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The power consumption of AG&P is highly dependent on the number of projects taken
every year. For huge projects, the power demand is maximized due to the simultaneous
operations and continuous use of all equipment. The following table shows the breakdown
(kW-hr) (kW)
Assuming continuous projects in ten years (starting from the projected year 2013), the
2018 632.98
2019 915.79
2020 956.36
2021 998.72
2022 1042.96
In reference to the actual power consumption during the peak of the operation for
construction projects, an increase of 4% per annum is projected for the possible additional
equipment and facility upgrades. The years 2016 and 2017 has few projects, and 2018
has incoming project by mid-year. By year 2022, the projected power demand will be
1042.96 kW.
Plant Capacity
The average power demand is based on the gathered data from AG&P’s annual
consumption from Aboitiz Power. For 2022, the projected average is:
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑚𝑎𝑛𝑑
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐷𝑒𝑚𝑎𝑛𝑑 =
𝐿𝑜𝑎𝑑 𝐹𝑎𝑐𝑡𝑜𝑟
Given the average load factor of 0.44 (based on 2016 and 2017 average load factors),
1.04𝑀𝑊
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐷𝑒𝑚𝑎𝑛𝑑 = 0.44
𝑴𝒂𝒙𝒊𝒎𝒖𝒎 𝑫𝒆𝒎𝒂𝒏𝒅 = 𝟐. 𝟑𝟕 𝑴𝑾
The reserved capacity is measured to be 15% of maximum demand, and the plant
𝑷𝒍𝒂𝒏𝒕 𝑪𝒂𝒑𝒂𝒄𝒊𝒕𝒚 = 𝟐. 𝟗𝟎 𝑴𝑾
The designed 3-MW diesel power plant capacity is based on the stated calculations and
The power plant design requires 3MW of power on daily basis. Assuming 6 units of diesel
generator set,
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐷𝑒𝑚𝑎𝑛𝑑
𝐺𝑒𝑛𝑠𝑒𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 =
𝑁𝑜. 𝑜𝑓 𝐺𝑒𝑛𝑠𝑒𝑡𝑠
3 𝑀𝑊
𝐺𝑒𝑛𝑠𝑒𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 =
6 𝑢𝑛𝑖𝑡𝑠
𝟎. 𝟓𝑴𝑾
𝑮𝒆𝒏𝒔𝒆𝒕 𝑪𝒂𝒑𝒂𝒄𝒊𝒕𝒚 = = 𝟓𝟎𝟎 𝒌𝑾/𝒖𝒏𝒊𝒕
𝒖𝒏𝒊𝒕
According to International Standards Organization (ISO), prime running power is the
maximum power a generator set has during a variable power sequence for an unlimited
manufacturer must be followed to reach these standards (ISO 8528-1 of 2005). It is not
advisable that the variable load exceed 70% average of the prime power rating during
𝑮𝒆𝒏𝒔𝒆𝒕 𝑪𝒂𝒑𝒂𝒄𝒊𝒕𝒚
𝑷𝒓𝒊𝒎𝒆 𝑷𝒐𝒘𝒆𝒓 =
𝟕𝟎%
500 𝑘𝑊
𝑃𝑟𝑖𝑚𝑒 𝑝𝑜𝑤𝑒𝑟 =
0.70
For equipment selection, the designer decided to compare two generator sets, and the
one with better specifications and design advantages to offer will be used. The diesel
generator sets being compared are selected considering the factors such as ease of
This generator set will accomplish a 24/7 operation providing 3 MW power supply in
compliance to the prime power requirement of 714.24 kW. For maintenance servicing and
longer operational life of Option A, it is recommended to have additional 2 units, for a total
of 8 generator sets. Scheduling of operational hours and idle time for maintenance will be
FUEL SYSTEM
For safe operation, the generator sets will be running at 70% of its full-load
At 70% load X
By interpolation:
𝑘𝑔
0.75 − 0.70 0.035 ⁄𝑠 − X
=
0.75 − 0.50 𝑘𝑔 𝑘𝑔
0.035 ⁄𝑠 − 0.025 ⁄𝑠
𝒌𝒈⁄
𝑿 = 𝒎𝒇𝒖𝒆𝒍 𝒂𝒕 𝟕𝟎% = 𝟎. 𝟎𝟑𝟑 𝒔
As scheduled, each generator set will operate for 18 hours a day. Then the volume
𝑚𝑓𝑢𝑒𝑙 18 ℎ𝑜𝑢𝑟𝑠
𝑉𝑑𝑎𝑦𝑡𝑎𝑛𝑘 = 𝑥 ⁄𝑑𝑎𝑦
𝜌𝑓𝑢𝑒𝑙
𝑘𝑔
𝜌𝑓𝑢𝑒𝑙 = 838.9 , 𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑓𝑢𝑒𝑙 𝑜𝑖𝑙 𝑜𝑓 35°𝐴𝑃𝐼 (16℃ 𝑜𝑟 60℉)
𝑚3
𝑘𝑔
0.033
𝑉𝑑𝑎𝑦𝑡𝑎𝑛𝑘 = 𝑠 (3600𝑠 ) 𝑥 18 ℎ𝑜𝑢𝑟𝑠
⁄𝑑𝑎𝑦
𝑘𝑔 1ℎ𝑟
838.9 3
𝑚
𝑉𝑑𝑎𝑦 𝑡𝑎𝑛𝑘 = 𝜋𝑟 2 ℎ
2.55204𝑚3
ℎ=
𝜋(0.6 𝑚)2
ℎ = 2.2565 𝑚
For design allowance, use tank radius of 0.65 m and tank height of 2.3 m
LUBRICATING SYSTEM
As stated in the generator set manufacturers’ manual, the lubrication system only
requires a sump refill with filter, which is already installed in the equipment, with a
COOLING SYSTEM
The cooling system of the selected generator set is equipped with a large fan
located in front of the engine proper. The maximum airflow at rated speed for
radiator arrangement is rated 1464 m3/min. For the internal engine cooling, the
L, and engine coolant capacity (with radiator) of 149 L (CAT Diesel Generator Set,
MACHINE FOUNDATION
In compliance to the Philippine Mechanical Code of 2008, foundation mass should
be from three to five times the weight of the machinery it is supposed to support.
That is;
Therefore,
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐹𝑜𝑢𝑛𝑑𝑎𝑡𝑖𝑜𝑛 = 7103𝑘𝑔 𝑥 5
𝑾𝒆𝒊𝒈𝒉𝒕 𝒐𝒇 𝑭𝒐𝒖𝒏𝒅𝒂𝒕𝒊𝒐𝒏 = 𝟑𝟓𝟓𝟏𝟓𝒌𝒈 𝒑𝒆𝒓 𝒆𝒏𝒈𝒊𝒏𝒆
compliance to the prime power requirement of 714.24 kW. For maintenance servicing and
longer operational life of Option B, the designer recommends to have additional 2 units,
for a total of 8 generator sets. Scheduling of operational hours and idle time for
FUEL SYSTEM
For safe operation, the generator sets will be running at 70% of its full-load
At 70% load X
By interpolation:
𝑘𝑔
0.75 − 0.70 0.034 ⁄𝑠 − X
=
0.75 − 0.50 𝑘𝑔 𝑘𝑔
0.034 ⁄𝑠 − 0.024 ⁄𝑠
𝒌𝒈⁄
𝑿 = 𝒎𝒇𝒖𝒆𝒍 𝒂𝒕 𝟕𝟎% = 𝟎. 𝟎𝟑𝟐 𝒔
As scheduled, each generator set will operate for 18 hours a day. Then the volume
𝑚𝑓𝑢𝑒𝑙 18 ℎ𝑜𝑢𝑟𝑠
𝑉𝑑𝑎𝑦𝑡𝑎𝑛𝑘 = 𝑥 ⁄𝑑𝑎𝑦
𝜌𝑓𝑢𝑒𝑙
𝑘𝑔
𝜌𝑓𝑢𝑒𝑙 = 838.9 , 𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑓𝑢𝑒𝑙 𝑜𝑖𝑙 𝑜𝑓 35°𝐴𝑃𝐼 (16℃ 𝑜𝑟 60℉)
𝑚3
𝑘𝑔
0.032 𝑠 3600𝑠
𝑉𝑑𝑎𝑦𝑡𝑎𝑛𝑘 = ( ) 𝑥 18 ℎ𝑜𝑢𝑟𝑠⁄𝑑𝑎𝑦
𝑘𝑔 1ℎ𝑟
838.9 3
𝑚
𝑉𝑑𝑎𝑦 𝑡𝑎𝑛𝑘 = 𝜋𝑟 2 ℎ
2.55204𝑚3
ℎ=
𝜋(0.6 𝑚)2
ℎ = 2.1677 𝑚
For design allowance, use tank radius of 0.65m and tank height of 2.2m
LUBRICATING SYSTEM
lubricating oil pump located in oil pan or on side of the engine. A pressure regulator
valve is provided in full-flow oil filter head as insurance against interruption of oil
Maximum cleansing and filtration is achieved through use of both by-pass and full-
flow, lubricating oil filters. Full-flow filters are standard on all engines; by-pass
filters are used on all turbocharged models and optionally on all other engines.
Fuel pumps and injectors are lubricated by fuel oil (Cummins Power Diesel
COOLING SYSTEM
generator set also includes a fan, with a load of 32.1 kW (prime), and a cooling
system for engine with radiator having a capacity of 200.6 L, flowing at a rate of
14.825 L/s (Cummins Power Diesel Generator Set Model DFHB – Specifications
– General).
AIR SYSTEM
The combustion air flow rate is 64.2 m3/min, alternator cooling air flow rate of 117.6
be from three to five times the weight of the machinery it is supposed to support.
That is;
Therefore,
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐹𝑜𝑢𝑛𝑑𝑎𝑡𝑖𝑜𝑛 = 7973𝑘𝑔 𝑥 5
𝑾𝒆𝒊𝒈𝒉𝒕 𝒐𝒇 𝑭𝒐𝒖𝒏𝒅𝒂𝒕𝒊𝒐𝒏 = 𝟑𝟗𝟖𝟔𝟓 𝒌𝒈 𝒑𝒆𝒓 𝒆𝒏𝒈𝒊𝒏𝒆
Parameters
Fuel system (fuel intake) 0.033 kg/s (per engine) 0.032 kg/s (per engine)
prime power)
mass)
Based on the table of values above, it is concluded that the better choice of generator set
to accomplish the power demand of AG&P is Option B. The option offered the same
output with a lower fuel consumption, smaller day tank dimension, and lower exhaust
discharge rate. The chosen equipment also provides smaller fan load and a larger coolant
capacity for engine heat dissipation. The only disadvantage of choosing this generator
set is that it is heavier than the other, whereas it needs additional foundation weight to
According to the designer, it is not advisable to install a waste heat recovery system in
order to maximize the output power that can be produced by the power plant. The
installation cost from this additional unit is not economical and the power output is small,
During operational hours, only six out of eight generator sets will be running
simultaneously, two of which are off for three hours after every nine hours of running time.
𝑚𝑓𝑢𝑒𝑙
𝑄𝑓𝑢𝑒𝑙 = (𝑛𝑜. 𝑜𝑓 𝑒𝑛𝑔𝑖𝑛𝑒𝑠)
𝜌𝑓𝑢𝑒𝑙
𝑘𝑔
0.032 𝑠 1000𝐿
𝑄𝑓𝑢𝑒𝑙 = ( )(6 𝑒𝑛𝑔𝑖𝑛𝑒𝑠)
𝑘𝑔 1𝑚3
838.9 3
𝑚
As previously stated, six generator sets will be running at the same time.
𝑚𝑓𝑢𝑒𝑙
𝑄𝑓𝑢𝑒𝑙 = (𝑛𝑜. 𝑜𝑓 𝑒𝑛𝑔𝑖𝑛𝑒𝑠)
𝜌𝑓𝑢𝑒𝑙
𝑘𝑔
0.032
𝑄𝑓𝑢𝑒𝑙 = 𝑠 (1000𝐿 ) (6 𝑒𝑛𝑔𝑖𝑛𝑒𝑠)
𝑘𝑔 1𝑚3
838.9 3
𝑚
𝑳
𝑸𝒇𝒖𝒆𝒍 = 𝟎. 𝟐𝟐𝟕
𝒔
LUBRICATION SYSTEM
For the designated equipment, the lubricating oil system does not require miscellaneous
external cooling devices such as heat exchangers or cooling towers in lowering the lube
oil temperature. Only periodic maintenance servicing for engine lubrication is needed.
MAIN STORAGE TANK SPECIFICATIONS
𝑚3
𝑉𝑚𝑜𝑛𝑡ℎ𝑙𝑦 𝑓𝑢𝑒𝑙 = (2.4516 ) (8 𝑒𝑛𝑔𝑖𝑛𝑒𝑠) 𝑥 30 𝑑𝑎𝑦𝑠
𝑑𝑎𝑦
Since the monthly fuel volume requirement for the power plant is huge, the designer’s
decision is to use two main tanks. The decision is also for the advantage of maintenance
servicing. That is, when a tank is for inspection or breakdown, there is a two-week fuel
𝑉𝑚𝑜𝑛𝑡ℎ𝑙𝑦 𝑓𝑢𝑒𝑙
𝑉𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑡𝑎𝑛𝑘 =
2
588.384 𝑚3
𝑉𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑡𝑎𝑛𝑘 =
2
𝑉𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑡𝑎𝑛𝑘 = 𝜋𝑟 2 ℎ
Each main tank must contain a minimum volume of 294.192 m3 of diesel fuel (300 m3
for allowances). To comply with API 650, the following table shows the typical sizes of
20 6.1 2350 28.0 18 5.5 42,500 161 Formatted: Indent: Left: 0"
25 7.6 3670 45.6 18 5.5 66,000 250 Formatted: Indent: Left: 0"
25 7.6 3670 45.6 24 7.3 88,000 334 Formatted: Indent: Left: 0"
30 9.1 5290 65.6 24 7.3 127,000 481 Formatted: Indent: Left: 0"
35 10.7 7190 89.3 30 9.1 216,000 819 Formatted: Indent: Left: 0"
Source: “Welded Steel Tanks for Oil Storage,” American Petroleum Institute, Washington,
𝑉𝑛𝑒𝑤 = 330 𝑚3
According to the previous table, the nearest value to accommodate the requirements
To comply with the Philippine Mechanical Code of 2012, the thickness of the shell plate
M Ft Mm In
The calculated main tank diameter is 6m, hence, a shell plate thickness of 5mm must be
used. The main storage tank and day tanks will be fabricated by the company itself since
AG&P is a steel fabrication company, using the calculated dimensions and values stated
on previous pages.
As designed, the shell plate thickness parallel to Philippine Mechanical Code of 2012
will be 5 mm. The proponent decided to add a corrosion allowance of 5mm (shell plate
thickness of 10mm), since the assembly and erection site is nearby the shore, making it