Bicol College of Applied Science and Technology

BICOL COLLEGE OF APPLIED SCIENCE AND TECHNOLOGY College of Engineering and Architecture City of Naga S/Y 2012-2013
(In partial fulfillment as a requirement in Power Plant Engineering)
Submitted by: ROMANO S. NUPIA BSME 5 Submitted to: Engr. EDUARDO A. CALZO PME Instructor
FEBRUARY, 2013 2nd Semester
BICOL COLLEGE OF APPLIED SCIENCE AND TECHNOLOGY College of Engineering and Architecture City of Naga
Engr. Eduardo A. Calzo PME Mechanical Engineering Department Bicol College of Applied Science and Technology
Sir: In compliance with the fulfilment of the requirements on the subject Power Plant Design, I would like to submit the design entitled Diesel Power Plant Design, in accordance with your instructions.
This includes computations and illustrations which are researched and summarized necessary to accomplish this design
I hope that this design will meet your approval.
Thank you and God bless.
Sincerely yours, NUPS
ACKNOWLEDGMENT
I have taken efforts in this design. However, it would not have been possible without the kind support and help of many individuals. I would like to extend my sincere thanks to all of them. To my major instructor, Engr. Eduardo A.Calzo, PME, for the unselfish and untiring dedication, encouragement, valuable guidance and advice throughout the period of this study. To my classmates and friends who gives their timeless effort, suggestions and comments which give me strength in doing this design. To my parents for manual support and strength, for the sacrifices and understanding, for guiding me in the right path, help and for everything. To everyone who sent comments, corrections and suggestions in my sincerest appreciations. And to God the father of all, the source of truth and wisdom from whom all good things came, effort and opportunity to learn, to love and to share.
TABLE OF CONTENTS Title Page ------------------------------------------- 1
Letter of Transmittal --------------------------------------------2 Acknowledgement Table of Contents Design Problem --------------------------------------------3 ---------------------------------------------4-5 ----------------------------------------------6
Load Survey ---------------------------------------------7-14 Summary of load Load Curve ----------------------------------------------15
----------------------------------------------16
Machine Foundation Design ------------------------------------18-23 Fuel Oil Consumption ----------------------------------------------23-24 Fuel Oil Storage Tank & Dimension ----------------------------24 Day Tank -------------------------------------------------------25-29 -------------------------------------29-40
Cooling Water System
Air Intake System&Exhaust System -----------------------------41-42 Air Starting System Lubrication System Pump Lube Oil -----------------------------------------------42-44 -----------------------------------------------44 -----------------------------------------------45-48
Proposal of Work Schedule ---------------------------------------48 Glossary ---------------------------------------------------------49
Bibliography ---------------------------------------------------------50
DESIGN PROBLEM: A Diesel Power Plant will be constructed to save the community of Barangay San Pacol, Naga City. The Power Plant will supply power to be available for 24 hours. Requirements: 1. Determine the no. of customer in the community. 2. Identify the kind and no. of residential, commercial and shops. 3. Identify the customers by zone. 4. Determine the time usage for the customer in 24 hours. 5. Determine the total requirement power in the area. 6. Draw the map of the area and indicate the customer in its zone. 7. Design the power plant including its auxiliaries. 8. Design the foundation of the engine. 9. Specify the required no. of diesel power units. 10. Provide space for future expansion. 11. Design the power house engine. 12. Prepare the work schedule of the project. Assumptions: 1. 2. 3. 4. 5. 6. Plant capacity factors 60% Fuel supply in the area good for 45 days. Electrical connection including distribution line is not in the assumptions. Professional Mechanical Engineers should be consulted. 20 x 30 tracing papers Draw the plant view, side view and perspective of the plant.
BARANGAY PACOL RESIDENCE INFORMATION PER ZONE AS OF 2010
ZONE 1 Total No. Of Households 930 Total No. Of Population 6,146 Total No. Of Out-ofSchool Total No. Of High school 718 Total No. Of Rich Level A Rich 5 Level B Average 530 Level C Poor 395 182 24 75 175 107 89 5 80 105 17 4 5 3 17 30 6 6 1 34 34 69 77 19 18 918 589 708 882 647 441 190 121 178 198 117 95 2 3 4 5 6 7
TOTAL
1,829
10,331
230
28
27
12
32
15
16
360
969
68
746
1,047
ZONE 1 - 930 HOUSEHOLDS

Appliances Air Con. Unit Coffee Maker Computer Cd Player/Dvd Player Christmas Lights Electric Fan Fluorescent 40 watt 60 watt 75 watt 100 watt Food Blender Fruit Juicer Hand Iron Hair Blow dryer Incandescent 11 watt 16 watt 20 watt 30 watt Microwave Oven Radio Range (w/ oven) Refrigerator-Freezer -16 cu ft -20 cu ft Rice Cooker Stereo Toaster TV -25" color -19" color -45" screen -13"color TV/VCR Vacuum Cleaner Water Dispenser Washing Machine TOTAL Units 183 71 270 535 435 768 589 50 38 18 100 59 535 150 2450 445 243 45 69 645 32 400 246 467 356 279 469 59 5 286 135 476 525 Wattage 1000 1200 250 85 25 170 40 60 75 100 300 100 1000 1000 11 16 20 30 1450 26 12200 380 420 320 90 900 300 160 147 45 630 100 920 Schedule of Use 9 am - 9 pm 7 am - 8 am 9 am - 12 mn 4 pm - 7 pm 7 pm - 5 am 1 pm - 9 pm 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 11 am-12 nn 11 am-12 nn 6 am - 7 am 9 am - 10 am 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 4 pm - 5 pm 6 am - 9 am 11 am-12 nn/6 pm-7 pm Daily Daily 6-7 am/11 am-12 nn/6-7 pm 6 am - 9 am 6 am - 7 am 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 7 am - 10 am Daily 9 am - 12 nn Hrs use/day 12 1 15 3 10 9 7 7 7 7 2 2 1 1 7 7 7 7 1 3 2 24 24 3 3 1 14 14 14 14 3 24 2 Total Wattage 183000 85200 67500 45475 10875 130560 23560 3000 2850 1800 30000 5900 535000 150000 26950 7120 4860 1350 100050 16770 390400 152000 103320 149440 32040 251100 140700 9440 735 12870 85050 47600 483000 3289515 kW-H 2196.00 85.20 1012.50 136.43 108.75 1175.04 164.92 21.00 19.95 12.60 60.00 11.80 535.00 150.00 188.65 49.84 34.02 9.45 100.05 50.31 780.80 3648.00 2479.68 448.32 96.12 251.10 1969.80 132.16 10.29 180.18 255.15 1142.40 966.00 18481.51


Appliances Air Con. Unit Coffee Maker Computer Cd Player/Dvd Player Christmas Lights Electric Fan Units 23 16 79 97 78 100 Wattage 1000 1200 250 85 25 170 Schedule of Use 9 am - 9 pm 7 am - 8 am 9 am - 12 mn 4 pm - 7 pm 7 pm - 5 am 1 pm - 9 pm Hrs use/day 12 1 15 3 10 9 Total Wattage 23000 19200 19750 8245 1950 17000 kW-H 276.00 19.20 296.25 24.74 19.50 153.00
Fluorescent 40 watt 60 watt 75 watt 100 watt Food Blender Fruit Juicer Hand Iron Hair Blow dryer Incandescent 11 watt 16 watt 20 watt 30 watt Microwave Oven Radio Range (w/ oven) Refrigerator-Freezer -16 cu ft -20 cu ft Rice Cooker Stereo Toaster TV -25" color -19" color -45" screen -13"color TV/VCR Vacuum Cleaner Water Dispenser Washing Machine TOTAL 19 2 0 0 7 8 99 8 267 75 8 0 2 97 0 88 0 54 47 2 16 35 5 13 1 3 89 40 60 75 100 300 100 1000 1000 11 16 20 30 1450 26 12200 380 420 320 90 900 300 160 147 45 630 100 920 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 11 am-12 nn 11 am-12 nn 6 am - 7 am 9 am - 10 am 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 4 pm - 5 pm 6 am - 9 am 11 am-12 nn/6 pm-7 pm Daily Daily 6-7 am/11 am-12 nn/6-7 pm 6 am - 9 am 6 am - 7 am 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 7 am - 10 am Daily 9 am - 12 nn 7 7 7 7 2 2 1 1 7 7 7 7 1 3 2 24 24 3 3 1 14 14 14 14 3 24 2 760 120 0 0 2100 800 99000 8000 2937 1200 160 0 2900 2522 0 33440 0 17280 4230 1800 4800 5600 735 585 630 300 81880 360924 5.32 0.84 0.00 0.00 4.20 1.60 99.00 8.00 20.56 8.40 1.12 0.00 2.90 7.57 0.00 802.56 0.00 51.84 12.69 1.80 67.20 78.40 10.29 8.19 1.89 7.20 163.76 2154.01

Appliances Air Con. Unit Coffee Maker Computer Cd Player/Dvd Player Christmas Lights Electric Fan Fluorescent 40 watt 60 watt 75 watt 100 watt Food Blender Fruit Juicer Hand Iron Hair Blow dryer Incandescent Units 35 24 74 97 64 165 135 59 3 0 15 12 148 15 Wattage 1000 1200 250 85 25 170 40 60 75 100 300 100 1000 1000 Schedule of Use 9 am - 9 pm 7 am - 8 am 9 am - 12 mn 4 pm - 7 pm 7 pm - 5 am 1 pm - 9 pm 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 11 am-12 nn 11 am-12 nn 6 am - 7 am 9 am - 10 am Hrs use/day 12 1 15 3 10 9 7 7 7 7 2 2 1 1 Total Wattage 35000 28800 18500 8245 1600 28050 5400 3540 225 0 4500 1200 148000 15000 kW-H 420.00 28.80 277.50 24.74 16.00 252.45 37.80 24.78 1.58 0.00 9.00 2.40 148.00 15.00
10
11 watt 16 watt 20 watt 30 watt Microwave Oven Radio Range (w/ oven) Refrigerator-Freezer -16 cu ft -20 cu ft Rice Cooker Stereo Toaster TV -25" color -19" color -45" screen -13"color TV/VCR Vacuum Cleaner Water Dispenser Washing Machine TOTAL
158 98 17 0 7 168 0 125 3 76 59 14 105 2 24 4 24 23 103
11 16 20 30 1450 26 12200 380 420 320 90 900 300 160 147 45 630 100 920
5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 4 pm - 5 pm 6 am - 9 am 11 am-12 nn/6 pm-7 pm Daily Daily 6-7 am/11 am-12 nn/6-7 pm 6 am - 9 am 6 am - 7 am 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 7 am - 10 am Daily 9 am - 12 nn
7 7 7 7 1 3 2 24 24 3 3 1 14 14 14 14 3 24 2
1738 1568 340 0 10150 4368 0 47500 1260 24320 5310 12600 31500 320 3528 180 15120 2300 94760 554922
12.17 10.98 2.38 0.00 10.15 13.10 0.00 1140.00 30.24 72.96 15.93 12.60 441.00 4.48 49.39 2.52 45.36 55.20 189.52 3366.02

Appliances Air Con. Unit Coffee Maker Computer Cd Player/Dvd Player Christmas Lights Electric Fan Fluorescent 40 watt 60 watt 75 watt 100 watt Food Blender Fruit Juicer Hand Iron Hair Blow dryer Incandescent 11 watt 16 watt 20 watt 30 watt Microwave Oven Radio Range (w/ oven) Refrigerator-Freezer -16 cu ft -20 cu ft Units 10 3 23 17 26 78 21 2 0 0 0 3 89 0 175 17 0 0 0 78 0 15 0 Wattage 1000 1200 250 85 25 170 40 60 75 100 300 100 1000 1000 11 16 20 30 1450 26 12200 380 420 Schedule of Use 9 am - 9 pm 7 am - 8 am 9 am - 12 mn 4 pm - 7 pm 7 pm - 5 am 1 pm - 9 pm 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 11 am-12 nn 11 am-12 nn 6 am - 7 am 9 am - 10 am 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 4 pm - 5 pm 6 am - 9 am 11 am-12 nn/6 pm-7 pm Daily Daily Hrs use/day 12 1 15 3 10 9 7 7 7 7 2 2 1 1 7 7 7 7 1 3 2 24 24 Total Wattage 10000 3600 5750 1445 650 13260 840 120 0 0 0 300 89000 0 1925 272 0 0 0 2028 0 5700 0 kW-H 120.00 3.60 86.25 4.34 6.50 119.34 5.88 0.84 0.00 0.00 0.00 0.60 89.00 0.00 13.48 1.90 0.00 0.00 0.00 6.08 0.00 136.80 0.00
11
Rice Cooker Stereo Toaster TV -25" color -19" color -45" screen -13"color TV/VCR Vacuum Cleaner Water Dispenser Washing Machine TOTAL
5 13 3 15 34 2 0 0 5 23
320 90 900 300 160 147 45 630 100 920
6-7 am/11 am-12 nn/6-7 pm 6 am - 9 am 6 am - 7 am 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 7 am - 10 am Daily 9 am - 12 nn
3 3 1 14 14 14 14 3 24 2
1600 1170 2700 4500 5440 294 0 0 500 21160 172254
4.80 3.51 2.70 63.00 76.16 4.12 0.00 0.00 12.00 42.32 803.21

Appliances Air Con. Unit Coffee Maker Computer Cd Player/Dvd Player Christmas Lights Electric Fan Fluorescent 40 watt 60 watt 75 watt 100 watt Food Blender Fruit Juicer Hand Iron Hair Blow dryer Incandescent 11 watt 16 watt 20 watt 30 watt Microwave Oven Radio Range (w/ oven) Refrigerator-Freezer -16 cu ft -20 cu ft Rice Cooker Stereo Toaster TV -25" color -19" color -45" screen -13"color TV/VCR Vacuum Cleaner Units 4 0 5 35 21 69 2 1 0 0 0 0 25 0 124 5 0 0 0 19 0 10 0 5 7 0 3 45 2 0 0 Wattage 1000 1200 250 85 25 170 40 60 75 100 300 100 1000 1000 11 16 20 30 1450 26 12200 380 420 320 90 900 300 160 147 45 630 Schedule of Use 9 am - 9 pm 7 am - 8 am 9 am - 12 mn 4 pm - 7 pm 7 pm - 5 am 1 pm - 9 pm 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 11 am-12 nn 11 am-12 nn 6 am - 7 am 9 am - 10 am 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 5 pm - 12 mn 4 pm - 5 pm 6 am - 9 am 11 am-12 nn/6 pm-7 pm Daily Daily 6-7 am/11 am-12 nn/6-7 pm 6 am - 9 am 6 am - 7 am 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 7 am - 10 am Hrs use/day 12 1 15 3 10 9 7 7 7 7 2 2 1 1 7 7 7 7 1 3 2 24 24 3 3 1 14 14 14 14 3 Total Wattage 4000 0 1250 2975 525 11730 80 60 0 0 0 0 25000 0 1364 80 0 0 0 494 0 3800 0 1600 630 0 900 7200 294 0 0 kW-H 48.00 0.00 18.75 8.93 5.25 105.57 0.56 0.42 0.00 0.00 0.00 0.00 25.00 0.00 9.55 0.56 0.00 0.00 0.00 1.48 0.00 91.20 0.00 4.80 1.89 0.00 12.60 100.80 4.12 0.00 0.00
12
Water Dispenser Washing Machine TOTAL
1 9
100 920
Daily 9 am - 12 nn
24 2
100 8280 70362
2.40 16.56 458.43
13
TOTAL LOAD SURVEY FOR ZONE 1 TO ZONE 7 - 1829 HOUSEHOLDS

14
LOAD SURVEY VALUES & LOAD GRAPH PER HOUR RATING TIME 1AM 2AM 3AM 4AM 5AM 6AM 7AM 8AM 9AM 10AM 11AM 12PM 13PM 14PM 15PM 16PM 17PM 18PM 19PM 20PM 21PM 22PM 23PM 24AM kW-Hr CONSUMPTION 10467.95 10467.95 10467.95 10467.95 10467.95 11390.71 12900.48 11908.23 21757.77 21804.61 22885 19371.59 20217.61 19943.46 17950.74 20243.29 19622.02 22131 24086.76 22446 22435 17220.99 16387.53 12963.28 LOAD GRAPH OF kW-Hr CONSUMPTION 436.1645 436.1645 436.1645 436.1645 436.1645 474.61275 537.52 496.1764167 906.5739167 908.5255833 953.536 807.14975 842.4005833 830.9776667 747.9476667 843.4705833 817.58425 922.130125 1003.615125 935.2367917 934.7911667 717.5411667 682.8137083 540.136625
15
LOAD SURVEY VALUES & LOAD GRAPH PER HOUR RATING

1200
1000
LOAD GRAPH OF kW-Hr CONSUMPTION
800
600 Series1
400
200
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
HOURS
16
SOLUTION: Based from Power Plant Engineering by Frederick T. Morse; Fig. 6-33; we are to use 3 units of F8-135-SC Diesel Engines (1 unit is continuous in operation 24 hours; another unit for 9 am up to 12 am; another unit as a reserve; all of which must be capable of continuous operation at last for a limited duration of time) as based from our load curve. DIESEL ENGINE SPECIFICATIONS: Engine Type: Engine Height: Engine Length: Engine Width: Engine Weight: Generator for kW rating at 450 RPM: Units: F8-135 SC Diesel Engine 2.604 m 5.944 m 2.299 m 23,814 kg 525 kW 3 Units (1 unit is continuous in operation 24 hours; another unit for 9 am up to 12 am; another unit as a reserve; all of which must be capable of continuous operation at last for a limited duration of time)
17
MACHINE FOUNDATION DESIGN Design Procedure for Machine Foundation Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 4: The Power Plant Building; Foundation; pages 105 to 113; & The PSME Code; we are to use the following equations to design the Diesel Engine Foundations. For the Length of the Foundation, LF: Lf = Lb + 2c Where: Lf = Length of the Machine Foundation; m or ft Lb = Length of the Bed plate (given in Machine Specs); m or ft c = Clearance; 10% of the length of the bed plate
Lf = Lb + 2c Lf = 5.944 m + 2(0.1) (5.944m) Lf = 5.944m + 1.1888m Lf = 7.1328m For the Width of the Foundation, a: a = w + 2c Where: a = Width of the Machine Foundation; m or ft w = Width of the Bed plate (given in Machine Specs); m or ft c = Clearance; 10% of the length of the bed plate a = w + 2c a = 2.299 m + 2 (0.1) (2.299m) = 2.299 m + 0.4598 m a = 2.7588 m
18
For the Weight of the Foundation: Wf = 3 to 5 times the weight of the Machine Since; Weight of the Machine, Wm = 23,814 kg Therefore; using 5 Wf= 23,814 kg x 5 Wf = 119,070 kg Base width of the Foundation, b: Using table 4.4 page 105 of P.P.E. byFrederick Morse. For Best Brick Masonry Bearing Capacity 145 - 195 Tonnes/m Sb = 195 Tonnes/m Sb = 195,000 kg/m Using the Formula:
Where: Sb = Safe Soil Bearing Capacity; tons/m2 (195 tons/m2 or 195000 kg/m2) Wm = Weight of the Machine; kg Wf = Weight of the Machine Foundation; kg b = Base Width of the Machine Foundation; m Lf = Length of the Machine Foundation; m N = Safety Factor; usually a value of 2
19
0.205 m Since; b < a, let b = a Therefore; b = 2.7588 m The Volume of the Foundation, VF: Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 4-2: Approximate Weights of Building Material; page 90; using reinforced concrete as our base material and using its approximate density we have = 2406 kg/m.
49.49 m3 The Depth of the Foundation, hf: Since the width and the lower width are equal, then we have a rectangular block as for our foundation. The width, Wf, would be equal to the width of the foundation.
Where: hf = depth of the machine foundation a = width of the machine foundation Lf = length of themachine foundation Vf = volume of the machine foundation a = 2.7588 m, since a = b
2.515 m
20
Materials for the Machine Foundation: Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 4-1: Data on Concrete Mixes to Yield 1 cu. m Concrete; page 90; using a mixture of 1:3:5 as it is often used for foundations we have the following data. Using a Mixture of 1:3:5 (1 part of cement, 3 parts of sand, and 5 parts of stone) to produced 1 cu. meter of concrete using 1:3:5 mixtures, the ff. are needed: 6.2 sacks of cement 0.52 m3 of sand 0.86 m3 of stone We are given 6.2 sacks of cement per m3& 3 units of Diesel Engines and computing for the quantity or required numbers of sacks we have. = (6.2 sacks of cement/1m3 of concrete) x 49.49 m3 of concrete = 306.838 sacks of cement per unit of Diesel Engine For 3 units; (306.838 sacks per unit) 3 units = 920.514 or 921 sacks of cement for the 3 Diesel Engine. Computing for the quantity or volume of sand for the mixture we have. = (0.52 m3 of sand / 1m3 of concrete) 49.49 m3 concrete = 25.7348 m3 of sand For 3 units; 25.7348 m3 of sand (3 units) = 77.2044 m3 or 78 m3 of sand for the 3 Diesel Engine Computing for the quantity or volume of gravel or stone for the mixture we have. = (0.86 m3 of stone/1m3 of concrete)49.49 m3 concrete = 42.5614 m3 of gravel For 3 units; 42.5614 m3 of gravel (3 units) = 127.6842 m3 or 128 m3 of gravel for the 3 Diesel Engine
21
Anchor Bolts: Based from The PSME Code of 1993, Anchor Bolts should be embedded in the concrete at least 30 times to the Bolt Diameter. Assume that the diameter of the Anchor Bolts is 25mm.Then the length of the Anchor Bolts is. LAB = 25 mm x 30 LAB = 750 mm or 0.75 m Length of Sleeves, Ls: Based from The PSME Code of 1993, Chapter 2; Commercial and Industrial Building; Article 2.4 Machinery & Equipment; Section 2.4.1.7, page 9; the length of the sleeve should be 18 times that of the bolt diameter. Therefore we have. Ls = Bolt Diameter x 18 = 25 mm x 18 Ls = 450 mm or 0.45 m Internal Diameter of Sleeves, Ds: Based from The PSME Code of 1993, Chapter 2; Commercial and Industrial Building; Article 2.4 Machinery & Equipment; Section 2.4.1.7, page 9; the internal diameter of the sleeve should be 3 times that of the bolt diameter. Therefore we have. Ds = Bolt Diameter x 3 = 25 x 3 = 75 mm or 0.075 m Number of Steel Bars, NSB: Based from Marks Standard Handbook for Mechanical Engineers; 9th Edition; Section 6: Materials of Engineering; 6.2 Iron & Steel; Weights of Square & Round Bars; page 6-46; with a 1 in (25.4 mm) round steel bar for our foundation it is given that it has 2.670 lb/in. Converting we have 3.97 kg/m as for its weight. Using the given formula we have.
Where: NSB = Number of Steel Bars WF = Weight of the Machine Foundation m% = percent multiplier; % to 1%
22
WSB = Weight of the Steel Bars; kg Computing for the required number of steel bars as obtained from the data above, we have.
Total Length of the Steel Bars, LSB: Since most of the manufactured steel bars in the market have a standard length of 6.1 m, then we simply have. LSB = NSB x 6.1 m = 300 x 6.1 m = 1830 m
FUEL CONSUMPTION
Our diesel power plant design requiresthree units of F8-135-SC with generator rating of 525 kW, one unit is operating in 24 hours, one unit for 9 am-12 am, and the other unit is for reserve.Plant capacity factor is 60%. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table A 16: Normal Efficiencies of Engine type Synchronous Generators; page 675; at a kilowatt rating of 525 kW with 450 rpm, by interpolation we have 94.3375 %. Deductions upon this efficiency are also given. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 6 3: Standard Deduction (Engine Generator Efficiency); page 185; at a generator efficiency of 94.1 % to 95 % with a full load operation we deduct 1.2 so we have a 93.1375 % Net Generator Efficiency. From the statement above we can now obtain the fuel consumption for the plant. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Figure 6 15: Range of Variable Load Performance of Diesel Plants; page 164; at 60% rated load the fuel consumption is about 0.1625 kg/Bhp-Hr. With such the maximum rate of fuel usage would be as follows.
= (1,510.67 Bhp) x (0.1625 kg/Bhp-hr) Maximum Rate of Fuel Use = 245.48 kg/hr
23
For a 24 hours operation of the 2 units, then maximum rate of fuel usage would be given as follows. Maximum Rate of Fuel Use = 245.48 /hr x 24 hr/day Maximum Rate of Fuel Use = 5,891.52 kg/day Based from Marks Standard Handbook for Mechanical Engineers, 9th Edition; Section 6: Materials of Engineering; 6.1 General Properties of Materials; Approximate Specific gravities & Densities; page 6 8; as most industrial oils have an average density of 914 kg/m3 and obtaining for its specific volume then we have 1.094 x 10-3 m3/kg then the fuel consumption in terms of volume would be. Fuel Consumption = (5,891.52kg/day) (1.094 x 10-3 m3/kg) (1 x 103 Litters/m3) = (6.445 m3/day)(1x103 Litters/m3) Fuel Consumption = 6,445.32 Litters/day Required Storage of Fuel Oil: Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Figure 6 15: Range of Variable Load Performance of Diesel Plants; page 164; at 60% plant capacity the kilowatt-hour per liter oil ranges from 2.5 liter to 3.48 liters. One (1) Diesel Genset unit will operate continuously while another for 15 hours each per day at peak loads. For fuel consumption for within a 45 day supply we have. Required Storage = 45 days x (6,445.32 Liters/day) Required Storage = 290,039.4 Liters Dimensions of the Fuel Oil Storage Tank: From Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 12 4: Dimension of the Bulk Storage Tank; page 459.From the table the largest capacity of the tank is just 109,716 litters. Since we have 290,039.4 litters we need to use 4 tanks within the 45 days. It will require 72,509.85 litters for each tank. Then we are about to use the tank that has the capacity of 73,392 litters. The dimension of the cylindrical bulk tank is given as follows. Diameter Length Plate Thickness Weight 3.05 m 10.06 m 7.94 mm 7335 kg
24
Required Storage of Day Tank: As the operation in motion, the greatest consumption of each diesel engine will occur at its full load rating. Let the day tank volume be good for a 1 day (24 hours) operation. At full load rating, maximum full load consumption would be. 245.48 kg/hrx 24 hrs = 5,891.52 kg For a 1 day operation, assume that the day tank will charge 4465.92 kg per day. Since the fuel oil is cooled during the transfer & operation we must obtain the value to compute the volume. Assuming we are using a California grade fuel oil, based from Marks Standard Handbook for Mechanical Engineers, 9th Edition, Section 7: Fuels & Furnaces; Table 7.1.9 Analyses and High Heat Values of Crude Petroleum, Typical Distillates, and Fuel Oils; page 7 13; at 60 F (15.6 C) the specific gravity of it would be 0.9554. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 5: Fuels & Combustion; Internal Combustion Engine Fuel; pages117 to 119; Using API (American Petroleum Institute) standard, assuming an oil temperature of 6 C and the equations 5 3, the API would be.
The density of oil at 15.6C (60 F) would be equal to the specific gravity at such temperature. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 5: Fuels & Combustion; Internal Combustion Engine Fuel; pages117 to 119; the volumetric coefficient of expansion of oil is 0.0007 per C. The contractions of oil at 5 C we have. Contraction from a 6 C cooling = 0.0007 x 6 = 0.0042 The density of fuel oil at 5 C would be. Density at 6 C=0.9554 / 0.9958 = 0.9981 kg/litter The volume would now be equal to. V = [5,891.52kg / 0.9981 kg/litter] (1 x 10-3 m3/1 Litters)
25
V = 5.9 m3 Assuming a 15 minute charging for the day tank, the volume flow rate would be.. Q = [5.9 m3/ 15 min] (1 x 103 Litters/m3) = 0.3933 m3/min Q = 393.3 Litters/min Dimensions of the Fuel Oil Day Tank: Given a volume of 4.47 m3 and assuming we have a cylindrical day tank, then using the following equation below we can obtain the dimension required for the day tank.
Where: V = Volume of the cylinder; m3 d = Diameter of the cylinder; m h= Height or Length of the cylinder; m Assuming we have a 2.5 m length of the day tank, deviating from the dimension and computing for the diameter we have.
Therefore, the dimension of the day tank is 1.73 m diameter by 2.5 m length cylindrical tank per Diesel Engine. Fuel Oil Transfer Pump: Based from Marks Standard Handbook for Mechanical Engineers, 9th Edition; Section 8: Machine Elements; 8.7 Pipe, Pipe Fittings and Valves; Table 8.7.3 Properties of Commercial Steel Pipes; page 8 148; assuming we are to use a nominal pipe size of 1 in outside diameter schedule 40 for the suction line pipe and a nominal pipe size of 1 in outside diameter schedule 40 for the discharge line pipe, the following data is given as follows.
26
Suction Line Pipe: Schedule 40 Outside Diameter Inside Diameter Discharge Line Pipe: Schedule 40 Outside Diameter Inside Diameter 1 in (true size of 1.660 in) 1.380 in (or 0.0351 m) 1 in (true size of 1.9 in) 1.610 in (or 0.0409 m)
Computing for the specific velocity rate at both the suction and discharge we simply use the given equation below.
Where: Q = Volume Flow Rate; m3/min V = Velocity of Fluid; m/sec d = Internal Diameter; m Computing now for the velocity at the suction we have.
Computing now for the velocity at the discharge we have.
Assuming that the pump is in the datum line, the height of delivery is 4.5 meters, the storage is placed 2.5 meters below, a friction loss of 0.75; then with the given & computing now for the discharge head.
27
Where: FL = Friction Losses for Discharge; 0.75 m ZD = Elevation from Datum to Discharge; 4.5 m VD = Velocity Head at Discharge; 6.8 m/sec
Computing now for the suction head
Where: FL = Friction Losses for Suction; -0.65 m ZS = Elevation from Datum to Suction; -2.5 m due to the location VS = Velocity Head at Suction; 5 m/sec
Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 13: The Gas Loop; 13 10 Water Pumps; pages 545 to 546; we use the equations provided to obtain the required pump. As both the suction and discharge heads are given, we can now obtain the pump operating head. With the given, the pump operating head is Pump Operating Head = Discharge Head + Suction head = 7.6 m 1.9 m Pump Operating Head = 5.7 m Assuming that the pump efficiency is 70 %, and then we have.
Where: Q = Volume Flow Rate; 393.3 Litters/min
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O = Density of oil; 914 kg/m3 (or 0.914 kg/litters) H = Pump Operating Head; 5.7 m P= Pump Efficiency; 70 %
0.65 hp or 0.75 hp Therefore, we are to use 3/4 hp oil pump for the fuel oil transfer. COOLING WATER SYSTEM Required Circulating Cooling Water: Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Cooling System; pages 177 to 178; we are to use a cooling (preferably a forced draft cooling tower) as it is minimal upon consideration cost, bulk, and auxiliary power. This would provide an immediate cooling for the Diesel Engines frame jackets in the heated parts. To obtain the circulating cooling water requirements, we are to use the equation provided by several references. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Cooling System; page 178; using the equation below we are to use the given equation to obtain the required circulating cooling water.
Where: W = circulating cooling water; Litter/hour
Rated bhp = rated brake horsepower t1 t2 = inlet water temperature; C = outlet water temperature; C
Accordingly, we must first obtain the rated brake horsepower as readily provided in the Diesel Engine type F8-135-SC Specification. Deviating from the law of conservation of energy (simply stated as Energy In = Energy Out) then the rated horsepower of the engine would be equal to the generator output. Losses would be present so the net efficiency would be used to offset the generator output. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table A 16: Normal Efficiencies of Engine type Synchronous Generators;
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page 675; at a kilowatt rating of 525 kW with 450 rpm, by interpolation we have 94.3375 %. Deductions upon this efficiency are also given. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 6 3: Standard Deduction (Engine Generator Efficiency); page 185; at a generator efficiency of 94.1 % to 95 % with a full load operation we deduct 1.2 so we have a 93.1375 % Net Generator Efficiency.Therefore the rated break horsepower is equal to the equation below.
Assuming that the temperature range would be 10 C, as most of the cooling tower range applied in the industry from the manufacturer ranges from 5.6 C to 16.7 C, then we use an assumed values of 75 C & 65 C for the inlet water temperature and outlet water temperature respectively, we can now obtain the required circulating cooling water for the cooling tower. With the 2 units we have 1,510.66 hp. So the required circulating cooling water is.
Based from Marks Standard Handbook for Mechanical Engineers, 9th Edition; Section 6: Materials of Engineering; 6.1 General Properties of Materials; Specific Gravity and Density of Water at Atmospheric Pressure; page 6 10; at 75 C the density of water is 974.86 kg/m3. WC= (101,906.1 Litters/hr)(1hr/60 min)(1m3/1000 Litters) x (974.86 kg/m3) WC = 1,655.74 kg/min Therefore, we need 101,906.1 Litters/hour or 1,655.74kg/min for the circulating cooling water for the 2 Diesel Engine Genset units.
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Water Jacket Circulating Pump: Based from Marks Standard Handbook for Mechanical Engineers, 9th Edition; Section 8: Machine Elements; 8.7 Pipe, Pipe Fittings and Valves; Table 8.7.3 Properties of Commercial Steel Pipes; page 8 149; assuming we are to use a nominal pipe size of 3 in outside diameter schedule 40 for the suction line pipe and a nominal pipe size of 2 in outside diameter schedule 40 for the discharge line pipe, the following data is given as follows. Suction Line Pipe: Schedule 40 Outside Diameter Inside Diameter Discharge Line Pipe: Schedule 40 Outside Diameter Inside Diameter 2 in (2.875 in) 2.469 in (or 0.0627 m) 3 in (3.5 in) 3.068 in (or 0.0779 m)
Where: Q = Volume Flow Rate; m3/min (101,906.1 Litters/hr)(1hr/60 min)(1m3/1000 Litters) Q = 1.7m3/min V = Velocity of Fluid; m/sec d = Internal Diameter; m
Computing now for the velocity at the suction we have.
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Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 13: The Gas Loop; 13 10 Water Pumps; pages 545 to 546; we use the equations provided to obtain the required pump. As both the suction and discharge heads are given, we can now obtain the pump operating head. With the given, the pump operating head is Pump Operating Head = Discharge Head + Suction head = 9.6 m 1.4 m
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Pump Operating Head = 8.2 m Assuming that the pump efficiency is 70 %, and then we have.
Where: Q = Volume Flow Rate; (101,906.1 Litters/hr)(1hr/60 min) Q =1,698.4Litters/min w = Density of water; 1000 kg/m3 (1 kg/litters) H = Pump Operating Head; 8.2 m P= Pump Efficiency; 70 %
4.42 hp or 4.5 hp Therefore, we are to use 4 1/2 hp water pump for the water jacket transfer for each Diesel Genset unit. Required Raw Water for the Cooling Tower: Since most heat exchangers experience a steady state equation and deviating from the energy balance equation [mC (hC1 hC2) = mR (hR1 hR2)] assuming that the continuous flow would nullify the offsetting effects of density and enthalpy, and assuming that temperature difference with 6 C of 34 C @ inlet and 28 C @ outlet, then we can use the equation below for simplicity.. QC (tC1 tC2) = QR (tR1 tR2) Where: QR = Quantity of Raw Water circulating the cooling tower, Litter/min QC = Quantity of Circulating Cooling Water; 1,698.4 Litters/min tR1 = temperature of raw water at outlet; 34 C
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tR2 = temperature of raw water at inlet; 28 C tC1 = temperature of jacket cooling water at inlet; 75 C tC2 = temperature of jacket cooling water at outlet; 65 C Using the equation, the quantity of raw water is.
Based from Marks Standard Handbook for Mechanical Engineers, 9th Edition; Section 6: Materials of Engineering; 6.1 General Properties of Materials; Specific Gravity and Density of Water at Atmospheric Pressure; page 6 10; at 28 C the density of water is 996.242 kg/m3. WR= 2,830.67 Litters/min x (1 m3/1000 Litters) x (996.242 kg/m3) WR= 2,820 kg/min Raw Water Pump: Assuming that the parameters for the circulating water jacket pumps are the same with the raw water pump, together with the assumptions, and then the requirements would be close and be useful for the raw water pump computation. Computing now for the velocity at the suction we have.
Where: Q = Volume Flow Rate; m3/min (2,830.67 Litters/min)(1m3/1000 Litters) Q = 2.83m3/min V = Velocity of Fluid; m/sec d = Internal Diameter; m
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Computing now for the velocity at the suction we have.
Where: FL = Friction Losses for Suction; -0.65 m ZS = Elevation from Datum to Suction; -2.5 m due to the location VS = Velocity Head at Suction; 9.9 m/sec
Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 13: The Gas Loop; 13 10 Water Pumps; pages 545 to 546; we use the equations
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provided to obtain the required pump. As both the suction and discharge heads are given, we can now obtain the pump operating head. With the given, the pump operating head is Pump Operating Head = Discharge Head + Suction head = 17.2 m 1.8 m Pump Operating Head = 15.4 m Assuming that the pump efficiency is 70 %, and then we have.
Where: Q = Volume Flow Rate; (2,830.67 Litters/min) w = Density of water; 1000 kg/m3 (1 kg/litters) H = Pump Operating Head; 15.4 m P= Pump Efficiency; 70 %
13.8 hp or 14 hp Therefore, we are to use 14 hp water pump for the raw water transfer for each Diesel Genset unit. Required Quantity of Make-up Water: Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 6: Internal Combustion Engine Power Plant; 6-7 Evaporative Cooling; page 181; using the given mass balance and heat balance equations we can obtain the required make up water for the cooling tower. For mass balance we use. 1 kg air + SH1 + WW + W = 1 kg air + SH2 + WW Deviating for simplicity we have.
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W = SH2 SH1 For heat balance we use. h1 + WWhfa+ Whf= h2 + WWhfb Deviating for simplicity we have.
Where: SH1 = Humidity Ratio of Entering Air; kg moisture/kg dry air SH2 = Humidity Ratio of Leaving Air; kg moisture/kg dry air Ww = Water Circulating per kg of dry air; kg W = Make-up Water per kg of dry air; kg h1 = Enthalpy of Moist Air Leaving; kJ/kg of dry air h2 = Enthalpy of Moist Air Entering; kJ/kg of dry air hfa = Enthalpy of Water in the Spraying Nozzles; kJ/kg hfb = Enthalpy of Water in the Basin; kJ/kg hf = Enthalpy of Make-up Water; kJ/kg Assuming we are given the following relative humidity and temperatures. Relative Humidity: Entering Air = 60% Leaving Air Temperature: Entering = 28 C DB Leaving = 34 C DB WBT = 21 C = 90%
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Based from Marks Standard Handbook for Mechanical Engineers; 9th Edition; Figure 12.4.13: Psychometric Chart in SI Units; page 12 97; the following are given and obtained so we have. At R.H. 60% and dry bulb temperature of 28 C @ entering point. SH1 = 0.01425 kg moisture/kg dry air
At R.H. 90% and dry bulb temperature of 34 C@ leaving point. SH2 = 0.031 kg moisture/kg dry air
Based from Refrigeration & Air Conditioning by W. F. Stoecker& J. W. Jones; Table A-2: Moist Air; pages 418 to 419, with the assumed temperatures the enthalpy are as follows. At 28 C, h1 At 34 C, h2 = 89.952 kJ/kg = 122.968 kJ/Kg
Using the equation of mass balance we use. W = SH2 SH1 = (0.031 0.01425) kg moisture/kg dry air W = 0.01675 kg moisture/kg dry air Based from Refrigeration & Air Conditioning by W. F. Stoecker& J. W. Jones; Table A1: Water: Properties of Liquid and Saturated Vapor; pages 416 to 417, with the assumed temperatures the enthalpy are as follows. At 34 C, hfa = 142.38 kJ/kg At 28 C, hfb = 117.31 kJ/kg Assuming we have a make-up water temperature of 18 C; based from Refrigeration & Air Conditioning by W. F. Stoecker& J. W. Jones; Table A-1: Water : Properties of Liquid and Saturated Vapor; pages 416 to 417; with the assumed temperature the enthalpy and pressure is.. hf= 75.50 kJ/kg P = 2.062 kPa Using the equation of energy balance we have.
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Since 2,830.67 kg/min of raw water is given, the air flow is.
Based from Marks Standard Handbook for Mechanical Engineers; 9th Edition; Figure 12.4.13: Psychometric Chart in SI Units; page 12 97; the following are given and obtained so we have. DB temperature = 28 C WB temperature = 21 C The specific volume, v, is 0.87 m3/kg dry air. Then the air flow would be. Air Flow = 2,228.87 kg/min (0.87 m3/kg) Air Flow = 1,939.12 m3/min The required make-up water then is. Make-up Water = Air Flow x W Make-up Water = 1,939.12 kg/min x 0.01675
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Forced Draft Fan: Based from Kents Mechanical Engineers Handbook: Volume II: Power Volume, 12th Edition, by J. Kenneth Salisbury; Table 13: Skeleton Capacity, Table for Tube Axial Fans; page 1 89, we are to choose a fan that would provide a capacity of air flow of 809.54 m 3/min or 28588.64 ft3/min. We select a fan with the following size. Fan Size: 60-3 Motor hp: Rpm: Capacity: Static Pressure Size of Cooling Tower: For the total cooling requirements we must first obtain the total cooling water requirements. Water Requirements = Circulating Jacket Water + Raw Water Water Requirements = (101,906.1 Litters/hr)(1hr/60 min)+ 2,830.67 Litters/min Water Requirements = 4,529.105 Litters/min x (1 gallon/3.7854 Litters) Water Requirements = 1,196.5gpm Assuming we have water concentration of 3.0 gpm per ft2, then the area of the cooling tower is. Area of Cooling Tower = 1,196.5gpm / (3.0 gpm/ft3) = 398.8 ft2 Assuming we have a square sized cooling tower, then the size of the cooling tower would be. Side of Cooling Tower = = 20ft 5.5 hp 570 36,300 ft3/min in SP
So the dimensions of the cooling tower that would service the diesel engines is 20 ft x 20 ft or 6.1 m x 6.1 m.
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AIR SYSTEM The purpose of the air system in the power plant is very important, as the prime mover itself is dependent upon combustion. The functions of the intake and exhaust systems are to deliver clean combustion air to the engine and dispose of the exhaust quietly with the minimum loss of performance. Air Intake System: The air intake system usually consists of air intake duct or pipe appropriately supported, a silencer, an air cleaner, and flexible connections as required. This arrangement permits location of area of air intake beyond the immediate vicinity of the engine, provides for the reduction of noise from intake air flow, and protects vital engine parts against airborne impurities. The air intake will be designed to be short and direct and economically sized for minimum friction loss. The air filter will be designed for the expected dust loading, simple maintenance, and low pressure drop. Oil bath or dry filter element air cleaners will be provided. The air filter and silencer may be combined. Based from Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 6: Internal Combustion Engine Power Plant; 6 6: Auxiliary Systems; Intake & Exhaust Passages; pages 174; an engine needs from 0.056 to 0.084 m3 of air per min per hp developed. Assuming we have maximum intake of 0.084 m3/min of air per hp developed during operation, with 563.68 kW (or 755.33hp) then the flow rate of the intake would be.
Assuming we have a flow velocity of 800 m/min, then the dimensions of the intake pipe would be.
The diameter of the intake pipe would be 0.32 meter or 320 mm. Therefore, we are to use a pipe with such diameter.
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Exhaust System: The exhaust system consists of a muffler and connecting piping to the atmosphere with suitable expansion joints, insulation, and supports. In cogeneration plants, it also provides for utilization of exhaust heat energy by incorporating a waste heat boiler which can be used for space heating, absorption refrigeration, or other useful purpose. This boiler produces steam in parallel with the vapor phase cooling system. The exhaust silencer attenuates exhaust gas pulsations (noise), arrests sparks, and in some cases recovers waste heat. The muffler design will provide the required sound attenuation with minimum pressure loss. Based from Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 6: Internal Combustion Engine Power Plant; 6 6: Auxiliary Systems; Intake & Exhaust Passages; pages 175 to 176; the exhaust system must carry approximately 0.168 0.224 m3/min of gases per hp developed. Assuming we have a maximum discharge of 0.224 m3/min of gases per hp developed on an average exhaust temperature, with 563.68 kW (or 755.33hp) then the flow rate of the discharge would be.
Assuming we have a flow velocity of 1500 m/min, then the dimensions of the exhaust pipe would be.
The diameter of the exhaust pipe would be 0.39 meter or 390 mm. Therefore, we are to use a pipe with such diameter. Air Starting System: The vast majority of diesel engines installed in power plants are started with compressed air. Compressed air is directed by a distributor directly into the combustion chamber or is provided to an air motor which rotates the engine. Dedicated compressors typically provide starting air at 250 psig. The system must provide adequate storage to allow multiple attempts to start the engines. The compressed air start system will included two air compressor units, each
42
with diesel engine-electric motor drive, and two main air storage tanks. The compressors will be rated at 250 psig operating pressure, and each will have a capacity capable of restoring any single storage receiver from 150 psig to 250 psig in 30 minutes or less. Each main storage tank will provide adequate air to the individual air start tanks at each diesel engine, supply air to the utility shop air outlets, and provide a second source to air to the instrument air system. Each air start tank will be sized to provide two 30 - second start sequences without recharging and will be rated at 300 psig working pressure. Each main storage tank will have a volume equal to three air start tanks plus a volume equal to one instrument air receiver, and an additional volume to supply the utility shop air requirement. Therefore, we need 4 units of Air Compressors for the 2 Diesel Engines. Both Air Compressors must have a 250 psig operating pressure. This working pressure is uniform regardless of the diesel engine size.
Required Capacity Air Storage Tank:
Assuming we are using a two stage air compressor with a 250 psig working pressure and a compressor power of 200 hp. Based from http://www.engineeringtoolbox.com/compressed-airreceivers-d_846.html with the topic Compressed Air Receivers and using the provided tables. Recommended Receiver Volume per HP
Compressor Power (hp) 5 7.5 10 15 20 25 30 40 50 60 75 100 125 200 350 450 500 kW 3.7 5.6 7.5 11.2 14.9 18.7 22.4 29.8 37.3 44.8 56 74.6 93.3 149.2 261.1 335.7 373 Recommended Receiver Volume (cu. ft) 3 4 5 8 11 13 16 21 27 32 40 54 67 107 188 241 268 (gal) 20 30 40 60 80 100 120 160 200 240 300 400 500 800 1400 1800 2000 (cu. meter) 0.1 0.1 0.2 0.2 0.3 0.4 0.5 0.6 0.8 0.9 1.1 1.5 1.9 3 5.3 6.8 7.6
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For the storage tank, assuming the storage volume is twice that of the air receiver and the utility shop requirements consumes half of the receiver, then the air storage volume would be. Total Volume = 3 m3 + (3 m3 x 2) + (3 m3 x 0.5) Total Volume = 10.5 m3 = 370.8 ft3 Dimensions of the Air Storage Tank: Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 12 4: Dimension of the Bulk Storage Tank; page 459; with a required storage of 10.5 m3 or 10500 litters then we are to use a tank of the next closest value of 11860 litters, the dimensions of a cylindrical bulk tank is given as follows. Diameter Length Plate Thickness Weight LUBRICATION SYSTEM Daily Lubricating Oil Consumption: Lubrication is essential to any machine element; this includes the diesel engines as well as its auxiliaries. Our design requires 3 units of F8-135-SC Diesel Engines with 525 kW generator rating; 1 unit is continuous in operation; another unit for 9 am to 12 am shift; another unit as a reserve; all of which are capable of continuous operation at least for a limited duration of time assuming that maintenance to either one of them is required. A future expansion is also provided. Our plant capacity factor is given at 60%. From the discussion above we have a 93.1375 % Net Generator Efficiency for each engine during the operation. The brake horsepower would then be the same as the obtained. Therefore, the brake horsepower is equal to. 2.44 m 2.54 m 6.35 mm 1844 kg
44
For a continuous operation, the generated power would be. Generated Power = 563.68 kW x 24 hours = 13,528.32 kW-hr Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 6: Internal Combustion Engine Power Plant; 6 6: Auxiliary Systems; Lubrication; page 174; most diesel power plants have an average consumption of 1 gallon of Lubricating oil per 1600 kW-Hour generated at full load rating. For both the diesel engines that operate continuously, then the total generated power would be. Generated Power = 13,528.32 kW-hr + (563.68 kW x 15hr) = 21,983.52 kW-hr Since 1 gallon of Lubricating oil per 1600 kW-hr generated at full load rating is give as an average consumption for lubrication, for one day consumption, we have. Oil Consumption = (21,983.52kW-hr) x (1 gallons / 1600 kW-Hr) = 13.7 gallons/day Similarly with the fuel oil, for 45day consumption, we have. Oil Consumption = 13.7 gallons/day x 45 days = 616.5 gallons Dimensions of the Lube Oil Storage Tank: By conversion. Volume = 616.5 gallons x (3.7854 Litters/gallons) x (1 x 10-3 m3/1 Litters) = 2.33 m3 Assuming that the tank is filled within 5 minutes as compared for the fuel oil, then. Volume Flow Rate = 2,330 Litters / 5 min = 466 Litters/min =0.466 m3/min Using a cylindrical drum for storage with a 1 meter diameter, the length could be obtained and so is the dimension.
The dimensions of the lube oil tank would be in 1 m diameter by 2.97 m length. Lube Oil Transfer Pump: Assuming that the fuel oil and the lube oil storage tanks and discharge settings are the same, together with the assumptions, then the requirements would be close and be useful for the lube oil transfer pump computation.
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Suction Line Pipe: Schedule 40 Outside Diameter Inside Diameter Discharge Line Pipe: Schedule 40 Outside Diameter Inside Diameter 1 in (true size of 1.660 in) 1.380 in (or 0.0351 m) 1 in (true size of 1.9 in) 1.610 in (or 0.0409 m)
Computing for the specific velocity rate at both the suction and discharge we simply use the given equation below.
Where: Q = Volume Flow Rate; m3/min V = Velocity of Fluid; m/sec d = Internal Diameter; m Computing now for the velocity at the suction we have.
46
Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 13: The Gas Loop; 13 10 Water Pumps; pages 545 to 546; we use the equations provided to obtain the required pump. As both the suction and discharge heads are given, we can now obtain the pump operating head. With the given, the pump operating head is Pump Operating Head = Discharge Head + Suction head = 8.5 m 1.4 m Pump Operating Head = 7.1 m Assuming that the pump efficiency is 70 %, and then we have.
47
Where: Q = Volume Flow Rate; 393.3 Litters/min O = Density of oil; 914 kg/m3 (or 0.914 kg/litters) H = Pump Operating Head; 5.7 m P= Pump Efficiency; 70 %
0.96 hp or 1 hp Therefore, we are to use 1hp oil pump for the fuel oil transfer. PROPOSED SCHEDULE OF WORK & ESTIMATE TIME OF COMPLETION Assuming we start the project at the month of January of 2010, then we are to follow the proposed schedule given below.
Time and Month October 2012 to November 2012 Target Work Output Load survey for the costumer kilowatt consumption; Gathering and surveying of the environment within the location; Planning and securing necessary permit Computation for the required plant operation which includes the following: Select the engine type, Design of the Generator Set, Design of its Fuel Oil System, Design for its Cooling Water System, Design for its Lubrication System, Design for its Air Handling System, Design for the Engine Dimension, others; Thorough re-evaluation of the plant design; Obtaining contracts and advice from various engineering firms Construction of the plant site; Purchase of equipment; Construction of Administration Building and Others; Installation of equipment Initial operation; Recalibration of equipment Relevance Initial work frame for the project; idealization for the project's continuity Initial work framefor the plant's construction and operation; Idealization for the plant layout, operation and maintenance Idealization of the plant site Testing phase of the project; Checking for flaws and defects Final project Phase
December 2012 to February 2013
March 2013 to October 2013 November 2013 to December 2013 January, 2014
Turnover of Plant operation to the owner/firm
48
GLO S SA R Y BrakeHorsepower(Bhp):A WorkIndicator;ameasureoftheworkproducedbyanengine, calibratedanddetermined bytheforce exertedonafrictionbrake. Compressor:Acompressorisa mechanical device thatincreases thepressureofa gaswhile reducingitsvolume.Compressorsaresimilar topumps;both increase the pressureon afluidand both can transport thefluid throughapipe. CoolingTower:Anequipment thatprovidescoolingtoany processed&heated fluid;Atallopentopped structure inwhich thesteam producedbyanindustrial process iscondensed DieselEngine:AnEnginethatusesdieselfuel forcombustion;aninternalcombustionenginethat ignitesdiesel fuelusingcompressionalone,ratherthanusingan electricalsparksuchas sparkplugs. Kilowatt-hour (kWh):Theelectricalenergyunitofmeasureequaltoone supplied to, ortakenfrom, anelectriccircuit steadilyforone hour. thousandwattsofpower
Lubricants:Substancesusedtoreduce friction betweenbearingsurfaces,orincorporatedinto othermaterialsusedasprocessingaidsinthemanufactureofotherproducts,orusedascarriers ofother materials. Pump:Apumpisadeviceusedtomovefluids,suchasgases,liquidsorslurries.Apump displacesavolume byphysicalormechanicalaction.Pumpsdonotcreatepressurethey displacefluid causingaflow.Addingresistancetoflowcauses pressure. only
Safety Factor:Theratioofthestrengthofaconstructionmaterialorstructuralparttoamaximum load which itwill have tosupport. It isusedtomultiplya machinefunctionto at least definealimit. Storage Tank: A storage tank is a container, usually for holding liquids, sometimes for compressedgases(gastank).Thetermcanbeusedforbothreservoirs(artificiallakesand ponds), andformanufacturedcontainers.
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B IBLI O G R AHY Avallone, Eugene &Baumeister, MechanicalEngineers; 9thEdition Theodore III; Marks Standard Handbook for
Morse,FrederickT.; PowerPlantEngineering(Adaptedto MKS Units) Salisbury,J.Kenneth;KentsMechanicalEngineersHandbook:Volume2:PowerVolume;12 thEditi on Raka,A. J., Srivastava, AmitPrakash, Dwivedi,Manish;PowerPlantEngineering Stoecker,W.F.& Jones, J.W;Refrigeration &AirConditioning; 2ndEdition PhilippineSocietyofMechanicalEngineers;ThePSMECodeof1993;1993RevisionofPSME Code www.engineeringtoolbox.com
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BICOL COLLEGE OF APPLIED SCIENCE AND TECHNOLOGY College of Engineering and Architecture City of Naga S/Y 2012-2013

(In partial fulfillment as a requirement in Power Plant Engineering)

FEBRUARY, 2013 2nd Semester

I hope that this design will meet your approval.

Thank you and God bless.

Sincerely yours, NUPS

TABLE OF CONTENTS Title Page ------------------------------------------- 1

Load Survey ---------------------------------------------7-14 Summary of load Load Curve ----------------------------------------------15

Cooling Water System

Proposal of Work Schedule ---------------------------------------48 Glossary ---------------------------------------------------------49

BARANGAY PACOL RESIDENCE INFORMATION PER ZONE AS OF 2010

ZONE 1 - 930 HOUSEHOLDS

ZONE 2 - 190 HOUSEHOLDS

ZONE 3 - 121 HOUSEHOLDS

ZONE 4 - 178 HOUSEHOLDS

158 98 17 0 7 168 0 125 3 76 59 14 105 2 24 4 24 23 103

ZONE 5 - 198 HOUSEHOLDS

320 90 900 300 160 147 45 630 100 920

6-7 am/11 am-12 nn/6-7 pm 6 am - 9 am 6 am - 7 am 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 9 am - 11 pm 7 am - 10 am Daily 9 am - 12 nn

1600 1170 2700 4500 5440 294 0 0 500 21160 172254

ZONE 6 - 117 HOUSEHOLDS

Water Dispenser Washing Machine TOTAL

100 8280 70362

2.40 16.56 458.43

TOTAL LOAD SURVEY FOR ZONE 1 TO ZONE 7 - 1829 HOUSEHOLDS

LOAD SURVEY VALUES & LOAD GRAPH PER HOUR RATING

LOAD GRAPH OF kW-Hr CONSUMPTION

Computing now for the velocity at the discharge we have.

Computing now for the suction head

Where: Q = Volume Flow Rate; 393.3 Litters/min

Where: W = circulating cooling water; Litter/hour

Computing now for the velocity at the suction we have.

Computing now for the velocity at the discharge we have.

Computing now for the suction head

Computing now for the velocity at the suction we have.

Computing now for the velocity at the discharge we have.

Computing now for the suction head

Computing now for the velocity at the discharge we have.

Computing now for the suction head

December 2012 to February 2013

Turnover of Plant operation to the owner/firm

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