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Diesel electric power station

Example (1):
A power supply company has to install a Diesel electric power plant at a hill station having an altitude of 900 m above the sea-level. 4 units 2 each of 500 kW and each of 300 kW are chosen to suit the load curve. The engines used are of the 4-stroke, 375 r.p.m. airless injection type. The maximum demand on the station is to be 1400 kW at 0.8 power factor lagging. The average load factor will be 50% and the annual capacity factor 44%. The generator efficiency may be taken as 93%. Find: a) The ratings of the diesel engines; b) The energy produced/year c) The main dimensions of the engines and generators; d) The annual fuel consumption; e) The quantity of the water required for cooling system, if 30% of the heat in the fuel is lost to the cooling water. f) The space required for each unit, and show the general layout of the engine-generators set.

Solution:
The generator efficiency, G = 0.94 Engine Capacity to drive 500 kW generator=500/0.94 = 538 or 540 kW Engine Capacity to drive 300 kW generator=300/0.94 = 323 or 325 kW The rating of the engine at altitude of 900 m is reduced to approximately 0.94% of that at sea-level (see Fig.) If the engine are not supercharged, the sea-level ratings are 540/0.94= 575 kW and 325/0.94=346 kW If the engines are supercharged, capacities of 540 kW and 325 kW will be suitable

(b) Main dimensions of engines:


Take supercharged engines at greater altitude, and assume maximum power each cylinder as 75 kW, so Each 540 kW engine will have 540/75=7.2 8 cylinders , each 67.5 kW Each 325 kW engine will have 325/75=4.3 6 cylinders, each54 kW

Dimensions of 67.5 kW Cylinder:


Let L/d= 1.4 and m.e.p= 6 bar So, pressure, p = (pmep L AN)/60 67.5 x 1000= (60x105x1.4 d x /4 d2 *375/2)/60 Or, d= 0.322 m and L=1.4*0.322 = 0.45 m

Dimensions of 54 kW Cylinder:
Same process can be fellow for 54 kW cylinder so that we get d=0.3 m and L= 0.42 m

(c) Energy produced/year:


Energy produced / year = maximum demand * Load factor * 8760 = 1400 * 0.5 * 8760 = 6.132 *106 kWh

(d) Annual fuel consumption:


The energy produced kWh / fuel Consumption can approximately Find from a chart as see in Fig. Then, for C.F of 0.44, we get approximately 2.3 kWh/ liter of oil. Since, Annual fuel oil Consumption ,

Diesel electric power station

=6.132 *10 /2.3 = 2.66 * 10 liter of oil

(e) Water required:


Fuel consumption / hour = 2.66*106/ 8760 = 304 Liter of oil Take the calorific value of oil as 40,000 kJ/kg, and the heat lost by the cooling water 30% of input heat by fuel, then Heat input from fuel/hr. = 40,000 * 304 = 121,600,00 kJ Heat absorbed by water=121,600,00*0.3 = 3648,000 kJ/hr. Take the difference between inlet and outlet water cooling temperature as 11 Co, therefore; Water required/hr. = 3648000/(4.18*11)= 79.339*103 kg/hr. = 1322.3 kg/min. (where Cp of water is taken as 4.18 kJ/kgK) The selection of the pump should be taken at maximum load , = 1322.3/load Factor = 1322.3/0.5 = 2645 kg/min. OR The capacity of the pump at least 3000 kg/min. or 3000 Lit./min.

(f) Main dimensions of the generator:


The rating of the 500 kW generator at 0.8 power factor lagging is 500/0.8 = 625 kW The output of the generator can be given in terms of the main dimensions, D & L as P= 10.4 *10-3 * *ac * L * * n , Taking: Average flux density , = 6.2 * 10-5 wb/cm2 Specific electric loading, ac = 350 A conductors/cm periphery N=375/60 r.p.s Therefore, 625=10.4*10-3*6.2*10-5 * 350 * D2L *375/60 hence, D2L=442,000 cm2 The frequency is calculated by , f =pn/2 where: p= no. of poles and if f= 50 c/s (hertz). Therefore no. of poles=16 Assuming, the pole pitch = to the length core Pole pitch is the distance of curvature between centers of successful poles and length of core is the length of rotor). In general the length of core, L, in low speed Salient pole generator is small and can be taken as 0.8 to 1.2 times the pole pitch. Then, L= D/16 Therefore, D2L= D3/16= 442,000 Hence, D=132 cm and L= 26 cm Same process can be taken for the rating of 300 kW generator, therefore, D=111 cm and L= 22cm.

Diesel electric power station

4 Energy produced/, kWh/lit. oil fuel

0 0 20 40 60 % capacity factor 80 100

Relation between capacity factor and energy produced kWh/lit. oil fuel

100 % of the sea-level rating 90 80 70 60 50 40 1000 2000 3000

T urbo-supercharged Unsupercharged

4000

5000

Altitude above sea level, m Effect of altitude on the diesel power plant output

Diesel electric power station

Space Required by Station: 500 kW set:


Diameter of each cylinder, d=32.2 cm, Allowing for the thickness of the cylinder walls, d can be taken as 40 cm. Then, minimum space required for 8 cylinders is 8*40 = 320 cm. The length of the generator core is 26 cm. Therefore, the total length including all other mechanical arrangements for fly wheel, bearing, etc. will about 750 cm. The width will about 228 cm. The total height of the engine is 365 cm of which 274 cm will be above the floor level.

300 kW set:
The space required by a 300 kW unit can be estimated in same way. The space required for 6- cylinders= 6*37.5= 225 cm The length of the generator core = 22 cm The total length of the set including the mechanical arrangements will be about 580 cm. The width is about 228 cm and the height is about 365 cm of which 274 cm will be above the floor.

m6 Wk tes m 5.7 Wk 005 tes


Future expansion -300

Diesel electric power station

Example (2):
If the cost of the plant in the previous example 10 1000 $/kW, insurance and taxes 2% of costs, interest on investment 65 and depreciation of the plant 7%, find the fixed costs. The cost of fuel oil/kg may be taken as 0.2 $/liter, and that of lubricating oil/liter as 1 $. Assuming the amount of lubricating oil required is 1 liter for every 400 kWh. The calorific value of the fuel is 40000 kJ/kg. Maintenance costs 8000 $/year; 1/3 of this may be taken as fixed and the remainder as variable. Operation costs 10,000 $/year. Find the variable costs and the total costs and the cost /kwh energy generated.

Solution: Fixed costs:


The capacity of the plant 1600 kW Initial cost 1600*1000 = 1,600,000 $ Fixed cost rate = Interest + Depreciation +Insurance & taxes = 6 + 7 +2= 15 % Initial cost rate = 0.15 * 1,600,000 = 240,000 $ 1/3 of maintenance cost may taken as fixed cost = 1/3*8000=2,667 $ Fixed cost rate/year = 2,667 +240,000 =242,667 $ Ans.

Variable Costs:
Annual fuel consumption (from previous example)=2.66*106 Liters Fuel costs/year= 0.2*2.66*106=532,000 $ Annual lubricating oil consumption = 6.132*106/400 = 1.533*104 Liters Lubricating oil consumption/year= 1 * 1.533*104= 1.533*104 $ Operating cost/ year=10,000 $ 2/3 of maintenance cost may be taken as operating cost=2/3*8000=5333 $ Total operating cost rate/year=10,000+5333=15333 $ Ans. Total annual cost rate= fixed cost rate + variable cost rate = 242,667+15333=258000 $ The unit energy cost / kWh = 258000/ 6.132*106= 0.0421 $/kWh Ans.

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