Power Plant Design PART III

RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Location
Guinsiliban, Camiguin
Camiguin, the smallest province in Northern Mindanao (Region X), had a total population of
74,232 persons based on the results of the 2000 Census of Population and Housing. It was
the second to the smallest in the Philippines in terms of population. It registered an annual
growth rate of 1.88 percent from 1995 to 2000, higher than the 1.08 percent growth rate
during the 1990 to 1995 period. If the current rate continues, the population of Camiguin was
expected to double in 37 years.
The number of households rose to 14,826, higher by 1,352 households from the 1995 figure.
The average household size was 5.0 persons (same as the national average), which was
lower than the 1995 average of 5.04 persons.
Of the five municipalities in Camiguin, its capital Mambajao, which comprised 42 percent of
the total provincial population, was the largest in terms of population size. Catarman,
Mahinog, and Sagay followed with 21 percent, 17 percent and 14 percent, respectively. Of the
total population, Guinsiliban had the least share (seven percent).
Camiguin had the least population in Northern Mindanao (Region X), contributing only 2.70
percent to the 2.7 million population of the region. At the national level, Camiguin shared 0.10
percent to the total Philippine population of 76.5 million as recorded in the Census 2000.
Of the total household population five years old and over, about two out of five persons had
attended or completed elementary education. Thirty one percent had either attended or
finished high school while 12 percent had attended college. Only four percent were academic
degree holders. More than half of those who had attended or finished elementary education
(53.1 percent) and post secondary (54.7 percent) were males. On the other hand, those who
had attended or finished college, academic degree holders and post baccalaureate were
predominantly females.
About 45 percent of the total population in Camiguin classified themselves as Cebuano.

Kamigin/Kinamiging followed with 36 percent and the Boholanos, with 11 percent. The
remaining three percent were either Binisaya or belonged to other ethnic groups.
There were 15,449 housing units in Camiguin, of which 14,735 were occupied. This registered
an increase of 23.3 percentage points from 1990, a ratio of 1.01 household per occupied
housing unit, and 5.03 persons per occupied housing unit. Almost all (98.6 percent) occupied
housing units were single houses, an increase of 22 percentage points from the 1990 figure.
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 structures on Guinsiliban and a household population of 1023.
Demographic Data:
Total No. of Population: 5,092
Household Population: 1023
Structures:
(Group A)
Single House: 1002
Duplex: 6
(Group B)
Multi-Unit Residential: 3
Commercial/Industrial/Agricultural: 1
Graphical Representation of Load
LoadPer Hour
2500
2000
W
k 1500
n
i
d
a
o Load Per Hour
L 1000
500
0
Load Table (GROUP A)
Load Table (GROUP B)

Total Power Consumption Table

25449.08kW-hr/day
Design Overview
Peak Load = 2357.16 kW, 2.35716mW

Plant Capacity: 3200 kW, 3.2mW
No. of Engines: 5
Engine Capacity Number of Hours of Operation/day

Unit 1 – 800 kW 18 hours/day
Unit 5 – 800 kW Reserve
Schedule of Engine Operation
Time of Engine Time

Operation Operating Interval
12AM - 6AM UNIT 1,2 & 3 6 hours

6AM -12NN UNIT 2,3 & 4 6 hours
12NN - 6PM UNIT 4,1 & 2 6 hours
6PM - 12AM UNIT 3,4 & 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:

Use 50-98 tones/m2 for compact clay (from PPE by F.T. Morse, Table 4-4 p.105)
Soil Bearing Pressure (Sb)
Weight of foundation
Where:
Wf = weight of the foundation, kgs
We = weight of the engine, kgs
e = empirical coefficient
n = engine speed, RPM
Use e = 0.11 (from PSME code, Table 2.4.2.3 (4), p.11)
Volume of foundation
Where:
Vf = volume of foundation [m3]
ρc = density of concrete = 2406 kg/m3
Depth of Foundation
Where:
hf = depth of foundation [m]
Lf = length of foundation [m]

wf = width of the foundation [m]
Length of the foundation:
Where:
Lb = length of bedplate [m]
Le = length of engine [m]
Width of the foundation:
Where:
wb = width of bedplate [m]
we = width of the engine [m]
Soil Stress
Soil Stress
Soil Stress
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
For cement:
1 x 6.2 x 1.70 m3 = 10.54 m3
For sand:
3 x 0.52 x 1.70 m3 = 2.65 m3
For gravel:
5 x 0.86 x 1.70 m3 = 7.31 m3
For Reinforcing Bar:

Using 14 mm diam. rebars
Flexure formula
Eccentricity from mid-base

Y1 = 1/2h = ½ (1.25m) = 0.625m
Y2 = 1/3h = 1/3(1.25m) = 0.42m
A1 = Lf x h = (5 m)(1.25 m) = 6.25 m2
A2 = ½ Lf x b
Where:
if b < wf, then wf = b; use b = wf = 2.5 m
A2 = ½ Lf x b = ½ (5 m)(2.5 m) = 6.25 m2
∑A = A1 + A2 = (6.25 + 6.25) m2 = 12.5 m2
∑AY = A1Y1 + A2Y2 = [(6.25)(0.625) + (6.25)(0.42)] m3 = 6.53 m3
m=
For Bolts:
Diameter = 1/8 x (bore) = 1/8 x (150mm) = 18.75 mm
Length = 7/8 x (stroke) = 7/8 x (160 mm) = 140 mm
Use L = 30D (from ASME code)
L = 30 (18.75 mm) = 562.5 mm
No. of bolts
Where:
Tbolts
From Table AT 7 – DME by V.M. Faires

Material: AISI 8630 (for connecting rods, bolts, shapes)
Sy = 100 ksi = 100, 000 psi; Fy = 7 (max. for shock)
Tbolts
No. of bolts
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 @ 60°F
(From Power Plant Theory and Design by P.J. Potter, Table 5-4, and p.187)
Generator Output (EP) = 800 kW
Specific Fuel Consumption
Where:
BP
(For 1800 rpm & 494.73 kW Ave. Load)

(From Power Plant Theory and Design by P.J. Potter, Figure 9-27, p.445)
BP
Specific Fuel Consumption
Plant Operation = 24 hrs/day

Engine Operating Hours/day = 18 hrs/day
Expected Fuel Delivery Schedule = every 15 days
% Rated Capacity
From PPE by F.T. Morse, Fig 6-15, p.164

Max. fuel consumption = 0.25 kg/kW-hr
Min. fuel consumption = 0.21 kg/kW-hr
Volume of Day Tank
Where:
mF = daily fuel consumption [kg/day]
ρF = density of fuel = 917 kg/m3
mF = max. fuel consumption x BP x engine operating hours/day

= (0.25 kg/kW-hr) (818 kW) (18 hrs/day)
= 3681 kg / day
Dimension of Day Tank
(From the above equation)
Assume:
HDT = 2DDT = 2 (1.37 m) = 2.74 m
Thickness of Fuel Day Tank
Where:
PT = pressure inside tank
Where:
γfuel = 8.996 kN/m3
PT = 2.74 m x 8.996 kN/m3 = 24.65 kN/m2 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)
n = 75%
Storage Tank for 30 days operation
Dimension of Storage Tank
(From the above equation)
Assume:
HST = 2DST = 2 (4.25 m) = 8.5 m
Material for Fuel Tank: AISI No. 321 (stainless steel)
Thickness of Fuel Storage Tank
Where:
PT = pressure inside tank
Where:
PT = 8.5 m 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 = Design factor of safety
F.S.y = 2 (for stainless steel from DME by V.M. Faires Table 1.1, p.20)
n = 75%
Transfer Pump from Fuel Storage Pump to Day Tank

Assumption:
Desired Operating Time for Fuel Pump = 1 hr/day
ηp = 72%
Power input for Unit 1, 2, 3, 4 and 5
Where:
EPi = electrical power input [kW] or [hp]
TDH = total dynamic head [m]
Q = volume flow rate [m3/s
Where:
VDT = volume of fuel at day tank [m3/s]
t = time of pump operation [sec]
= 0.00111 m3/s
1 hp is used for unit 1 transfer pump

Design for Heat Exchanger
For 800 kW Generator Set (Per Unit 1, 2, 3, 4 & 5)
Theoretical and Actual Limits of Cooling Water and Jacket Water

(From PPE by F.T. Morse, p.178)
tji = jacket water inlet temperature = 37.8 °C
tjo = jacket water outlet temperature = 65.6 °C
tcwi = cooling water inlet temperature = 32.2°C
tcwo = cooling water outlet temperature = 54.4 °C
LMTD
Δtmax = (65.6 – 54.4) °C = 11.2 °C

Δtmin = (37.8 – 32.2) °C = 5.6 °C
LMTD
Qj = mj x cpj x Δtj
Where:
Qj = heat rejected from jacket water = 358.9 kW (from catalog)
mj = mass of jacket water
Δtj = temp. Difference of jacket water= (65.6 – 37.8) °C = 27.8 °C
Cpj = 4.187 kJ / kg-K (for water)
Where:
A = surface area of heat exchanger
U = overall coefficient of heat transfer
LMTD = log mean temp. Difference
Solving for U (from PPT & D by P.J. Potter, Fig. 8-9, p.351 and p. 352)
Where:
= coefficient of heat transfer
Ft = temp. Correction factor
Fm = tube material and thickness correction factor
Fc = cleanliness factor
Fp = prime mover factor
Tube Specifications:
Material: Aluminum Brass 18 BWG ¾”
Water Velocity = 9 ft/s
Ft = 1.08
Fm = 0.96
Fc = 0.85
Fp = 1.0
C = 270
Where:
mcw = mj = 11,088 kg/hr

υ = specific volume of circulating water @ t
From steam table @ 51.7 °C (by interpolation)

υ = 1.01295 L/kg
From PPT & D by P.J. Potter, p. 357

“For each ¾” No. 18 BWG tube will pass 1.042 GPM/1 fps”
Where:
0.1963 ft2/lin. ft = outside surface area of ¾” tube (18 BWG)
(From PPT & D by P.J. Potter, Table 8-1, p.353)
Design for Cooling Tower

For 800 kW Generator (Per Unit 1, 2, 3, 4 and 5)
BP = 818 kW = 1,096.51 hp
Installation Data:
t2 = engine water into heat exchanger (in) = 65.6 °C
t1 = engine water into heat exchanger (out) = 37.8 °C

tb = cooling water to heat exchanger = 32.2 °C
ta = cooling water to heat exchanger = 48.9 °C (max. state of humidified air)
Make-up water = 15.6 °C ; 29.4 °C DB & 21.1 °C WB (@ atmospheric condition)
Using the formula (from PPE by F.T Morse, eq. 6-16, p. 178)
Where:
W = cooling water [1 / hr)
Bhp = rated brake horsepower
t1 & t2 = inlet & outlet water temperatures [°C]
Let ww = water flow in the cooling tower circuit
From PPE by F.T. Morse, p. 181

The theoretical maximum humidified state of the air leaving is 48.9 ° C at 100 % humidity.
Assume 5.5 °C differential and 90% RH
From Psychometric Chart @ 29.4 °C DB & 21.1 °C WB:

SH1 = 0.0123 kg
h1 = 79.088 kJ/kg
Using the formula (from PPE by F.T Morse, eq. 6-19 & 6-20, p. 182)
Where:
Td = dry bulb temperature [°C] = (48.9 – 5.5) °C = 43.4 °C
RH = percent relative humidity
Ps = saturation pressure of water vapor @ td
Pa = atmospheric pressure [kg/cm2]

hg = enthalpy at td, dry and saturated [J/kg]
From Steam Table @ 43.4 °C:

Ps = 0.0895 kg/cm2 (converted value)
Hg = 2,580,140 J/kg
Using the formula (from PPE by F.T Morse, eq. 6-17 & 6-18, p. 177)
Mass balance for cooling tower:
Heat balance for cooling tower
Ww = 1.7 kg water / kg dry air (from above equation)
From Psychometric Chart

Since υair @ 29.4 °C & 21.1 °C = 0.862 m3/kg
= 60 %
From PPE by F.T. Morse, p. 182

Recommended Type: Natural Draft Cooling Tower
Cooling Tower Pipe
; QCTP = mcw (υf @ 32.2 °C)
From Steam Table (by interpolation)

υf = 1.00506 L/kg = 0.0010506 m3/kg
Velocity of water @ HX = Velocity of water at cooling tower

9 ft/s = 2.74 m/s
Material Specification (from PSME code, p.200)

Size: 1 ½ in. Inside Dia.: 1.5 in Wall thickness: 0.2 in

Schedule: 80x Outside Dia.: 1.9 in
Cooling Tower Pump

PCT = (QCTP)(γwater)(TDH)
Assume z = 2 m ; TDH = 2 m
PCT = (0.00324 m3/s)(9.807 kN/m3)(2 m) = 0.064 kW = 0.085 hp
Assume ηp = 75 %
Fan Power of Cooling Tower
Fan Capacity
QA = mAυA
Where:
mA = mass of air = 1.59 kg/s
υA = specific vol. of air
ρA = density of air @ standard condition = 1.2 kg/m3
Cooling Tower Floor Area

Concentration of Water = 80 L/min-m2
Variable Load Calculations
(We use 3200kW from catalog 800kw X 4 genset)


Catalogue


Perspective View


Side View
Top View
List of Materials
Materials Quantity
Cement 3675
Gravel 435
Anchor Bolts 1/8 x 7/8 3315
Renforcing Bars 14mm x 20ft 65
Aluminum Brass Tube 3/4" 120
List of Equipments
Equipment Quantity
800kW Diesel Genset (IDLC 800-
2M) 5
Fuel Transfer Pump 1hp 5
Cooling Tower Pump 0.11hp 10
Cooling Water Fan 0.27hp 10
Heat Exchanger

Cooling Tower
Fuel Tank
Machine Foundation
Rizal Technological University

Boni Ave., Mandaluyong City

Mechanical Engineering Department
In partial fulfillment
Of the course requirements on
ME 54L - Power Plant Design Lab
Submitted by:
Submitted to:
Engr. Gerry Cabrera
Submitted on:
March 14, 2011

Power Plant Design PART III

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Power Plant Design PART III

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RIZAL TECHNOLOGICAL UNIVERSITY

College of Engineering and Industrial Technology

About 45 percent of the total population in Camiguin classified themselves as Cebuano.

College of Engineering and Industrial Technology

College of Engineering and Industrial Technology

Graphical Representation of Load

College of Engineering and Industrial Technology

Load Table (GROUP A)

Load Table (GROUP B)

College of Engineering and Industrial Technology

Total Power Consumption Table

Peak Load = 2357.16 kW, 2.35716mW

College of Engineering and Industrial Technology

Engine Capacity Number of Hours of Operation/day

Schedule of Engine Operation

Time of Engine Time

12AM - 6AM UNIT 1,2 & 3 6 hours

Each Unit has a 6 straight hours break.

Design for Machine Foundation

Mixture for Concrete Foundation:

College of Engineering and Industrial Technology

Soil Bearing Pressure:

Soil Bearing Pressure (Sb)

College of Engineering and Industrial Technology

Lf = length of foundation [m]

Length of the foundation:

Width of the foundation:

College of Engineering and Industrial Technology

College of Engineering and Industrial Technology

3 x 0.52 x 1.70 m3 = 2.65 m3

For Reinforcing Bar:

College of Engineering and Industrial Technology

Eccentricity from mid-base

if b < wf, then wf = b; use b = wf = 2.5 m

College of Engineering and Industrial Technology

From Table AT 7 – DME by V.M. Faires

College of Engineering and Industrial Technology

Design for Fuel Tank

Type of Oil: Diesel Fuel Oil

Generator Output (EP) = 800 kW

Specific Fuel Consumption

(For 1800 rpm & 494.73 kW Ave. Load)

Specific Fuel Consumption

Plant Operation = 24 hrs/day

College of Engineering and Industrial Technology

From PPE by F.T. Morse, Fig 6-15, p.164

mF = max. fuel consumption x BP x engine operating hours/day

Dimension of Day Tank

(From the above equation)

Thickness of Fuel Day Tank

College of Engineering and Industrial Technology

Storage Tank for 30 days operation

Dimension of Storage Tank

(From the above equation)

College of Engineering and Industrial Technology

Transfer Pump from Fuel Storage Pump to Day Tank

Power input for Unit 1, 2, 3, 4 and 5

Q = volume flow rate [m3/s

College of Engineering and Industrial Technology

1 hp is used for unit 1 transfer pump

Theoretical and Actual Limits of Cooling Water and Jacket Water

Δtmax = (65.6 – 54.4) °C = 11.2 °C

College of Engineering and Industrial Technology