Post on 25-Oct-2015
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Power Plant Design for Sagay, Camiguin1
ACKNOWLEDGEMENT
First of all, we would like to say thank you for giving us the strength and health to
do this project work until it done not forgotten to my our family for providing everything
such as money to buy anything that are related to this work and their advised, which is
the most needed for this project. Internet, books, computers and all that as my source to
complete this project they also supported us and encouraged us to complete this task
so that we will not procrastinate in doing it. Then we would like to thank our professor
for guiding us and our friends throughout this project. We had some difficulties in doing
this task, but he taught us patiently until we knew what to do, he tried and tried to teach
us until we understand what we supposed to do with the project work. Last but not the
least, our friends who were doing this project with us and sharing our ideas they were
helpful that when we combined and discussed together we had this task done.
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INTRODUCTION
In a diesel power station, diesel engine is used as the prime mover. The diesel burns
inside the engine and the products of this combustion act as the working fluid to
produce mechanical energy. The diesel engine drives alternator which converts
mechanical energy into electrical energy. As the generation cost is considerable due to
high price of diesel, therefore, such power stations are only used to produce small
power.
Although steam power stations and hydro-electric plants are invariably used to generate
bulk power at cheaper costs, yet diesel power stations are finding favour at places
where demand of power is less, sufficient quantity of coal and water is not available and
the transportation facilities are inadequate. This plants are also standby sets for
continuity of supply to important points such as hospitals, radio stations, cinema houses
and telephone exchanges.
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The diesel engine is recognized as the most promising powertrain in the foreseeable
future due to its superior thermal efficiency and reliability. The diesel engine has been
widely used in commercial vehicles, industrial applications and today’s passenger cars
and light-duty trucks.
A diesel engine is a type of compression-ignition engine using diesel fuel. Diesel
engines can be classified into various categories. Understanding the differences and the
unique characteristics of each category of diesel engines is important for diesel engine
system design.
HISTORY
The first man, who had invented the engine with ignition from compression, was E.
Steward. He was interested in engines, what can work without spark plugs. In Steward’s
engine the air was compressed and compressed air was blown into the combustion
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chamber. Unfortunately, Steward had not come into mind to test the efficiency of that
type of engines.
Developing the concept of “economy-type heat-engine”, Rudolph Diesel in 1890
invented the engine much more efficient due to high compression ratio. In his book he
suggested to use the powdered coal, but it was difficult in real life – the coal dust has an
abrasive properties and it should be found the way to put it somehow in combustion
chamber. So it was suggested to use the tailing that remains after oil refining in such
engines. So in 1897 Diesel had patented the engine design, later named Diesel engine.
Rudolf Diesel was born in Paris in 1858. His parents were Bavarian immigrants. Rudolf
Diesel was educated at Munich Polytechnic. After graduation he was employed as a
refrigerator engineer. However, he true love lay in engine design. Rudolf Diesel
designed many heat engines, including a solar-powered air engine. In 1893, he
published a paper describing an engine with combustion within a cylinder, the internal
combustion engine. In 1894, he filed for a patent for his new invention, dubbed the
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diesel engine. Rudolf Diesel was almost killed by his engine when it exploded. However,
his engine was the first that proved that fuel could be ignited without a spark. He
operated his first successful engine in 1897.
POWER PLANT DESIGN FOR SAGAY
Diesel Power Plant for Sagay, Camiguin produces power in the range of 6.4 MW.
And they are used standby sets for continuity of supply such as hospitals, cinema
theatres and industries.
ADVANTAGES OF A DIESEL ENGINE
More efficient and economical to use.
Fuel vapor is not explosive.
Exhaust gases are less poisonous – less carbon monoxide.
Greater lugging power and torque.
Engines are durable and if properly cared for will maintain their economy.
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Fuel is less volatile – no vapor lock problems
Can use a variety of fuels and mixtures.
DISADVANTAGES OF DIESEL ENGINE
The fuel in diesel engine is ignited by the heat of the compressed air.
HPFP of diesel engine is extremely unreliable unit.
The exhaust filter is warming up in the flow of exhaust gas.
it is expensive
Noise and vibration till the latest times could not be separated from the words
“Diesel engine”.
ADVANTAGES OF DIESEL POWER PLANT
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The design and layout of the plant are quite simple.
It occupies less space as the number and size of the auxiliaries is small.
It can be located at any place.
It can be started quickly and it can pickup load in a short time.
There are no standby losses.
DISADVANTAGES OF DIESEL POWER PLANT
The plant has high running charges as the fuel (diesel) used is costly.
The plant doesn’t work satisfactorily under overload conditions for a longer
period.
The plant can only generate small power.
The cost of lubrication is generally high.
The maintenances charges are generally high.
WHY WE CHOOSE DIESEL POWER PLANT
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Purpose
Diesel power plants produce energy though the combustion of chemical fuel, in
most cases diesel derived from petroleum, into mechanical energy. This energy
is then used to power an alternator which in turn generates electricity. Diesel is
preferred to other fuel types as these engines have a higher thermal efficiency
than other commercial generators of equivalent size.
Process
Most modern generators harness mechanical energy through the process of
electromagnetic induction. In this system, the mechanical energy produced by
the diesel engine moves an electrical conductor, such as a magnetically charged
wire, in a magnetic field. The movement of the conductor creates a difference in
voltage between the two ends of the charged wire, creating a flow of electric
charges and thereby generating electricity.
LAYOUT OF DEISEL POWER PLANT
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ESSENTIAL ELEMENTS OF DIESEL POWER PLANT
I. DIESEL ENGINE
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Diesel engine is a compressor ignition (CI) engine.
The two – stroke cycle engine is more favored for diesel power plants.
The air required for the diesel engine is drawn through the air filter form the
atmosphere and compressed inside the cylinder.
The fuel (diesel) from the diesel engine is drawn though a filter from the all-day
tank and injected into the cylinder through fuel injector.
Because of the high temperature and pressure of the compressed air, the fuel
burns and the burn gases expand to do work on the moving part inside the
cylinder called piston.
This movement of the piston rotates a flywheel and the engine is directly couple
to electric generator.
The gases after expansion inside the cylinder are exhaust into the atmosphere
and passes through a silencer in order to reduce the noise.
II. STARTING SYSTEM
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The starting motor will crank the engine. The starting motor will spin the engine at
a high enough rpm to allow the engine’s compression to ignite the fuel and start
the engine running.
The engine will then accelerate to idle speed. When the starter motor is
overdriven by the running motor it will disengage the flywheel.
III. FUEL SUPPLY SYSTEM
It consists of storage tank, strainers, fuel transfer pump and all day fuel tank. The
fuel oil is supplied at the plant site by rail or road. The oil is stored in the storage
tank. From the storage tank, oil is pumped to smaller all day tank at daily or short
intervals. From this tank, fuel oil is passed through strainers to remove
suspended impurities. The clean oil is injected into the engine by fuel injection
pump.
IV. AIR INTAKE SYSTEM
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This system supplies necessary air to the engine for fuel combustion. It consists
of pipes for the supply of fresh air to the engine manifold. Filters are provided to
remove dust particles from air which may act as abrasive in the engine cylinder.
V. EXHAUST SYSTEM
This system leads the engine exhaust gas outside the building and discharges it
into atmosphere. A silencer is usually incorporated in the system to reduce the
noise level.
VI. COOLING SYSTEM
The temperature of the burning fuel inside the engine cylinder is in the order of
15000 0C to 20000 0C. In order to lower this temperature water is circulated
around the engine.
The water envelopes (water jacket) the engine. The heat from the cylinder,
piston, combustion chamber etc., is carried by the circulating water.
The hot water leaving the jacket is passed through the heat exchanger.
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The heat from the heat exchanger is carried away by the raw water circulated
through the heat exchanger and is cooled in the cooling tower.
VII. LUBRICATING SYSTEM
The system minimises the wear of rubbing surfaces of the engine. It comprises of
lubricating oil tank, pump, filter and oil cooler. The lubrication oil is drawn from
the lubricating oil tank by the pump and is passed through filter to remove
impurities.
LOCATION MAP
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LOCATION
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Sagay, Camiguin
Sagay is a Philippine municipality. It is located in the province Camiguin in Region
X Northern Mindanao which is a part of the Mindanao group of islands. The municipality
Sagay is seated about 16 km south of province capital Mambajao and about 732 km
south-south-east of Philippine main capital Manila. The geographic coordinates of
Sagay are 9° 6' 21'' N, 124° 43' 29'' E.
Administratively the Municipality of Sagay is subdivided into 9 barangays. One forms
the center of the city wheras the other 8 are in the outlying areas. Some of them are
even several kilometers away from the center of the Municipality.
According to the 2007 census, Sagay has a population of 11,198 residents and is part
of the big group of 1073 cities and municipalities in the Philippines which have more
than 10.000 residents but did not reach 50.000 population yet. Based on the number of
its inhabitants Sagay is number 1483 of the most populous cities of the Philippines and
at 424 in Mindanao group of islands and at 4 of the most populous cities of province
Camiguin. With an area of 44.13 km² Sagay occupies a relatively small urban area.
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Accordingly, there is a high population density. In Sagay, by average, 253.75 people
live in one square kilometer. With this value, Sagay is only number 105 in Mindanao
and is nationally ranked 728th of the most densely populated cities in the Philippines.
According to the Philippine income classification for provinces, cities and municipalities
Sagay is a 5th class municipality. The urbanization status of Sagay is classified as
partly urban.
Among the bigger cities and municipalities in the neighborhood of Sagay there
areCagayan De Oro City (Misamis Oriental) 69 km south, Gingoog City (Misamis
Oriental) 55 km south-east, Manolo Fortich (Bukidnon) 83 km south, City Of
Cabadbaran (Agusan Del Norte) 88 km east, Butuan City (Agusan Del Norte) 90 km
east, Balingasag (Misamis Oriental) 40 km south, Tagoloan (Misamis Oriental) 63 km
south, Buenavista (Agusan Del Norte) 76 km east, Talakag (Bukidnon) 98 km south as
well as 50 km south of Sagay the municipality Jasaan (Misamis Oriental).
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Municipalities Total Population Percentage Male Female
Camiguin 74,232 100 37,847 36,385
Catarman 15,368 20.7 7,864 7,522
Guinsiliban 5,092 6.9 2,620 2,472
Mahinog 12,592 17.0 6,368 6,224
Mambajao (Capital) 30,806 41.5 15,657 15,149
Sagay 10,356 14.0 5,338 5,018
Guinsiliban is 6.9% of total population of Camiguin therefore we can assume that out of
14,735 Occupied Housing Unit there are 1002 single houses which represents the
majority of the building structure on Guinsiliban and a household population of 1023.
Demographic Data:
Total No. of Population: 5,092
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Household Population: 1023
Structures:
Group A Group B
Single House: 1002 Multi- Unit Residential: 3
Duplex: 6 Commercial/Industrial/Agricultural: 1
GROUP A
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GROUP B
Total Power Consumption Table
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Time GROUP ANo. of
ConsumerPower
Consumption GROUP BNo. of
ConsumerPower
ConsumptionTotal Load (w-
hr)1 1632960 2016 810 16000 8 2000 16489602 1632960 2016 810 24000 8 3000 16489603 1632960 2016 810 24000 8 3000 16489604 2237760 2016 1110 16000 8 2000 22537605 2136960 2016 1060 24000 8 3000 21609606 2136960 2016 1060 91200 8 11400 22281607 1532160 2016 760 94000 8 11750 16261608 2056320 2016 1020 102000 8 12750 21583209 2056320 2016 1020 110000 8 13750 2166320
10 2378880 2016 1180 32000 8 4000 241988011 1854720 2016 920 28000 8 3500 188272012 1854720 2016 920 61200 8 7650 191592013 1854720 2016 920 48000 8 6000 190272014 1310400 2016 650 16000 8 2000 132640015 1310400 2016 650 24000 8 3000 133440016 1310400 2016 650 29200 8 3650 133960017 1532160 2016 760 29200 8 3650 156136018 2136960 2016 1060 37200 8 4650 217416019 4354560 2016 2160 53200 8 6650 440776020 4677120 2016 2320 37200 8 4650 471432021 2459520 2016 1220 53200 8 6650 251272022 2459520 2016 1220 37200 8 4650 249672023 1632960 2016 810 64000 8 8000 169696024 1632960 2016 810 32000 8 4000 1664960
Total Load
(w-hr / 24hrs.)
49815360 w-hr
1082800 w-hr
Total Load (w-hr / 24hrs.) 50898160 w-hr
Design Overview
Peak Load = 2357.16 kW, 2.35mW
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Plant Capacity: 3200 kW, 3.2mW
No. of Engines: 5
Engine Capacity Number of Hours of Operation/day
Unit 1 --- 800 kW 18hours/day
Unit 2 --- 800 kW 18hours/day
Unit 3 --- 800 kW 18hours/day
Unit 4 --- 800 kW 18hours/day
Unit 5 --- 800 kW Reserve
Schedule of Engine Operation
Time of Operation Engine Operating Time Interval
12AM-6AM Unit 1,2 and 3 6 hours
6AM-12NN Unit 2,3 and 4 6 hours
12NN-6PM Unit 1,4 and 2 6 hours
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6PM-12AM Unit 3,4 and 1 6 hours
Each Unit has a 6 straight hours break
DESIGN FOR MACHINE FOUNDATION
For 800 kW Generator Set (Per Unit 1,2,3,4 and 5)
Mixture for Concrete Foundation:
Use 1:3:5 concrete mixture ratio (from PPE by F.T. Morse, Table 4-1 p.90)
Soil Bearing Pressure:
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Use 50-98 tones / m2 for common brick masonry
(from PPE by F.T. Morse, Table 4-4 p. 105)
Soil Bearing Pressure (Sb) = 50tonnes
m2x1000kg1 ton = 50,000 kg/m2
Weight of Foundation
Wf = e x We x √n
Where:
Wf = weight of the foundation, kgs
We = weight of the engine, kgs
N = engine speed, RPM
Use e = 0.11 (from PSME code, Table 2.4.2.3 (4), p.11)
Wf = 0.11 x 7897 kg x √1800 rpm = 36, 859.21 kg
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Volume of Foundation
Vf = W fρc
Where:
Vf = Volume of foundation [m3]
ρc = density of concrete = 2406 kg/m3
Vf = 36,859.21kg
2406kg /m3 = 15.32 m3
Depth of Foundation
h = Vf
wf x Lf
Where:
Hf = depth of foundation [m]
Lf = length of foundation [m]
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Wf = width of the foundation [m]
Length of the Foundation
Lf = Lb + 10% Lb
Where:
Lb = length of bedplate [m]
Le = length of engine [m]
Lb = Lb + 6 in x 25.4mm1∈¿¿ = 4,267 mm + 6 in x
25.4mm1∈¿=¿¿5,047.4 mm
Lf = 4,419.4 mm + (0.10)(4,419.4 mm) = 4,861.34 mm
Lf = 4,861.34 mm x 1m1000m
= 4.86 = 5 m
Width of the Foundation
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Wf = Wb + 10%Wb
Where:
Wb = Width of bedplate
We = width of the engine [m]
Wb = Wb + 6 in x 25.4mm1∈¿¿ = 2, 083 mm + 6 in x
25.4mm1∈¿¿ = 2, 235.4 mm
Wb = 2,235.4 mm + (0.10)(2,235.4 mm) = 2,458.94 mm
Wf = 2,458.94 mm x 1m
1000mm = 2.46 m = 2.5 m
h = 15.32m3
5mx2.5m = 1.22 = 1.25 m
Soil Stress
Soil Stress = Wf +Wbwf x lf
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Soil Stress = 36,859.21 kg+7,897kg
(5m)(2.5m) = 3,580.50 kg/m2
Foundation Materials:
Concrete Mixture Ratio = 1 : 3 : 5
X + 3x + 5x = 15.32 m3
9x = 15.32 m3
X = 15.32 m3 / 9
X = 1.70 m3
Absolute Volume Material = Specific Weight of Material / (Bulk S.G.)(Sp. Weight of
Water)
For Cement:
1 x 6.2 x 1.70 m3 = 10.54 m3
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Absolute Volume Material = 94
lbbag
(1)
(3.15)(62.4 lb / ft3) = 0.48 ft3/bag x
1m3
(3.28 ft)3= 0.014 m3/bag
No. of bags = 10.54m3
0.014m3/bag = 753 bags
3 x 0.52 x 1.70 m3 = 2.65 m3
Absolute Volume Material = 110
lbbag
(3)
(2.64)(62.4 lb / ft3) = 2 ft3/bag x
1m3
(3.28 ft)3= 0.057 m3/bag
For Gravel:
5 x 0.86 x 1.70m3 = 7.31m3
Absolute Volume Material = 96
lbbag
(5)
(2.66)(62.4 lb / ft3) = 2.89 ft3/bag x
1m3
(3.28 ft)3= 0.082 m3/bag
No. of Bags = 7.31m3
0.082m3/bag=¿89 bags
For Reinforcing Bar:
Using 14 mm diam. Rebars
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WRB = 1%Wf = (0.01)(36.859.21 kg) = 368.59 kg
Weight of Rebar/pc = density of steel x VRB
Weight of Rebar/pc – 7800 kg/m3 x (π/4)(14 mm/1000m)2 (6.1m) – 29.3 kg
No. of Reinforcing Bars = W eig h t of RebarWeigh t of Rebar / pc =
368.59kg29.5kg
=¿12.58 = 13 pcs
Flexure formula
Fb = mxl
Eccentricity from mid-base
Y1 = 1/2h = ½ (1.25m) = 0.625m
Y2 = 1/3h = 1/3 (1.25m) = 0.42m
A1 = Lf = h = (5m) (1.25m) = 6.25m2
A2 = ½ Lf x b
Where:
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B = 2(We+Wf )
50,000kg/m3(Lf ) = 2(7,897kg+36,859.21kg )
(50,000kg /m3)(5m) = 0.36m
If b < Wf, then Wf = b; used b = Wf = 2.5 m
A2 = ½ Lf x b = ½ (5m)(2.5m) = 6.25m2
∑A = A1 + A2 = (6.25 + 6.25) m2 = 12.5m2
∑AY = A1Y1 = A2Y2 = [(6.25) (0.625) + (6.25) (0.42)] m3 = 6.53 m3
C = ∑AY∑ A
= 6.53m3
12.5m2 = 0.52 m
For Bolts:
Diameter = 1/8 x (bore) = 1/8 x (150mm) = 18.75 mm
Length = 7/8 x (stroke) = 7/8 x (160mm) = 140 mm
Use L = 30D (from ASME code)
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L = 30 (18.75 mm) = 562.5 mm
No. of bolts = m
Tbolts
Where:
Tbolts = SdπD3
16
From Table AT 7 – DME by V.M. Faires
Material: AISI 8630 (for connecting rods, bolts, shapes)
Sy = 100ksi = 100,000psi; Fy = 7 (max. for Shock)
Sy = 0.5(100,000)
7 = 7,142.86 psi x
101.325 kpa14.7 psi
= 49,234.69 kpa
Tbolts = (49,234.69kn/m3)(π )(0.01875m)3(1000N
1KN)
16 = 20.28 N.m
No. of Bolts = 1,368.81kg−mx 9.81N
1kg20.28N .m
= 662.13 = 663 bolts
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Design for Fuel Tank
For 800 kW Generator Set (Per Unit 1, 2, 3, 4, and 5)
Type of oil: Diesel Fuel Oil
Specific Gravity = 0.917 @ 600F
(From Power Plant Theory and design by P.J. Potter, Table 5-4, and p.186)
SGf = ρf
ρH 20 ; ρf = SGf x ρH 20 = 0.917 x
1000kg
m3 = 917 kg/m3
Generator Output (EP) = Fuel Consumption
BP
Where:
BP = BPηa
ηg = 97.8% (For 1800 rpm & 494.73 kW Ave. Load)
(From Power Plant Theory and Design by P.J. Potter, figure 9-27, p.445)
BP = 800kW0.978
= 818 kW
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Specific Fuel Consumption
= 224.5L /hr x 1m3
1000 Lx 917kg /m3
818kW = 0.25 kg / kW hr
Plant Operation = 24 hrs/day
Engine Operation Hrs/Day = 18 hrs/day
Expected Fuel Delivery Schedule = Every 15 days
% Rated Capacity
= OperatingHours /day
24hrs x 100% =
18hrs24hrs
x 100% = 75%
From PPE by F.T. Morse, Fig. 6-15, p.164
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Max. Fuel Consumption = 0.25 kg/kW-hr
Min. Fuel Consumption = 0.21 kg/kW-hr
Volume of Day Tank
VDT = mFρF
Where:
mF = daily fuel consumption [kg/day], ρF = density of fuel = 917 kg/m3
mF = max. fuel consumption x BP x engine operating hrs/day
= (0.25 kg/kW-hr) (181kW) (18hrs/day)
= 3681 kg/day VDT = 3,681kg/day917 kg/m3
=¿4.01 m3/day
Dimension of Day Tank
VDT = π4
DDT2 H
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DDT - 3√ 2VDTπ (From the above equation) - 3√ 2(4.01m3)π
= 1.37m
Assume:
HDT = 2DDT = 2(1.37m) = 2.74m
Thickness of fuel Tank
TDT = PT xD DT
2xSYFSY
x n
Where:
PT = Pressure inside tank = HDT x YFuel
YFuel = 8.996 kN/m3
PT = 2.74m x 8.996 kN/m3 = 24.65 kN/m3 or kPa
Sy = Tensile Yield = 35,000 psi (from DME by V.M. Faires, Table AT 4, p. 568)
F.S.y = Design factor of Safety
F.S.y = 3(for stainless steel from DME by V.M. Faires Table 1.1, p.20)
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N = 75%
TDT = 24.65kPax 1.37mx
14.7 psi101.325kPa
2 x35,000 psi
3x0.75
= 0.3 mm; use 1 mm thickness
Storage Tank for 30 days operation
VST = VDT = x 30 days/month = 4.01 m3/day x 30 days/month = 120.3 m3/month
Dimension of storage tank
VST = π4
DST2 H
DST = 3√ 2VSTπ (From the above equation) - 3√ 2(120.3m3)π = 4.25m
Assume:
HST = 2DST = 2(4.25 m) = 8.5m
Material for fuel tank: AISI No. 321 (Stainless steel)
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Thickness of fuel storage tank
TST = PT xDST
2xSYFSY
x n
Where:
PT = pressure inside tank = HST x YFuel
YFuel = 8.996 kN/m3
PT = 8.5m x 8.996 kN/m3 = 76.46 kN/m2 or kpa
SY = Tensile Yield = 48,000 psi (from DME by V.M. Faires, Table AT 7, p.576)
F.S.y = 2(for stainless steel from DME by V.M. Faires Table 1.1, p.20)
n = 75%
TST = 76.46kPa x4.25m x
14.7 psi101.325kPa
2 x48,000 psi
2x 0.75
= 1.31 mm
Transfer Pump from Fuel Storage Pump to Day tank
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Assumption:
Desired operating time for fuel pump = 1 hr/day
ηP = 72%
Power input for unit 1, 2, 3, 4, and 5
EPi = QYfuelTDH
ηp
Where:
EPi = electrical power input [kW] or [hp]
Yfuel = 8.996 kN/m3
THD = total dynamic head [m]
TDH = Z2 – Z1 + P2−P1Yfuel
+ V 22−V 12
2g
TDH = (2.74)-(-8.5)m = 11.24 m
Q = volume flow rate [m3/s]
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Q --VDTt
Where:
VDT = volume of fuel at day tank [m3/s]
t = time of pump operation [sec]
Q --4.01m3/day1hrday
x 3600hrs=¿
0.00111 m3/s
EPi = (0.00111m3 /s)(8.996 kN /m 3)(11.24m)
0.72 = 0.16 kW x
1hp0.746kW
= 0.21 hp
1 hp is used for unit 1 transfer pump
VARIABLE LOAD CALCULATIONS
Plant Capacity = Peak Load + Peak Load (20)
= 2357.16kW + 471.432 kW = 2828.592 kW
(we use 3200kW from catalog 800kW x 4 genset)
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin40
Reserve over peak = plant capacity – peak load
= (3200kW – 2357.16kW) = 842.84kW
Average Load = Total load (kW−hrs )
dayNo .of hours day
= 25449.08kW−hrs /day
24 hrsday = 1060.378333kW
Capacity Factory - Average LoadPlant Capacity
- 1060.378333kW
3200kW = 33.14%
Annual capacity factor = Annual kW−hrs
kW Plant capacity x 8760 = 9,288,914kW−hrs year
3200 kW x8760 = 33.14%
Load Factor - Avegare LoadPeak Load
- 1060.378333kW2357.16kW
– 44.99%
Demand Factor – Peak load
Plant capacity - 2357.16kW3200kW
– 73.66%
Plant Factor = Average Load
Rating Equipment Supplying t he load =
1060.378333 kW32000kW (catalog) = 33.14%
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin41
ENGINE APPLICATION DATA
Engine Specifications
Manufacturer Mitsubishi
Engine Model # S12A2 – Y2PTAW-2
Engine Type 4 Cycle, 12 Cylinder
Induction System Turbochanged, Inter Cooler
Displacement, L (in3) 33.9 (2071)
EPA Emission Level Tier 2
HP at Rated Speed BHP (KW) 1207 (900)
Rated RPM 1800
Bore and Stroke in (mm) 5.19 x 6.30 (150 x 160)
Compressor Ratio 15.3:1
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin42
Air Filter Type Dry
Govermor Type/Model Proact2
Govermor Manufacturer Woodward
Freq Reg NL to FL Isochronous
Freq Reg Steady State +/- 0.25%
Engine Lubrication System
Oil Pan Capacity gal (L) 26.4 (100.0)
Oil Pan w/ Filter 31.7 (120.0)
Oil Filter Quantity 4
Oil Cooler Water Cooled
Recommended Oil 15W – 40
Oil Press Psi (kPa) 57 (393)
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin43
Engine Cooling System
Genset Max Ambient Temperature 113 (45)
Engine Coolant Cap qt (L) 105.7 (100.0)
Engine + Radiant System Cap qt (L) 402.0 (380.4)
Water Pump Type Centrifugal
Coolant Flow gpm (Lpm) 291 (1101.4)
Charge Cooler Flow gpm (Lpm) 124 (469.3)
Heat Rejected to Cooling Water
@ Rated kW: BTU/min (kW) 20418 (358.9)
Heat Rejected to Charge Cooler
@ Rated kW: BTU/min (kW) 16043 (282.0)
Heat Rejected to Ambient Air
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin44
@ Rated kW: BTU/min (kW) 4375 (76.9)
Max. Restriction of Cooling Air in
H20 (kPa) 0.5 (0.124)
Engine Exhaust System
Exhaust Manifold Type Dry
Exhaust flow @ Rated kW cfm (c-mm) 8192 (232)
Exhaust Temp. (Dry manifold) 0F (0C) 953 (497)
Max. Back Pressure InH20 (kPa) 23.6 (5.9)
Exhaust Outlet Diameter in (mm) 8.35 (212)
Exhaust Outlet Type JIS200A (approx. 8”)
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin45
Engine Electrical System
Changing Alternator Volts dc 24
Changing Alternator Amps 25
Grounding Polarity Negative
Started Motor Volts dc 24
Battery Recommendations
Battery Volts dc 24
Min Cold Cranking Amps 1100
Quantity Required 2
Ventilation Requirements
Cooling Airflow scfm (cmm) 40042 (1134)
Combustion Airflow cfm (cmm) 3107 (88)
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin46
Heat Rejected to Ambient
From Engine BTU/min (kW) 4375 (77)
From Alternator BTU/min (kW) 2275 (40)
Recommended Free Area Intake
Louver Size ft2 (m2) 87.0 (8.09)
Engine Fuel System
Recommended Fuel # 2 Diesel
Fuel Line at Engine
Supply Line Min ID in (mm) 0.75 (19)
Return Line Min ID in (mm) 0.75 (19)
Fuel Pump type Engine Driven
Fuel Pump Max Lift ft (m) 3 (1)
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin47
Fuel Flow to Pump gpm (Lph) 148 (560.2)
Fuel Filter
Secondary Filter 2 µm
Secondary Water Separator Not Included
Primary Filter Optional
Primary Water Separator Optional
Fuel Consumption – Standby Rating
100% Load gph (Lph) 65.2 (246.5)
75% Load gph (Lph) 46.8 (177.1)
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin48
50% Load gph (Lph) 32.2 (121.9)
25% Load gph (Lph) 19.3 (73.1)
Fuel Consumption – Prime Rating
100% Load gph (Lph) 59.3 (224.5)
75% Load gph (Lph) 42.6 (161.2)
50% Load gph (Lph) 29.3 (110.9)
25% Load gph (Lph) 17.6 (66.6)
Engine Output Deratings – Standby
Rated Temp 400C
Rated Altitude 1500 m
Max Altitude 5000 m
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin49
Temperature Derate -5% / 100C
Altitude Derate -1% / 100 m
Alternator Specifications
Alternator Type 4-Pole Rotating Field
Exciter Type Brushless
Excitation PMG
Insulation per NEMA MG1
Material Class H
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin50
Standby Temp Rise 150 0C
Prime Temp Rise 125 0C
Lead Connection 12 Lead, Reconnect able
Stator Pitch 2/3
Amortisseur Winding Full
Bearing Single Double Shielded
Drive Coupling Flexible Disk
Unbalance Load 20% of Standby Rating
Automatic Voltage Regulator
PMG Std MX321
Voltage Regulation No Load to Full Load
PMG Regulator +/- 0.5%
Load Acceptance 100% of Rating
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin51
Subtransient Reactance
480V, Per Unit 18%
TIF (1960 Weighting) <50
Line Harmonics 30% Max. Voltage Dip
Alt @ 480V SkVA HC1634G – 311 – 2350
Alt @ 480V SkVA HC1634H – 311 – 2680
Genset Controller Specifications
Baldor Intelligent NT Features
Large back-lit graphical LCD display
64 x 128 pixel resolution
Sealed Membrane Panel to IP65
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin52
Push Buttons for Simple Control
Start, Stop, Fault Reset, Horn Reset, Mode
Page, and Enter Keys
Display Metering and Protection
Oil Pressure Warning / Shutdown
High / Low Coolant Temperature Warning
High Coolant Temperature Shutdown
Low Coolant Level Shutdown
Low Fuel Level Warning / Shut Warning
Over Speed Protection
Battery Voltage Under / Over Warning
Running Hour Meter
Generator Under / Over Volts Warn / Shutdown
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin53
Generator Under / Over Freq Warn / Shutdown
Generator over Current Shutdown
Generator Output Metering for V1, V3, I1 – I3,
Hz, kW, kWh, kVAr, kWAh
User Configurable Inputs and Output
Up to 500 Event Based History Records
Integrated PLC Programming Functions
Interface to Remote Display or
Remote Annunciator
Controller Capable of Both Single or Multiple
Gensets Operating in standby or
Parallel Modes
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin54
Addition Standard Genset Features
Structural Steel Sub-Base
Sub-Base Lifting Eyes
Unit Mounted Radiator
Engine Mounted Fan
Fan Guard
Battery Changing Alternator
Battery Rack and Cables
Unit Mounted Control Panel
Spin-On Filters for Oil and Fuel
Enamel Set-Operator / Maintenance Manual
Factory Tested Prior to Shipment
Limited Warranty
Optional Agency Approvals
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin55
UL2200 (Review Option Availability)
NFPA110 (Request Remote Annuciator)
Weight and Dimensions (Open Unit)
Weight – Wet lb(Kg) 17410 (7897)
Overall Dimension Length x Width x Height
Inches 168 x 82 x 93
mm 4267 x 2083 x 2362
Note: Drawing is provided for reference only. Use engineering outline for installation
planning.
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin56
PERSPECTIVE VIEW
Power Plant Design / MEP544D2
Equipment
Quantit
y
800 kW Diesel Genset
(IDLC 800-2M)
5
Fuel Transfer Pump 1hp 5
Cooling Tower Pump
0.11hp
10
Cooling Water Fan
0.27hp
10
Materials Quantity
Cement 3675
Gravel 435
Anchor Bolts 1/8 x 7/8 3315
Renforcing Bars 14mm
x 20 ft
65
Aluminum Brass Tude
3/4 in
120
Power Plant Design for Sagay, Camiguin57
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin58
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin59
ECONOMICS
Design of fuel storage tank assumes that diesel to be used is 30ºAPI with a temperature
of 26.67ºC.
SG = ρfuelρwater
SG@ 15.6 0C = 141.5
30+131.5 = 0.8761
SG@ 26.6 0C = [(0.8761) (1- 0.00072) (26.67-15.6)]
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin60
SG @ 26.6 = 0.86911
ρfuel = (0.86911) (62.4) lb/ft3
ρfuel = 54.23 lb/ft3
HHV = 41, 130 + 139.6 (300API)
Qh = HHV = 45318 kJ/kg = 47.65 kw – hr/gal
QL = LHV =27.39 kw – hr/gal
Ave. = 47.65+27.39
2 = 10.13
Daily fuel consumption = 61,50010.13
= 6071.07 gal/day
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin61
Storage tank for 1 month
= Daily Consumption x 30 Days/month
= 6071.07 x Days/month
= 182132.28 gal/month
Monthly fuel delivery
Fuel delivery in liter
1 gal = 3.7854 liter
Capacity of trailer truck = 72, 000 liters
One month = (182132.28 gal /mont h)(3.7854)
72000 = 10 tank per month
ECONOMIC STUDIES
Capacity Factor = 52.08
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin62
Ave. Load of Power Plant = 125000 kw –hr
Monthly fuel consumption = 182132.28 gal/month
Semi – fuel consumption = 182132.28
2 = 91066.14
Assuming the diesel fuel is supplied by the government at a whole sale price @ .75
per/gal cost of fuel per year
= 182132.28 gal/month x 20 month x .75
= Php 1639190.52
POWER PLANT ECONOMICS
Power Plant Cost:
Cost per Kw installed Php = 500.00
Cost per unit 2000 Kw x 500.00 Php = 1,000,000
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin63
Total Cost per unit installed 5 x 500,000 Php = 2,500,000
Building Php = 400,000
Real State Php = 180,000
Equipment Php = 150,000
Engineering Fees Php = 70,000
Total Plant Cost Php = 3,300,000
Cost of Transmission Lines:
Primary line Php = 140,000
Secondary line Php = 800,000
The annual costs of Operation are as follows:
Francise and Publicity Php = 2.4 customer
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin64
Assuming 25, 000 customer Php = 60,000
Supervision and management Php = 30,000
Maintenance and repair Php = 10, 000
Oil waste and supply Php = 20,000
Fuel used Php = 2617.48
Maintenance in secondary lines Php = 70,000
Labor:
For Generation Php = 80,000
For Distribution Primary Php = 20,000
For Distribution secondary line Php = 20,000
For accounting Php = 60,000
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin65
Interest Rate = 6% Taxes. 5% insurance
Life = 50 years
Primary distribution = 20 years
Secondary distribution = 20 years
Salvage Value:
Power Plant = 10% of the first cost
Primary line = 20% of the first cost
Secondary = 20% of the first cost
Fixed element annual cost:
Capital cost - cost of the PLANT - Cost of the Primary line
- 2,470,000 – 70,000
- 2,540,00
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin66
Primary Salvage Value:
- 20% of the primary line
- .20 x 70,000
- Php 14, 000
From Equation (3-1) p. 71, PPE by F.T. Morse
Straight line annual depreciation reserve
= F−Sn
Where:
P – The principal sum
S – The final salvage value
N – Terms in years
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin67
Plant annual Depreciation Reserve:
= 2 ,470,000−247 ,000
50 years
Primary Line annual appreciation reserve
= 140,000−28,000
20 years = Php 5,600
Interest – taxes and insurance of the capital cost:
= (0.06 + 0.05) x 3,300,000 = 363,000
Plant maintenance and repair Php = 10,000
Supervision and management Php = 30,000
Plant Depreciation Php = 88,800
Primary line depreciation Php = 5,600
Total = Php 677,920
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin68
Energy Element:
Oil waste supply Php = 20,000
Labor for generation Php = 80,000
Maintenance on primary lines Php = 10,000
Labor on distribution Php = 20,000
Fuel consumption Php = 2617488
Total = Php 2,746,954
Customer Element:
Secondary line Salvage value:
= 20% of secondary line first cost
= .20 x 800,000 = Php 160,000
Secondary line annual depreciation reserve:
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin69
= 800,000−160,000
20 = 32,000
Interest, Taxes and Insurance of Secondary Line
= (0.06 + 0.05) + 800,000 = Php = 88,000
Publicity and franchine Php = 70,000
Labor for accounting Php = 60,000
Secondary line depreciation Php = 18,000
Total = Php 236,000
A) Cost per kW installed
= cost of plant+ primary line+secondary line
Kwinstalled =
= 3,300,000+140,000+800,000
5000 = Php 848 kW
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin70
B) Cost per kW – hr produced:
= ¿element−energy elementannual stationoutput
= 677920−2746954
1500kw−hrday
x30daymont h
x12mont hyear
= 0.09 cents kW –hr produced
C) Cost per kW – hr delivered:
= FE−EE−¿
( I−elec .transmission loss)(annual kw−hr output )
Allow 20% Elec. Transmission loss
= 22747954−677920−236000
(19)(22200 x103) = 0.05 cents kW-hr
Investors Profit:
Assume annual profit of capitalization over and store interest to be 8.0%
Capitalization = cost of the plant, primary and secondary distribution system
= 3,300,000 + 140,000 + 800,000
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin71
= 4,240,000 x .08 = Php 339,200
Straight Line Meter Rate:
Assuming the various element lost
Fixed element Php = 677920
Energy Php = 2,746,954
Customer element Php = 236,000
Profit Php = 339,200
Total = Php 4,000,074
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin72
Rate = Cost of annual productionannual stand by output
= 4,000,07444,400,000
= 0.09 cents kW/hr
Three Charge Rate
For this, let the profit element be placed with fixed element and customer
element in proportion to the capital (element) investment for customer element.
= 3,300,000 + 140,000
= 3,440,000
Demand charge = fixed element + portion of profit
= 677920+25653165
x339200 = 952,816.68
Assume over all diversity factor 4.5
Peak power plant demand 5,000 kw
Customer peak demand 5,000 x .45 + 22, 500 kW
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin73
Unit demand change 952816.6822540
= 27.68 kW –
hr
Maximum demand per month = 27.6812
= 2.308 per month
Energy element was:
= 2747954 for 24750 kW – hr / year
Hence the unit energy charge = customer element + remainder of profit
= 236,000 + 800,003,300,000
x 33920
= Php 244223.03
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin74
Dividing equally between 25,000 customers
The result is 244223.0325,000
= 9.76
= 9.7612
= Php .814 / month
COMPUTATION FOR TRANSFORMERS
Establishment
Transformer # 1 – 30 Quantities Capacity Total Watts
Residential A 756 Houses 2477 Watts 1,872,612 w
Transformer # 31 – 40 Quantities Capacity Total Watts
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin75
Residential B 252 Houses 2478 Watts 624456 w
For Transformer # 1 – 40, Residential A and B to be Total of 2,497,068 Watts -
hours
Establishment
Transformer # 41 - 45 Quantities Capacity Total Watts
Commercial A 2 135,350 Watts 270,000 w
Transformer # 46 - 50 Quantities Capacity Total Watts
Commercial B 2 135,350 Watts 270,000 w
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin76
For Transformer # 41 – 50, Commercial A and B to be Total of 541,400 Watts -
hours
FEEDERS LOAD BETWEEN TRANSFORMERS
Feeder #1 (Transformer 1 -10)
Max. Feeder Load =162420.40x 10
1.3
Max. Feeder Load = 1249387.692 Watts = 1249.388 kW
Feeder #2 (Transformer 11 - 20)
Max. Feeder Load =162420.40x 10
1.3
Max. Feeder Load = 1249387.692 Watts = 1249.388 kW
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin77
Feeder #3 (Transformer 21 - 30)
Max. Feeder Load =162420.40x 10
1.3
Max. Feeder Load = 1249387.692 Watts = 1249.388 kW
Feeder #4 (Transformer 31 - 40)
Max. Feeder Load =65445.6 x10
1.3
Max. Feeder Load = 503427.692 Watts = 503.427 kW
Feeder #5 (Transformer 41 - 45)
Max. Feeder Load =27000x 101.3
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin78
Max. Feeder Load = 207692.308 Watts = 207.692 kW
Feeder #5 (Transformer 46 - 50)
Max. Feeder Load =27000x 101.3
Max. Feeder Load = 207692.308 Watts = 207.692 kW
SUBSTATION LOAD BETWEEN FEEDERS
Substation #1
Max. Feeder Load =1249387.692x 3
1.2
Max. Feeder Load = 3123469.23 Watts = 3123.469 kW
Power Plant Design / MEP544D2
Power Plant Design for Sagay, Camiguin79
Substation #2
Max. Feeder Load =503427.692+(207692.308 x2)
1.2
Max. Feeder Load = 765676.9233 Watts = 765.679 kW
POWER PLANT LOAD BETWEEN SUBSTATIONS
Max. Feeder Load =3123469.23+765676.9233
1.1
Max. Feeder Load = 3535587.412 Watts = 3535.587 kW
Power Plant Design / MEP544D2