DESIGN IV MACHINERY SYSTEM

DEPARTMENT OF MARINE ENGINEERING

Fuel Oil System

Doc. No. 06 - 42 20 DN002-FO

Prepared by Approved by
Rev. Date Remark A.A.B. Dinariyana Dwi P, S.T.,MES.,
Sean Chen Gyarino
Ph.D.
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I. INTRODUCTION
The fuel oil system for a diesel engine must typically capable of handling blended
and other heavy fuel oil as well as distillate fuels. Fuel oil system, have 2 type
system, first is transfers system and second is service system. The fuel oil
transfers system provides the following functions:
1. The transfer of fuel oil from any tank used for storage to any other tank.
2.The transfer of oil from the fuel oil storage tanks to the settling tanks through
each settling tank fill line with automatic shutdown of the transfer pump upon
reaching the settling tank high-level alarm.

II. OBJECTIVES
The object of fuel oil system is:
a) Calculate Tank of the Fuel Oil System
b) Calculate Heater of the Fuel Oil System
c) Calculate Pump of the Fuel Oil System

III. REFERENCES
a) Class NK Part D Chapter 13 Section 13
b) Wartsila 26 Project Guide
c) SOLAS Chapter II-2 Part C Regulation 10

IV. LIST OF ABBREVIATIONS

vs : Velocity of fluid (m/s)
d : Inside diameter (mm)
t : time (s)
3
Q : Capacity m /hr
Rn : Reynold number
n : viscocity
hs : head static (m)
hp : head pressure (m)
hv : head velocity (m)
hf : head friction (m)
hl : head losses (m)
H : head total (m)
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V. SYSTEM DESCRIPTION
The fuel oil system for a diesel engine must typically capable of handling blended
and other heavy fuel oil as well as distillate fuels. Fuel oil system, have 2 type
system, first is transfers system and second is service system. The fuel oil
transfers system provides the following functions:
1) The transfer of fuel oil from any tank used for storage to any other tank.
2) The transfer of oil from the fuel oil storage tanks to the settling tanks through
each settling tank fill line with automatic shutdown of the transfer pump upon
reaching the settling tank high-level alarm.
MDO are loaded through deck fill connections that have sample connection
provided to permit the fuel to sampled as it is taken aboard. MDO is stored in the
fuel-oil storage tank. MDO is transferred from storage tank to either of the
separator using MDO transfer pump (DP5) (settling is not required) and then
directly into day tank via fuel oil transfer pump,which are equipped with a suction
strainer. the sfrom day tank, MDO pumped through MDO Preheater DH1 using
feed pump (DP1) directly into the engine injector.

The day tank should be provides two day tanks for MDO, each with a capacity
sufficient for at least 8 hours operation at maximum fuel consumption. The day
tank must be designed so that accumulation of sludge near the suction pipe is
prevented and the bottom of the tank should be sloped to ensure efficient
draining. MDO day tanks work in 1 atm pressure.

It is recommended that the viscosity is kept below 11 cSt in the day tanks.Then,
the heater will rise the temp to approx 50 degree in engine inlet. And pressure at
feed pump is 5 bar. The remaining fuel thet not burn in combustion chamber will
out from engine to intermediate tank, which the temp and pressure will be reduce
and circulate back to preheater.
Fuel Oil System Component :
1) Transfer pump
Function : Tranfer pump are used to move the fuel oil from storage tank
to settling Tank or to service tank for MDO.
2) Non Return valve, straight, screw down
Function : valves are used at high pressure and direction of flow in one
direction. In Fuel oil system, this valve is used on the outlet side of the
pump.
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3) Gate Valve
Function : valve is used to open and close or stop the fluid flow in the
4) Pressure Indicator
Function : Pressure indicators are used to gauge fluid pressure. Pressure
indicator placed on the suction and discharge side of the pump.
5) Safety Valve
Function : Safety valve is used to resolve back pressure on the discharge
side of the pump when the pressure on the discharge side of excess.
Safety valve used on the discharge side of the pump is connected to the
suction side of the pump
6) Strainer
Function : Strainer is used to filter the fluid that will go into the pump from
dirt.
7) Bellmouthed Pipe End
Function : Bellmounted used to makes it easy to the direction of fluid flow
in the suction in tanks. Bellmounted enlarged funnel-shaped end.
8) Filling pipe
Function : Filling pipe used to filling fuel oil to storage tank.
9) Sounding pipe
Function : to know the quantity of liquid in the tank.
10) Vent pipe
Function : The way out and entry of air when the tanks filled or discharge.
11) Separator
Function : Separator used to separate the MDO from water content, by
utilizing centrifugal caused rotation from the disc separator.
12) Supply/feed pump
Function : Supply/feed pump are used to pumping the fuel oil from
service/day tank to circulating pump.
13) Circulating pump
Function : Circulating pump are used circulating the fuel oil to injection
pump and keep the pressure and capacity required main engine.
14) Flow meter
Function : Flow meter used to measure the flow of the fuel oil.
15) Viscosity meter
Function : Viscosity meter used to measure the viscosity of the fuel oil
after through the final heater.
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16) Heater
Function : heater used to heating fuel oil after through circulating pump
for maintain of requirement.
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Calculation and Specification of
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VI. DESIGN REQUIREMENTS
Key
NO Reference Parameter Design
Equipment

Two fuel oil service tank for each type of fuel used
NK 2017 Part
Storage on board that is necessary for propulsion and vital
1 D Chapter 13
tank system or equivalent arrangements are to be
sec 13.9.1.6
provided.

NK 2017 Part
Fuel oil Fuel oil filling pipes form outboard are to be used
2 D Chapter 13
filling pipes exclusively for fuel.
sec 13.9.2.1

In ships where power pumps are used for pumping

Fuel oil NK 2017 Part fuel into settling & servive tanks, at least two
3 transfer D Chapter 13 independently powered fuel oil transfer pumps are
pumps sec 13.9.3 to be provided and these pumps are to be
connected and ready for use.

In cases where heaters are provided for fuel oil

system, they are to be equipped with temperature
NK 2017 Part
Fuel Oil controllers as well as high temeperature alarm
4 D Chapter 13
Heater device or low flow alarm device, unless where the
sec 13.9.5
oils would no to be heated to a temperature thas
0
is 10 C or less below the flash point of the fuel.

The sludge tank should be located directly

beneath the separators, or as close as possible
Sludge Wartsila 26
5 below the separators, unless it is integrated in the
Tank Project Guide
separator unit. The sludge pipe must be
continuously falling.
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Calculation and Specification of
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Separators are usually supplied as pre-assembled
units designed by the separator manufacturer.
Wartsila 26 Typically separator modules are equipped with:
6 Separators
Project Guide Suction strainer (1F02), Feed pump (1P02), Pre-
heater (1E01), Sludge tank (1T05), Separator
(1S01/1S02), Sludge pump, Control cabinets
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VII. SUMMARY OF CALCULATION
1. Calculated of Fuel Oil Pipe
Nominal Diameter = 40A
Inside diameter (dm) = 41.2 mm 1.62 inch
Thickness = 3.7 mm 0.15 inch
Outside diameter = 48.6 mm 1.91 inch
Material = Carbon Steel G.
Class Pipe = Class I

2. Pump Spesification
Pump selection of Separator Feed Pump (1P02)
Manufacturer SILI PUMP Voltage = 380 V
Type YCB-1/0.6 Freq = 50 Hz
Cap. [m^3/h] 1
Power [kW] 0.75
Speed [RPM] 1400

Pump selection of Stand by Supply Pump (1P08)

Manufacturer SILI PUMP Voltage = 380 V
Type YCB-8/0,6 Freq = 50 Hz
Cap. [m^3/h] 8
Power [kW] 3
Speed [RPM] 910

3. Separator Spesification
Spesification of MDO Separator Pre-Heater (1E01):
Manufacturer ALVA LAVAL
Type HEATPAC EHS-71-03
Cap. [kW] 24

Specification of MDF Separator (1S02):

Manufacturer Alva Laval
Type MAB 206
Cap. [kW] 8
3
Capacity [m /h] 10.6
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Specification of separator unit pipe diameter

dH [mm] 18.81
Selected pipe JIS G3456
Type Carbon Steel G.
Nominal size 20A
Outside d. [mm] 27.2
Schedule 40
Thickness [mm] 2.9
Inner d. [mm] 21.4

VIII. DETAIL OF CALCULATION

See attachment of Doc.No. 06 - 42 20 DN002-FO

IX. SPESIFICATION OF EQUPMENTS

See attachment of Doc.No. 06 - 42 20 DN002-FO

X. DRAWING OF SYSTEM
See attachment of Dwg.No. 04 - 42 20 DN002-FO
 DESIGN IV MACHINERY SYSTEM
DEPARTMENT OF MARINE ENGINEERING

ATTACHMENT
Calculation and Specification of Fuel
Oil System
Attachment of Doc.No. 06 - 42 20 DN002-FO
 Doc. No. 06 - 42 20 DN002-FO
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DETAIL CALCULATION

Principle Dimension:
Lpp = 112.94 m
B = 20.3 m
H = 10.8 m
T = 8.45 m
Vs = 12 m
Cb = 0.7648
Endurance = 12 days

Engine Specification
Type = Wartsila 8L26
SLOC = 0.5 g/kWh
SFOC 100% Load = 191.5 g/kWh
BHPmcr = 2600 kW
Speed = 900 rpm
3
γ MDO = 0.9 ton/m (DMB/MDO Spesification from Wartsila 26)
Endurance = 288 hours
Operation using MDO fuel

MAIN ENGINE CALCULATION

1. Calculation of MDO Storage Tank (1T01)
The capacity of storage tank is determined by time between bunkering and the fuel
consumption. The capacity of storage tank in this ship is designed by endurance of the ship.
WMDO1 = BHPME .SFOC .Endurance . 10-6
Where: BHPME = BHP Of Main Engine (kW) (Project Guide Wartsilla 26)
SFOC = Specific Fuel Oil Consumption (Project Guide Wartsilla 26)
Endurance = 288 hours (12 Days)
c = corrections, value between 1.03 - 1.05 = 1.05
6
= P x SFOC x t x c / 10
6
= 2600 x 191.5 x 288 x 1.05 / 10
WMDO1 = 150.56 Ton
V(WMDO1) = WMDO1 / y MDO
= 150.56/0.9
3
= 167.29 m
3
= 0.581 m Consumption per hours of 288 hours
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Additional Fuel Oil Volume of 4 %, For volume expansion caused by increasing
temperature (Ship Design and Construction, PGM, 2014) :
V(WMDO1) = (1 + 0,04) x V(WMDO1)
3
= 173.99 m
3
So, divided by 2 tank with : 86.99 m
3
The tank designed on port side & starboard side = 91.45 m
3
Total Volume MDO Storage Tank for M/E = 182.9 m

Calculation of MDO needs for Auxiliary Engine:

WMDO2 = P x SFOC x t x c / 106 P = 250 kW
6
= 2 x 250 x 195.8 x 288 x 1.05 / 10 SFOC = 195.8 g/kWh
= 29.60 ton
V(WMDO2) = WMDO2 / y MDO
= 29.6 / 0.9
3
= 32.89 m
Additional Fuel Oil Volume of 4 %, For volume expansion caused by increasing
temperature (Ship Design and Construction, PGM, 2014) :
V(WMDO1) = (1 + 0,04) x V(WMDO1)
3
= 34.21 m
3
So, divided by 2 tank with : 17.11 m
3
The tank designed on port side & starboard side = 17.15 m
3
Total Volume MDO Storage Tank for Auxiliary Engine = 34.29 m

2. Separator (1S02)
From the Project Guide, formula to calculate the capacity of the separator is :
Q = P x b x 24 (Engine Product Guide Wartsila 26 page 49)
ρxt
P = Max. Continuous rating of diesel engine 2600 kW
b = SFOC + 15% safety margin 220.23 g/kWh
3
ρ = density of fuel 900 kg/m
t = daily separating usually 23 or 23,5 hour 23.5 hour

Q= 2600 x 220.2 x 24
900 x 23,5
Q= 649.7 liter/hour
3
Q= 0.65 m /h
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Separator Spesification
Brand = Alva Laval
Type = MAB 206
Max capacity = 10.6 m3/h
Power = 8 kW

3. Separator Feed Pump (1P02)

From P.G Wartsila 26 , Feed pumps should be dimensioned for the actual fuel quality and
recommended throughput of the separator. The pump should be protected by a suction
strainer (mesh size about 0.5 mm). An approved system for control of the fuel feed rate to
the separator is required.
Design Data : MDO
Design Pressure 0.5 MPa
o
Design Temperature 50 C
Viscosity fo dimensioning electric motor 100 cSt
From storage tank to service tank in = 1 hour
Pump Capacity (Q) = Same as requirement Capacity of Separator
= 0.64974 m3/h
= 0.0001805 m3/s
3
Required capacity = 0.64974 m /h
Manufacturer SILI PUMP Voltage [V] 380 V
Type YCB-1/0.6 Freq [Hz] 50
3
Cap. m /h 1 Speed [RPM] 1400
Power [kW] 0.75 Pressure [MPa] 0.6

4. Separator Unit Pipe Diameter

According to Project Guide Wartsila 26, recommended maximum velocities for
HFO(Heavy Fuel Oil) and MDF operation is :
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So:
V = 1 m/s
Q from Separator:
Q = 0.00027778 m3/s
2
A = Q/V = 0.0002778 / 1 = 0.000278 m
D = √((4 x A) / 3,14) = √( ( 4 x 0.00028) / 3.14)
= 0.0188111 m
= 18.811088 mm
dH [mm] 18.81 Outside d. [mm] 27.2
Selected pipe JIS G3456 Schedule 40
Type Carbon Steel G. Thickness [mm] 2.9
Nominal size 20A Inner d. [mm] 21.4

5. Calculation of Separator Pre Heater Capacity (1E01)

From the Project Guide, formula to calculate the capacity of the separator is :
P = Q x ΔT (Engine Product Guide Wartsila 26 page 49)
1700
Q = Capasity of Separator Feed Pump (liter/hour)
T (Storage Tank) = 25 °C Required = 40 °C
ΔT = 15 °C Heater Spesification
P= 649.7 x 5 Manufacturer ALVA LAVAL
1700 Type HEATPAC EHS-71-03
= 5.733 kW Cap. [kW] 24

6. Sludge Tank (1T05)

The sludge tank should be located directly beneath the separators, or as close as
possible below the separators, unless it is integrated in the separator unit. The sludge
pipe must be continuously falling.

7. Calculation Volume of Service Tank (1T06)

According To Wartsila 26 Project Guide Page 6-13, Fuel Oil System , Two day tanks for HFO
are to be provided, each with a capacity sufficient for at least 8 hours operation at maximum
fuel consumption. A separate tank is to be provided for MDF. The capacity of the MDF tank
should ensure fuel supply for 8 hours. Settling tanks may not be used instead of day tanks.
The day tank must be designed so that accumulation of sludge near the suction pipe is
prevented and the bottom of the tank should be sloped to ensure efficient draining. The
temperature in the MDF day tank should be in the range 20...40°C. The level of the tank
must ensure a positive static pressure on the suction side of the fuel feed pumps.
(Wartsila 26 Project Guide)
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Two fuel oil service tank for each type of fuel used on board that is necessary for propulsion
and vital system or equivalent arrangements are to be provided. The capacity of each fuel
service tank required in before is to be sufficient for at least 8 hours at maximum
continuous rating of the main engine and normal operating load of the generators at sea.
NK 2017 Part D Chapter 13 sec 13.9.1
So, in this design , There are two MDO Tanks with capacity of
WMDO = BHP mcr x SFOC x Time x C
-6
where : C = 10
3
BHP = 2600 kW ρ MDO = 0.9 ton/m
SFOC = 191.5 g/kWh Capacity time taken : 8 hours
-6
WMDO = 2600 x 191.5 x 8 x 10
= 3.98 Ton
3
VMDO = WMDO / y MDO Each Tank From GA = 5.6 m
3 3
VMDO = 4.43 m Total Capacity of 2 Tanks = 11.2 m
Based on calculation on General Arrangement, the total capacity of MDO Service Tank
3
(8 hours) is 11.2 m

8. Stand-by pump MDF (1P08)

The stand-by pump is required in case of a single main engine equipped with an engine
driven pump. It is recommended to use a screw pump as stand-by pump. The pump
should be placed so that a positive static pressure of about 30 kPa is obtained on the
suction side of the pump.
Design Data:
Capacity (based on Wartsila 26 PG) = 6 x total consumption. of the connected engine
3
Capacity 3.485 m /h
Design pressure 1.6 MPa (16 bar)
Max. total pressure (safety valve) 1.0 MPa (10 bar)
Design temperature 50°C
Viscosity for dimensioning of electric motor 90 cSt
a. Pipe Selection
V = 1 m/s
Q from Project Guide:
3
Q = 0.001 m /s
2
A = Q/V = 0.0009681 / 1 = 0.000968 m
D = √((4 x A) / 3,14) = √( ( 4 x 0.00028) / 3.14)
= 0.0351183 m
= 35.118342 mm
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dH [mm] 35.12 Outside d. [mm] 48.6
Selected pipe JIS G3456 Schedule 40
Type Carbon Steel G. Thickness [mm] 3.7
Nominal size 40A Inner d. [mm] 41.2

b. Head Calculation
H : Hs + HP + HV + total Head-loss
Where :
- Head Static (Hz)
Distance from suction at MDO Storage Tank to discharge at MDO Service Tank
Hz : 2 m

- Head Pressure (Hp)

Pressure working in the suction and discharge has the different value, so :
hp = (Pdisch - Psuct) / ρg
hp = (16-7)/0.9*0.98
hp = 9.8 m

- Head Velocity (Hv)

The designed diameter of suction pipe and discharge is same, so acording to Q = VA
formula, the velocity is same at suction and discharge, because the Q is constant.
V Disc = V Suct V = 1 m/s
2 2
hv = (Vdisch - Vsuct ) / ρg
hv = 0 m

- Head Losses
1 Head loss in suction line
Re: ( D x V ) / υ
Where :
D : Inside diameter for main pipe = 35.12 mm
V : Flow Velocity = 1.00 m/s
2
u : kinematic viscocity = 0.000011 m /s at 40 Degree C
Re: ( ( 0,0902 ) x 1 ) / 0.000011 = 3192.58 If Re <2300,"laminer"
= Turbulent if Re >2300,"turbulen"
#Major loss: λ x L x v^2 / (D x 2g)
Where : λ : 0,02+0,0005/D = 0.0342
L : Length of Suction Side = 16 m
v: 1.00 m/s
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D : Pipe diameter = 35.12 mm
So, Major loss: λ x L x v^2 / (D x 2g)
Hmaj: 0,0255 x 16 x 1^2 / (0,0920 x (2x9,8)
Hmaj: 0.80 m

# Minor losses (hl)

No Types n k nxk
1 Filter or strainer 2 2.5 5
2 Elbow 90 2 0.7 1.4
3 T-join 4 1.14 4.56
4 Gate Valve 3 0.15 0.45
Total 11.41
Minor loss:(Σ n.k) x v² /2g
: 9.94 x 1² /(2x9.8)
: 0.58 m

Total Head Loss for Suction Line

: Major Head Loss + Minor Head Loss
: 1.38 m

2 Head losses in discharge line

# Major Loss
Major loss: λ x L x v^2 / (D x 2g)
Where : λ : 0,02+0,0005/D = 0.0342
L : Panjang Discharge Side = 6 m
v: 1.00 m/s
D : Pipe diameter = 35.12 mm
Major loss:
Hmaj : 0.0295x 6 x 1^2 / (0.0679 x (2x9.8))
Hmaj : 0.30 m

# Minnor losses (hl)

No Types n k nxk
1 Gate Valve 0 0.15 0
2 Elbow 90 0 0.7 0
3 T-join 1 1.14 1.14
4 SDRNV 1 1.35 1.35
Total 2.49
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Minor loss: (Σ n.k) x v² /2g
Hmin : 4.74 x 1² /(2x9.8)
Hmin : 0.13 m
Total Head Losses pada Discharge Line
: Major Head Loss + Minor Head Loss
: 0.43 m

Head total:Hs + Hp + Hv + Σ head losses (suction dan discharge)

: 7 + 0 + 0 + 13.6 + 7.07
: 13.60 m

Pump Spesification:
Manufacturer SILI PUMP Speed [RPM] 1450
Type 3GCR Pressure [MPa] 1.6
3
Cap. m /h 8.2 Power [kW] 7.5

9. Leak Fuel Tank, Clean Fuel (1T04)

Clean leak fuel is drained by gravity from the engine. The fuel should be collected in a
separate clean leak fuel tank, from where it can be pumped to the day tank and reused
without separation. The pipes from the engine to the clean leak fuel tank should be
arranged continuosly sloping. The tank and the pipes must be heated and insulated,
unless the installation is designed for operation on MDF only.
The leak fuel piping should be fully closed to prevent dirt from entering the system.
Clean C = 10.3 kg/h Clean tank fuel quantity (MDO at 100% load)
V Clean = Clean C x hours x c x 10-3/ p MDO
= 10.3 x 24 x 105% x 10-3 / p MDO
3
= 0.2884 m

10. Leak Fuel Tank, Dirty Fuel (1T07)

In normal operation no fuel should leak out from the components of the fuel system. In
connection with maintenance, or due to unforeseen leaks, fuel or water may spill in the
hot box of the engine. The spilled liquids are collected and drained by gravity from the
engine through the dirty fuel connection.
Dirty leak fuel shall be led to a sludge tank. The tank and the pipes must be heated and
insulated, unless the installation is designed for operation exclusively on MDF.
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11. MDF Cooler (1E04)
The fuel viscosity may not drop below the minimum value stated in Technical data.
When operating on MDF, the practical consequence is that the fuel oil inlet
temperature must be kept below 45°C. Very light fuel grades may require even
lower temperature.
Sustained operation on MDF usually requires a fuel oil cooler. The cooler is to be
installed in the return line after the engine(s). LT-water is normally used as cooling
medium.
If MDF viscosity in day tank drops below stated minimum viscosity limit then it is
recommended to install an MDF cooler into the engine fuel supply line in order to
have reliable viscosity control.
Design data:
Heat to be dissipated 2.5 kW/cyl
Max. pressure drop, fuel oil 80 kPa (0.8 bar)
Max. pressure drop, water 60 kPa (0.6 bar)
Margin (heat rate, fouling) min. 15%
o
Design temperature MDF Installation 50 C
Heat Transfer Load = 2,5 kW x 6
Heat Transfer Load = 15 kW
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II. Specification of Equipments.
a. Separator

b. Separator Feed Pump

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c. Separator Pre Heater

d. Stand By-Supply Pump