number of Rafter = 18 No.s
Total Compressive Load, Wc = (Total load of each Rafter x Total

Number of Rafter)
= ( 398 x 18 )
= 7164 Kg
Cross sectional area of Center column = 50.51 cm2 ( According to Stand
Induced Compressive stress, σic = Total compressive load(Wc)/Cross
Sectional Area of centre column(Ac)
= ( 7164 / 50.51)
= 142 Kg / cm2
Since σic < σac, Centre column Provided is a composite section of ISMC 200 & ISMC
250 is Satisfactory.
TRANSFER SKID :
PIPE AND PUMP

Length of the pipe = 12 m
TRANSFER SKID :
Pipe Design:
All the piping used in the fuel oil handling system is made of material SA 106 Grade B.
The required data to design the pipe is :
Required Discharge (Q) = 0.0002 m3 / sec
Q = AxV
A = Q/V
= 0.0002 / 0.9
= 0.0002
d = [(0.0002 x 4) / 3.12] 1/2
= 0.016 m
Inner diameter of the pipe = 0.016m

Length of the pipe = According to the plot plan.
PIPE THICKNESS
We have calculate the pipe thickness according to the internal

pressure of the steam which flow under the pipe.
T = ( P x D) / [2((S x E) + (P x Y))] + CA
Where
Pressure (P) = 3.5 Kg / cm2
Diameter(D) = 1.6 cm
Allowable Stress (S) = 1680 Kg / cm2
Joint efficiency = 0.7
Wall thickness factor (y) = 0.04
T = ( P x D) / [2((S x E) + (P x Y))] + CA
= (3.5 x 1.6) / [ 2((1680 x 0.7) + (3.5 x 0.04))] + CA
= 0.022 cm
Thickness of the Pipe is equal to 0.00022m

FILTER CALCULATIONS
The volume of the basket = 10 x diameter of the pipe (As

per
Customer)
= 10 x 0.016
= 0.16 m
The filtration Capacity is 500 microns

1 micron = 10-6 m
500 micron = 500 x 10-6
= 0.0005 m
= 0.5 mm
PUMP SELECTION :
Usually, Gear pumps are used for pumping fuel oil in most of the fuel oil
handling systems since they require lesser maintenance than other type of pumps and also
they are used for medium pressures and discharges.
P = Q x [(NPSH) + (DH)] / (270 x η)
P = power of pump in (HP)

Q = discharge of pump in (m3/sec)
NPSH = Net Positive Suction Head (m)
DH = Discharge Head (m)
η = efficiency of pump=0.5
Net Positive Suction Head :
The head of the fuel at the suction valve of the pump is known as the Net
Positive Suction Head.
NPSH = (Atm. head) - (Friction head + Vapour head)
Required Input data :

Atm. Head = 10.3 mwc
Now we have to find the Friction head loss by using the “DARCESE FORMULA”
H = (4fLV2) / (2gd)
Where,
= [(length of the suction pipe)
According to Standards of Pipe Fittings :

Tee (Le/D=45)
Gate Valve (Le/D=7.65)
Globe Valve (Le/D=270)
Ball Valve (Le/D=2.25)
Plug valve (Le/D=7.65)
Non return Valve (Le/D=90)
Overall length (L) = 2m

Reynolds number = VD / Design viscosity

= (0.9 x 0.016) / (180 x 10 -6 )
= 80

H = (4fLV2) / (2gd)
= 4.12 m

= (10.3 ) - (4.12 + 0.2 )
= 5.97 mwc
DELIVERY HEAD = (FRICTION HEAD LOSS)
For Friction Head Loss
H = (4fLV2) / (2gd)
Where,
d = dia. of pipe in m
= 0.015m
= [(length of the delivery pipe)
Overall length (L) = 12 m

Reynolds number = VD / kinematic viscosity
= (1.5 x 0.016) / (180 x 10 -6 )
= 133

H = (4fLV2) / (2gd)
= 55m
DELIVERY HEAD = (FRICTION HEAD LOSS)
= 55 m
P = Q x [(NPSH) + (DH)] / (270 x η)
= 1 x [5.9 + 55] / (270 x 0.5)
= 0.5 H.P
We require 0.5 Horse Power motor to pump the oil from the Storage tank to the Boiler
furnance.
TOTAL STEAM REQUIREMENT
THE HEAT LOAD TAKEN BY THE OIL IN THE SUPPLIER TANK (Q1)
The heat load taken by the oil (Q1) = [m Cp(T2 - T1)] / Ht
Assume Capacity of tanker as 12m3

= 12 x 980
= 11760kg
Q1 = [m Cp(T2 - T1)] / Ht
= [ 11760 x 0.44 x (55 – 12)] / (72)
= 3090 Kcal / hr.
Heat load taken by the material of the tank = m Cp (T1 – T2) / Ht

= 12 x 7850
= 94200 kg
Q2 = [m Cp(T2 - T1)] / Ht
= [ 94200 x 0.52 x (55 – 12)] / (72)
= 29254 Kcal / hr.
Heat loss from the tank Q3 = U x (T2 – T1) x A

= 72 x (55 – 12) x 6
= 18576kcal / hr.
Steam Requirement for Supplier tank(s1) = (Q1 + Q2 + Q3) x 1.1 / Latent heat
= ( 3090 + 29254 + 18576) x 1.1 /
512.89
= 109 Kg / hr
Steam Requirement for Storage tank(s2) = (Q1 + Q2 + Q3 + Q4 + Q5 +
Q6 + Q7+ Q8) x 1.1 / Latent heat
= (2076816 + 9710) / 512
= 4075 Kg / hr.
Heat loss through the pipe Q4 = (T2 – T1) / [(d1 / 2k) x (ln(d2 / d1))
+ (d1 / fd2)]
= (55 -12) / [ (0.061 / 2 x 0.044) x (ln
0.1 / 0.061)) + (0.061 / 17.46 x 0.1 )
= 113 Kcal / hr. m2
Surface area (A) = 3.14 x 0.1 x 134
= 42.076 m2
Rate of heat loss through the pipe(Q4) = Q4 x A
= 113 x 42.07
= 4754 Kcal / hr.
Steam requirement for pipe (s3) = 4754 / 512
= 9.28 Kg / hr.
TOTAL STEAM REQUIREMENT = s1 +s2 + s3 + s4

= 109 + 4075 + 9.28
= 4193 kg / hr

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INTRODUCTION

Some commonly used fuel oils are

Properties of Fuel Oil:

Uses of Fuel Oil:

A schematic diagram of a general fuel oil handling system is as shown in the

Fig.1 Fuel Oil Handling System

Components of Fuel Oil Handling System:

The main components of a fuel oil handling system as illustrated in

1. Centrifugal Pump: For high discharge and high pressure heads.

Gear pump design for hydraulic

• Meters: Different types of measuring instruments such as a thermometer, pressure

Fig.2 Duplex Filter

Fig.3 Front View of a Skid

Fig.4 Rear View of a Skid

1. Horizontal Storage Tank

Fig.8 Outflow Heaters

Fig.9 Outflow heater

Fuel Oil Out

Fig.10 In-line Heater

Fig.11 Day Tank

Other Equipment Used:

• 3 way ball valve

c. Total steam requirement :

 Steam requirement for across the Fuel Handling System to raise

Design of the above mentioned components are calculated by using the

I. PIPE AND PUMP

II. STORAGE TANK

Operating Pressure = 4.5 ata

IV. PIPE AND PUMP

Required Discharge (Q) = 0.002 m3 / sec

Inner diameter of the pipe = 0.061m

We have calculate the pipe thickness according to the internal

Thickness of the Pipe is equal to 0.00029m

The volume of the basket = 10 x diameter of the pipe (As

P = Q x [(NPSH) + (DH)] / (270 x η)

P = power of pump in (HP)

Net Positive Suction Head :

NPSH = (Atm. head + Suction head) - (Friction head + Vapour head)

Required Input data :

According to Standards of Pipe Fittings :

45º Elbow (Le/D=15.75)

Friction Coefficient (f) = 16 / Re (When Re <= 2100, if Re > 2100 we have

Friction Coefficient (f) = 16 / Re = 16 / 305 = 0.05

By substituting the values of Overall length and Friction Coefficient in the

NPSH = (Atm. head + Suction head) - (Friction head + Vapour head)

DELIVERY HEAD = (STATIC HEAD LOSS) + (FRICTION HEAD LOSS)

Level of Pump discharge w.r.t 0.0m = 0.6 m

For Friction Head Loss

Overall length (L) = 40 + (2 x 0.83) + (0.092)

Friction Coefficient (f) = 16 / Re (When Re <= 2100, if Re > 2100 we have

By substituting the values of Overall length and Friction Coefficient in the

DELIVERY HEAD = (STATIC HEAD LOSS) + (FRICTION HEAD LOSS)

P = Q x [(NPSH) + (DH)] / (270 x η)

To design the Floor Coil Heater we have to calculate

 The heat load taken by the oil for initial heating

Mass(m) = Volume x density

THE HEAT LOSS THROUGH SHELL, ROOF AND BOTTOM PLATES

HEAT LOSS THROUGH SHELL OF THE TANK :

Film Coefficient (f ) = (f) convection + (f) radiation

(f) convection = 1.957x(T3-T1)^0.25 x (2.857xV+1)^0.5

HEAT LOSS THROUGH ROOF PLATE :

Surface area (A) = (3.14 / 4) x d2

Heat loss through Bottom plate(Q4) = KA (Tavg – T1)

Max. Distance between two adjacent Rafter, (Xmax) = (3.14D100)/18