CHAPTER I

INTRODUCTION

In this introductory chapter, the rationale of the design, existing diesel

power plants in the Philippines, construction of the power plant, current energy

situation in the country, current load demand in the Philippines, target location,

available fuel resource, target customers, load demands for target customers,

and load projection s for the next ten years will be discussed.

Rationale of the Design

In this modern world the demand for electricity is higher than ever. There

is no doubt that the most important invention is electricity, which people depend

on in the current modern time.

The generation of the most flexible, economical and useful energy-

electricity is dependent on electrical power generating stations. A power plant

makes electricity out of the several energy sources like coal, oil or natural gas,

uranium, water, sun’s heat, wind and several other sources. This power

generating industry, often called electrical power plant, is an assemblage of

equipment that produces mechanical energy, converts into electrical energy and

delivers to the consumer.

1
 Upon receiving the assigned plant design task for Diesel Power Plant, the

group made several discussions wherein numerous ideas came up. Thus, the 20

MW Diesel Power Plant which aims the production of electricity for residential

remote area comes up into the picture.

A generating station in which diesel engine is used as the prime mover for

the generation of electrical energy is known as diesel power station. In a diesel

power station, diesel engine is used as the prime mover. The fuel mixture and air

is used as a working medium. During the time of the suction stroke atmospheric

air enters the combustion chamber. With the help of the injection pump fuel is

injected in to the chamber. Inside the engine the air and the fuel is mixed and the

charge must be ignited because of the compression present inside the cylinder.

The main principle observed in the diesel engine is the thermal energy it must be

converted in to the mechanical energy and further the mechanical energy must

be converted in to the electrical energy. The main purpose is to develop

electricity with the help of the alternator or generator. 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 favor 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.

2
 Though diesel power station can only be used to produce small amount of

power, the number of diesel power plant industry in the Philippines is still

increasing due to many advantages. Among these include: (a) the design and

layout of the plant are quite simple; (b) it occupies less space as the number and

size of the auxiliaries is small; (c) it can be located at any place; (d) it can be

started quickly and it can pick-up load in a short time;(e) there are no standby

losses; (f) it requires less quantity of water for cooling; (g) the overall cost is

much less than that of steam power station of same capacity; (h) the thermal

efficiency of the plant is higher than that of a steam power station; and (i) it

requires less operating staff.

The existence of the world’s industrialization today is generally

accompanied by great demand. There is no doubt that the earth’s future will

depend merely on energy generating plants to satisfy the increasing demand for

domestic, commercial and industrial consumption. The growth of population,

economical success and many other factors affect the demand of electricity. It is

gradually increasing as time passes and sufficient supply of energy conforms to

the substation capacity to meet the growing demand from time to time.

Existing Diesel Power Plants in the Philippines

In the Philippines, several diesel power plants have been established,

among these are the following:

3
 The Panay diesel power plant facility consists of the 36.5-MW Panay 1

Diesel Power Plant and the 110-MW Panay 3 diesel power plant. Panay 1 was

commissioned in 1979, while Panay 3, which is also known as the Pinamucan

diesel power plant, was relocated from its Batangas site after the expiration of

the BOT (build-operate-transfer) contract with Enron Power Development Corp.

in 2003. The plant was transferred to its present location to prevent a potential

near-term power shortage and to provide voltage stabilization in the island of

Panay.

The Panay 1 and 3 diesel plants are the only land-based facilities of

Napocor in the island. They are peaking plants that provide ancillary services

such as backup power, load following, system frequency, and voltage regulation.

The Bohol diesel power plant, Napocor’s first diesel plant in the Island,

was originally constructed together with the 1.2-MW Loboc hydro plant to provide

electricity to nearby towns. Consisting of four 5.5-MW identical generating units,

the Bohol facility continues to operate as a peaking and voltage-regulating plant.

Cebu Private Power Corporation (CPPC) owns and operates the 70-MW

Bunker C-fired power plant in Cebu. CPPC is one of the largest diesel power

plants in the island of Cebu. Commissioned in 1998, the CPPC plant was

constructed under a build-operate-transfer contract to supply 66 MW of power to

Visayan Electric Company, Inc. (VECO), an AboitizPower subsidiary. Currently,

CPPC has 66 mw of net sellable capacity, and is 60% owned by AboitizPower..

4
 Cabanatuan Electric Corporation was originally established as

SamahangMagsasaka, Inc. (SMI) in 1910 to put an end to the monopoly of the

palay threshing business in the town of Cabanatuan. It was a civic-minded

business organization composed of 96 members with a start-up capital of P

10,000.00.

The Western Mindanao Power Corporation operates a 100 MW diesel-

fired plant in Sangali, Zamboanga City that commenced operating in 1997.

WMPC supplies power to the Mindanao grid under an 18-year Energy

Conversion Agreement (ECA) with the National Power Corporation (NPC).

The Bauang Diesel Power Plant formerly owned by the Bauang Private

Power Corporation (BPPC) is a diesel-fired power plant which commenced

operations in July 1995 with a 215 MW-capacity. State-owned National Power

Corporation and the First Private Power Corp.

One Subic Power Generation Corporation operates a 116-megawatt

diesel power plant in Subic Bay Freeport Zone. The company is based in Subic,

the Philippines. As of May 12, 2014, One Subic Power Generation Corporation

operates as a subsidiary of Trans-Asia Power Generation Corporation.

Construction of the Power Plant

The proposed diesel power plant will have a total land area of two (2)

hectares. This would include: power house, jetty, cooling tower, pump house,

5
piping installation, tank farm, warehouse, storage room, switch gear room,

canteen, clinic, machine shop, HSSE office, admin building, guard house,

internal switch gear room, control room, and parking area. There will be a vacant

space in power house readily available in case of expansion. Contractors will be

hired for the construction of the building and an allotted amount of Php

34,784,533.33 will be used for this project.

Current Energy Situation in the Country

The Philippines is an emerging economy and its economy has greatly

shifted from agriculture to industry. In terms of energy use, conventional fossil

fuels (oil and gas) are the main source for its primary energy demands.

According to National Grid Corporation of the Philippines, the country’s total

installed capacity remained dominated by coal at 35% or 7,568 MW, followed by

renewable energy at 32% or 7,038 MW, oil-based at 17% or 3,584 MW, and

natural gas at 16% or 3,431 MW. In terms of power generation, coal remained

the major source of electricity for Luzon, Visayas, and Mindanao with a combined

share at 49% or 21,707 MWh. Newly operational plants from January-June 2017

are mainly coal and solar power plants which added 150 MW and 78 MW to the

total installed capacity. Capacities which will be coming in the pipeline are largely

coal power projects with 4,465 MW committed and 9,903 MW indicative

capacities.

6
Current Load Demand in the Philippines

According to the National Grid Corporation of the Philippines (NGCP), the

peak demand forecast for 2018 may exceed 2017 figures. On their forecast for

the Luzon grid, the peak demand would increase by 5.04 percent, compared with

that in 2017 or a total of 10,561 MW. Peak demand for the Visayas grid is

expected to go up by 8.51 oercent or a total of 2,143 MW, and the Mindanao grid

is expected to peak at 2,064 or an increase of 17.27 percent. Below is the figure

of the peak demand of year 2017.

Figure 1.1 Peak Demand in the Philippines, 2017

7
Target Location

The 20 Megawatt Diesel Power Plant will be located at Dela Paz Proper,

Batangas City because it is one of the remotest barrio of the municipality of

Batangas. It is located along the coast. Its nearest barangays are Dela Paz Pulot,

Dela Paz Aplaya and Lobo Batangas. The people from this barangays including

the people of Dela Paz Proper will be the target consumers of this design.

Because these barangays are located in a remote area the power generation and

transmission cost is high. With the vision of responding to the increasing cost of

the electricity in this community, the designers are proposing a Diesel Power

Plant for this community.

Figure 1.2.Dela Paz Topographic Map

8
 Figure 1.3 Target Plant Location

The best land for the installation of the Diesel Power Plant is clear, dry,

relatively flat and has good soil. For these reasons, “tillable” land is often an

excellent candidate to host a power plant. It was also found out that the cost of

land in this area is less costly, making it more likely to be constructed with a

power plant. Besides, the target location is near the coastal area where fuel oil

will be transported by ship and will be delivered at the plant’s jetty.

Available Fuel Resource

It is known that the use of diesel fuel has several environmental impacts.

In this design, the group decided to use B20 diesel fuel, a blend of 20% biodiesel

with 80% diesel fuel in accordance to Republic Act 9367, also known as

Philippines Biofuels Act of 2006. In more than 30 million miles of in-field

demonstrations, B20 has produced similar fuel consumption, horsepower, torque

and haulage rates as conventional diesel fuel. Biodiesel also has a superior

lubricity, which helps prevent engine wear, plus it has a higher cetane number

than U.S. diesel fuel, which classifies B20 as a premium grade fuel.

9
 For this design, the power plant will get its supply of fuel from Shell

Tabangao Batangas Refinery. In case of fuel shortage or lack of supply, the

power plant will get its supply of fuel from other nearby refineries such as Caltex

(Chevron) Batangas Refinery, Phoenix Petroleum Philippines, Inc., and

Philippine National Oil Corporation.

Target Customers

The cost of electricity in Batangas is high which amounts to P9.2587/kwh.

Through the establishment of this project, a minimum cost of electricity which

amounts to P6/kwh + VAT will be provided to its customers. In this way, the cost

of living of most of the citizens of Batangas will be reduced. Below is the list of

target customers of ELECPRO Corp. in Batangas according to Barangays and

gender.

Table 1.1

Population of Target Customers in Batangas by Barangay and by Sex, 2017

TOTAL
BARANGAY MALE FEMALE
POPULATION

Barangay 1 801 399 402

Barangay 2 687 342 345
Barangay 3 407 203 205
Barangay 4 1,736 865 872
Barangay 5 720 358 361
Barangay 6 2,279 1,135 1,144
Barangay 7 811 404 407
Barangay 8 655 326 329

10
Barangay 9 321 160 161
Barangay 10 401 199 201
Barangay 11 871 434 437
Barangay 12 1,562 778 784
Barangay 13 578 288 290
Barangay 14 334 166 168
Barangay 15 193 96 97
Barangay 16 223 111 112
Barangay 17 118 59 59
Barangay 18 433 216 217
Barangay 19 1,084 540 544
Barangay 20 390 194 196
Barangay 21 693 345 348
Barangay 22 266 132 134
Barangay 23 721 359 362
Barangay 24 3,265 1,626 1,639
Bilogo 2,076 1,034 1,042
Bucal 2,791 1,390 1,401
Calicanto* 11,704 5,828 5,875
Catandala 731 364 367
Concepcion 3,872 1,928 1,944
Conde Itaas 1,481 738 743
Conde Labac 2,000 996 1,004
Cumba 1,037 516 520
Cuta* 13,003 6,476 6,528
Dalig 2,550 1,270 1,280
Dela Paz Proper 2,697 1,343 1,354
Dela Paz Pulot Aplaya 661 329 332
Dela Paz Pulot Itaas 476 237 239
Dumantay 4,181 2,082 2,099
Dumuclay 3,689 1,837 1,852
Gulod Itaas* 5,617 2,797 2,820
Gulod Labac* 2,761 1,375 1,386
Haligue Kanluran 1,262 628 634
Haligue Silangan 1,927 960 968
Ilijan 4,447 2,215 2,233
Kumintang Ibaba* 11,498 5,726 5,772
Kumintang Ilaya* 11,710 5,831 5,878
Libjo* 12,440 6,195 6,245

11
Maapaz 236 117 118
Mabacong 2,126 1,059 1,067
Mahabang Dahilig 1,623 808 815
Mahabang Parang 3,707 1,846 1,861
Mahacot Kanluran 681 339 342
Mahacot Silangan 772 384 387
Malalim 1,350 672 678
Malibayo 523 262 260
Malitam* 7,586 3,808 3,778
Maruclap 1,086 541 545
Pagkilatan 1,499 746 752
Paharang Kanluran 1,490 748 742
Paharang Silangan 1,386 696 690
Pallocan Kanluran* 7,102 3,537 3,565
Pallocan Silangan 2,299 1,145 1,154
Pinamucan Ibaba 1,600 797 803
Pinamucan Proper 4,093 2,038 2,055
Pinamucan Silangan 1,277 636 641
Sampaga 4,516 2,249 2,267
San Isidro* 7,814 3,891 3,923
San Jose Sico 5,249 2,614 2,635
San Miguel 2,549 1,269 1,280
San Pedro 1,714 853 860
Simlong 4,312 2,147 2,165
Sirang Lupa 1,521 773 780
Sto. Domingo 1,987 1,011 1,019
Sto. Niño 2,859 1,424 1,435
Tabangao Ambulong 5,516 2,747 2,769
Tabangao Aplaya 3,573 1,817 1,832
Tabangao Dao 2,979 1,483 1,495
Talahib Pandayan 2,611 1,300 1,311
Talahib Payapa 652 325 327
Talumpok Kanluran 3,253 1,620 1,633
Talumpok Silangan 2,093 1,042 1,051
Tingga Itaas 3,230 1,609 1,622
Tingga Labac 6,675 3,324 3,351
Tulo 4,180 2,082 2,099
Wawa* 7,324 3,647 3,677
TOTAL 231,011 117584 113690

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 The list shown above are the areas nearest to Dela Paz Proper, Batangas

City, where the ELECPRO Corp. will be established. The number of household

is computed through:

𝑇𝑎𝑟𝑔𝑒𝑡 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑟𝑠 = 231,011

𝑃𝑒𝑟𝑠𝑜𝑛𝑠
= 4 (by approximation)
ℎ𝑜𝑢𝑠𝑒ℎ𝑜𝑙𝑑

231,011
𝐻𝑜𝑢𝑠𝑒ℎ𝑜𝑙𝑑 =
4

𝑯𝒐𝒖𝒔𝒆𝒉𝒐𝒍𝒅 = 𝟓𝟕, 𝟕𝟓𝟑

For the required capacity needed to supply the residential areas in Batangas, the

computation used is:

200𝑘𝑤ℎ
𝑃𝑙𝑎𝑛𝑡 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 𝑥 57,753 ℎ𝑜𝑢𝑠𝑒ℎ𝑜𝑙𝑑
𝑚𝑜𝑛𝑡ℎ

𝑃𝑙𝑎𝑛𝑡 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 11,550,600

𝑘𝑤ℎ 1𝑀𝑊 1𝑚𝑜𝑛𝑡ℎ

𝑃𝑙𝑎𝑛𝑡 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 11,550,600 𝑥 𝑥
𝑚𝑜𝑛𝑡ℎ 1000𝐾𝑤 720 ℎ𝑟

𝑷𝒍𝒂𝒏𝒕 𝒄𝒂𝒑𝒂𝒄𝒊𝒕𝒚 = 𝟏𝟔 𝑴𝑾 (for residential customers)

The remaining 4 MW is intended for commercial and industrial establishments.

The total plant capacity is 20 MW.

Load Demands for Target Customers

Figure 1.4 shows the load demands of the target customers of ELECPRO

Corp. From this data, the peak load is 16 MW which occurs during 6 o’clock in

the afternoon. This is due to the fact that majority of the citizens of Batangas

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arrive to their homes from their schools or works at 6PM. On the other hand, the

base load of 5MW occurs at 3 o’clock in the morning.

Load Projections for Ten Years

Table 1.2 shows the load projections of the target customers for year

2020-2029, wherein there is an approximately 2% increase in load demand. This

increase in demand is from the basis of 2% population growth rate in Batangas

projected by Philippine Statistics Authority.

Location Map

Dela Paz, one of the remotest barrio of the municipality of Batangas is

located along the coast, south of mountain Talim. The barrio is composed of five

sitios namely Maalbo, Bayanan, Bagilbil, Dapdapan and Pook. Its boundaries

include: Ilijan (on the south), Haligue Silangan (on the North), Dela Paz Pulot

Aplaya ((on the East) and seashore (on the west).

Figure 1.5 shows the location map of Dela Paz Proper, Batangas City.

14
 Figure 1.4 Load Demands of Target Customers

18

16

14

12

10

LOAD (MW)
8

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

15
 Table 1.2 Load Projections for Year 2020-2029

LOAD (MW)
TIME
2020 2021 2022 2023 2024 2025 2026 2027 2028 2029
1:00 AM 6 6.12 6.24 6.38 6.52 6.66 6.81 6.96 7.11 7.27
2:00 AM 5.5 5.61 5.72 5.85 5.98 6.11 6.24 6.38 6.52 6.66
3:00 AM 5.25 5.36 5.46 5.58 5.71 5.83 5.96 6.09 6.22 6.36
4:00 AM 5.8 5.92 6.03 6.17 6.3 6.44 6.58 6.73 6.88 7.03
5:00 AM 6.5 6.63 6.76 6.91 7.06 7.22 7.38 7.54 7.71 7.88
6:00 AM 7.6 7.75 7.91 8.08 8.26 8.44 8.63 8.82 9.01 9.21
7:00 AM 8.7 8.87 9.05 9.25 9.45 9.66 9.87 10.09 10.31 10.54
8:00 AM 9.7 9.89 10.09 10.31 10.54 10.77 11.01 11.25 11.5 11.75
9:00 AM 11 11.22 11.44 11.7 11.95 12.22 12.49 12.76 13.04 13.33
10:00 AM 12.7 12.95 13.21 13.5 13.8 14.1 14.41 14.73 15.06 15.39
11:00 AM 13.2 13.46 13.73 14.04 14.34 14.66 14.98 15.31 15.65 15.99
12:00 NN 12.9 13.16 13.42 13.72 14.02 14.33 14.64 14.96 15.29 15.63
1:00 PM 12.2 12.44 12.69 12.97 13.26 13.55 13.85 14.15 14.46 14.78
2:00 PM 12.1 12.34 12.59 12.87 13.15 13.44 13.73 14.04 14.34 14.66
3:00 PM 12.5 12.75 13.01 13.29 13.58 13.88 14.19 14.5 14.82 15.14
4:00 PM 15.6 15.91 16.23 16.59 16.95 17.33 17.71 18.1 18.49 18.9
5:00 PM 15 15.3 15.61 15.95 16.3 16.66 17.03 17.4 17.78 18.17
6:00 PM 16 16.32 16.65 17.01 17.39 17.77 18.16 18.56 18.97 19.39
7:00 PM 14 14.28 14.57 14.89 15.21 15.55 15.89 16.24 16.6 16.96
8:00 PM 12.6 12.85 13.11 13.4 13.69 13.99 14.3 14.62 14.94 15.27
9:00 PM 10 10.2 10.4 10.63 10.87 11.11 11.35 11.6 11.86 12.12
10:00 PM 7.9 8.06 8.22 8.4 8.58 8.77 8.97 9.16 9.37 9.57
11:00 PM 6 6.12 6.24 6.38 6.52 6.66 6.81 6.96 7.11 7.27
12:00 MN 6 6.12 6.24 6.38 6.52 6.66 6.81 6.96 7.11 7.27
TOTAL 244.75 249.65 254.64 260.24 265.97 271.82 277.8 283.91 290.15 296.54

16
Figure 1.5 Location Map

17
 CHAPTER II

DESIGN OBJECTIVES

In this part of the study, the general and specific objectives of the design

project for the establishment of 20 MW diesel power plant will be discussed.

General Objectives

The main objective of this study is to come up with the design of a a 20

MW diesel power plant that can generate enough power with the analysis and

evaluation of the plant performance based on the data gathered. It aims to supply

electric power to certain areas in Batangas wherein fuel consumption will be

reduced to ensure that the fuel charges will not be costly.

To avoid unnecessary interruption during production, the group will ensure

that there will be a reserved generator set in case problems occur in one of the

units. In addition, a glow plug will also be used to warm the cylinders prior to

starting in case that the engine is not working properly due to the cylinder

temperature.

Too much emission of carbon dioxide (CO2) into the atmosphere

contributes primarily to the earth's climate change. For the group to avoid these

kinds of problems, Selective Catalytic Reduction (SCR) will be used in this

design.

In addition, a silencer will also be used to avoid noisy production.

18
Specific Objectives

Specifically, this study aims to:

1. Evaluate three (3) design options presented using multiple realistic

constraints.

2. Select the suitable design specifications, stating the required engineering

standards to be used in the design and design tradeoffs.

3. Come up with the economic analysis considering the calculation of capital

expenditure, operating expenditure and total project cost using economic

indicators such as:

a. Net Present Value

b. Payback Period

c. Rate of Return

d. Rate of Investment

4. Prepare an environmental impact assessment which focuses on the

social-economic benefits of the project for each design option.

5. Develop a project construction execution plan which include the

construction management and strategy, quality control and assurance,

work scheduling and over-all management and commissioning of the

project.

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 CHAPTER III

TECHNICAL ASPECT

This chapter includes the preparation of the diesel power plant cycle. It

also includes the different equipment that is used in the process. Standards are

used to come up with a technically viable design. Technical catalogues and other

monographs are also used to carefully identify the design specifications of each

equipment.

Monograph of Proposed Diesel Power Plant Components

1. Diesel engine - Diesel engine is one of the main components present in

the diesel power plant. Mainly the engines are classified in to two types

they are two stroke engine and four stroke engine. In the diesel engine the

engine is straight away joined to the generator to develop power. In the

engine the air entered in the cylinder must be compressed. Fuel must be

injected by the end of the compression stroke. After the burning of the fuel

the burnt gases expand and apply pressure on the piston. To the

generator the shaft of the engine is straightly attached to the engine. After

the completion of the combustion the burnt gases are ejected in the

atmosphere.

2. Diesel Generator - Combination of a diesel engine with an electric

generator (often an alternator) to generate electrical energy.

20
3. Fuel Storage Tank - Storage tanks are containers that hold liquids,

compressed gases or mediums used for the short- or long-term storage of

heat or cold.

4. Day tank - Are designed to automatically maintain a full day's supply of

fuel for the generator set.

5. Starting Motor - A starter is a device used to rotate (crank) an internal-

combustion engine so as to initiate the engine's operation under its own

power. Starters can be electric, pneumatic, or hydraulic

6. Starting Oil Tank - Any tank for containing or storing oil such as a very

large oil storage container at a refinery.

7. Lubricating Oil Tank - lube oil tank provides a safe and effective method

of bulk storage for motor oils of all types.

8. Heat Exchanger - A device for transferring heat from one medium to

another.

9. Oil cooler - Oil cooling is the use of engine oil as a coolant, typically to

remove surplus heat from an internal combustion engine. The hot engine

transfers heat to the oil which then usually passes through a heat-

exchanger, typically a type of radiator known as an oil cooler.

10. Cooling tower - A tall, open-topped, cylindrical concrete tower, used for

cooling water or condensing steam from an industrial process.

11. Surge tank - A tank connected to a pipe carrying a liquid and intended to

neutralize sudden changes of pressure in the flow by filling when the

pressure increases and emptying when it drops.

21
12. Exhaust - Is usually piping used to guide reaction exhaust gases away

from a controlled combustion inside an engine or stove.

13. Silencer- A device for reducing the noise emitted by a loud mechanism.

14. Chimney – A vertical channel or pipe that conducts smoke and

combustion gases up from a fire or furnace and typically through the roof

of a building.

15. Louver - each of a set of angled slats or flat strips fixed or hung at regular

intervals in a door, shutter, or screen to allow air or light to pass through.

16. SCR Catalyst - Selective Catalytic Reduction (SCR) is an advanced

active emissions control technology system that injects a liquid-reductant

agent through a special catalyst into the exhaust stream of a diesel

engine.

17. Oil Filter - An oil filter is a filter designed to remove contaminants from

engine oil, transmission oil, lubricating oil, or hydraulic oil

18. Fuel Filter - A fuel filter is a filter in the fuel line that screens out dirt and

rust particles from the fuel, normally made into cartridges containing a

filter paper. They are found in most internal combustion engines.

19. Intake Air Filter - An apparatus designed to improve the quality of

circulating air by filtering out impurities. Once the air is returned to the

furnace fan, it is pulled through air filters to remove dust and dirt.

20. Transformer - An apparatus for reducing or increasing the voltage of an

alternating current.

22
21. Gear Pump - Uses the meshing of gears to pump fluid by displacement.

They are one of the most common types of pumps for hydraulic fluid

power applications. Gear pumps are also widely used in chemical

installations to pump high viscosity fluids.

22. Fuel Injection Pump – Is the device that pumps diesel (as the fuel) into

the cylinders of a diesel engine. Traditionally, the injection pump is driven

indirectly from the crankshaft by gears, chains or a toothed belt (often the

timing belt) that also drives the camshaft.

23. Oil Pump - Circulates engine oil under pressure to the rotating bearings,

the sliding pistons and the camshaft of the engine. This lubricates the

bearings, allows the use of higher-capacity fluid bearings and also assists

in cooling the engine.

24. Auxiliary Pump - This pump is not connected to the cooling of the engine.

Its primary function is to circulate warm coolant to the heater core. If too

little coolant is circulated, the blower fan will pull enough heat out of the

coolant and cause the heater core to get cold.

25. Raw water Pump - Contains an impeller which makes the pump operate.

It is usually fairly easy to access the impeller to inspect or replace it. The

enclosed system circulates fresh water and coolant through the engine

water jacket and through a heat exchanger.

26. Jacket Water Pump - Water jacket is a water-filled casing surrounding a

device, typically a metal sheath having intake and outlet vents to allow

water to be pumped through and circulated. The flow of water to an

23
 external heating or cooling device allows precise temperature control of

the device.

27. Relief Valve - A relief valve or pressure relief valve (PRV) is a type of

safety valve used to control or limit the pressure in a system; pressure

might otherwise build up and create a process upset, instrument or

equipment failure, or fire.

28. Safety Valve - The primary purpose of a safety valve is the protection of

life, property and environment. A safety valve is designed to open and

relieve excess pressure from vessels or equipment and to reclose and

prevent the further release of fluid after normal conditions have been

restored.

29. Check Valve - Check valve allows flow in one direction and automatically

prevents back flow (reverse flow) when fluid in the line reverses direction.

They are one of the few self-automated valves that do not require

assistance to open and close.

30. Control Valve - A valve used to control fluid flow by varying the size of the

flow passage as directed by a signal from a controller. This enables the

direct control of flow rate and the consequential control of process

quantities such as pressure, temperature, and liquid level.

24
 Figure 3.1 Schematic Diagram of Diesel Power Plant

DESIGN OF MACHINE FOUNDATION

Mixture for Concrete Foundation:

Use 1:2:4 concrete mixture ratio

Foundation Materials:

Concrete Mixture Ratio = 1: 2: 4

x + 2x + 4x = Vf

Weight of foundation

𝑊𝑓 = 𝑒 × 𝑊𝑒 × √𝑛

Where:

Wf = weight of the foundation, kgs

25
 We = weight of the engine, kgs

We of CAT C175-20 4000=24,500 kg

e = empirical coefficient

n = engine speed, RPM

Use e = 0.11 ((from PSME code of 1993, Table 2.4.2.3 (4), p.10)

𝑊𝑓 = 0.11 × 24,500 𝑘𝑔 × √1800 𝑟𝑝𝑚 = 114,339.17 𝑘𝑔

Volume of foundation
𝑊𝑓
𝑉𝑓 = 𝜌𝑐

Where:

Vf = volume of foundation [m3]

ρc = density of concrete = 2406 kg/m3

114,339.17 𝑘𝑔
𝑉𝑓 = 𝑘𝑔 = 47.52 𝑚3
2,406
𝑚3

x + 2x + 4x = 47.52 m3

x = 6.79 m3

𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙

𝐴𝑏𝑠. 𝑉𝑜𝑙. 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙
(𝐵𝑢𝑙𝑘 𝑆. 𝐺. )(𝑆𝑝. 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑊𝑎𝑡𝑒𝑟)

For cement:

1 x 6.79 m3 = 6.79 m3

𝑙𝑏
(1) 94 𝑓𝑡 3 1 𝑚3 𝑚3
𝑏𝑎𝑔
𝐴𝑏𝑠. 𝑉𝑜𝑙. 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = = 0.49 × = 0.014
𝑙𝑏 𝑏𝑎𝑔 (3.28 𝑓𝑡)3 𝑏𝑎𝑔
(3.1)(62.4 3 )
𝑓𝑡

26
 6.79 𝑚3
𝑁𝑜. 𝑜𝑓 𝐵𝑎𝑔𝑠 = 𝑚3
= 485 𝑏𝑎𝑔𝑠
0.014
𝑏𝑎𝑔

For sand:

2 x 6.79 m3 = 13.58 m3

𝑙𝑏
105 (2) 𝑓𝑡 3 1 𝑚3 𝑚3
𝑏𝑎𝑔
𝐴𝑏𝑠. 𝑉𝑜𝑙. 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = = 1.25 × = 0.035
𝑙𝑏 𝑏𝑎𝑔 (3.28 𝑓𝑡)3 𝑏𝑎𝑔
(2.7)(62.4 3 )
𝑓𝑡

13.58 𝑚3
𝑁𝑜. 𝑜𝑓 𝐵𝑎𝑔𝑠 = = 388 𝑏𝑎𝑔𝑠
𝑚3
0.035
𝑏𝑎𝑔

For gravel:

4 x 6.79 m3 = 27.16 m3

𝑙𝑏
105 (4) 𝑓𝑡 3 1 𝑚3 𝑚3
𝑏𝑎𝑔
𝐴𝑏𝑠. 𝑉𝑜𝑙. 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = = 2.17 × = 0.062
𝑙𝑏 𝑏𝑎𝑔 (3.28 𝑓𝑡)3 𝑏𝑎𝑔
(3.1)(62.4 3 )
𝑓𝑡

27.16
𝑁𝑜. 𝑜𝑓 𝐵𝑎𝑔𝑠 = = 438 𝑏𝑎𝑔𝑠
𝑚3
0.062
𝑏𝑎𝑔

QUATITY OF AGGREGATE NEEDED

Sand 388 bags

Gravel 438 bags
Cement 485 bags

Width of the foundation:

𝑏𝑓 = 𝑤𝑒 + 2(6 𝑖𝑛)

Where:

we= width of the engine [m]

27
 25.4 𝑚𝑚
𝑏𝑓 = 21,821 𝑚𝑚 + 2 (6 𝑖𝑛 × ) = 22,125.8 𝑚𝑚 ≈ 22.13 𝑚
1 𝑖𝑛

Length of the foundation:

𝐿𝑓 = 𝐿𝑒 + 2( 6 𝑖𝑛)

Where:

Le = length of engine [m]

25.4 𝑚𝑚
𝐿𝑓 = 6,943 𝑚𝑚 + 2 (6 𝑖𝑛 × ) = 7,247.8 𝑚𝑚 ≈ 7.25 𝑚
1 𝑖𝑛

Depth of Foundation:

2𝑉𝑓
ℎ𝑓 =
𝑏𝑓 × 𝐿𝑓

Where:

hf = depth of foundation [m]

Lf = length of foundation [m]

bf = width of the foundation [m]

2(47.52)𝑚3
ℎ𝑓 = = 0.59 𝑚
22.13 𝑚 × 7.25 𝑚

SPECIFICATIONS OF FOUNDATION
Length 7.25 m
Width 22.13 m
Depth 0.59 m
Weight 114.339.17 kg

28
Volume 47.52m3

DESIGN OF DAY TANK

Type of Oil: B20 Diesel Fuel (Biodiesel)

Note: Fuel Consumption = 1039.3L/hr (From Catalogue)

Material: Carbon Steel

1039.3 𝐿 24 ℎ𝑟
× × 3 𝑑𝑎𝑦𝑠(𝑓𝑜𝑟 𝑒𝑥𝑐𝑒𝑠𝑠) = 74,829.6 𝐿 = 19,767.89 𝑔𝑎𝑙
ℎ𝑟 𝑑𝑎𝑦

Thus, use Standard API Tank Size

Dimensions for 21,000 gal as follows:

DIAMETER= 𝐷𝐷𝑇 = 15 ft = 4.57 m

HEIGHT =𝐻𝐷𝑇 = 16 ft = 4.88 m

BARRELS = 500

WEIGHT = 11,200lbs = 5,080.23 kg

Volume of Day Tank

𝜋 𝜋
𝑉𝐷𝑇 = 𝐷𝐷𝑇 2 𝐻𝐷𝑇 = (15 𝑓𝑡)2 (16 𝑓𝑡) = 2,827.43 𝑓𝑡 3 = 80.13𝑚3
4 4

Density of B20 Diesel Fuel Oil

𝜌𝑓𝑢𝑒𝑙
𝑆. 𝐺. =
𝜌𝐻2𝑂

Where:

S.G. = specific gravity

29
S.G. at 15 ̊ C = 0.85823 (from ARPN Journal of Engineering and Applied

Sciences page 102, Table 3)

𝜌f= density of fuel

𝜌𝐻2𝑂 = density of water = 1,000 kg/m3

𝑘𝑔 𝑘𝑔
𝜌𝑓𝑢𝑒𝑙 = 𝑆. 𝐺.× 𝜌𝐻2𝑂 = 0.85823 (1000 ) = 858.23
𝑚3 𝑚3

Pressure of Day Tank

𝑃𝐷𝑇 = 𝛾𝑓 𝐻𝐷𝑇

Where:

𝛾𝑓 =specific weigh of fuel

𝑘𝑔 𝑚 𝑁 𝐾𝑁
𝛾𝑓 = 𝜌𝑓× 𝑔 = (858.23 ) (9.81 ) = 8419.24 = 8.42
𝑚3 𝑠2 𝑚3 𝑚3

𝐾𝑁
𝑃𝐷𝑇 = 8.42 × 4.88 𝑚 = 41.09 𝐾𝑃𝑎 = 5.96 𝑝𝑠𝑖
𝑚3

Thickness of Fuel Day Tank

𝑃𝐷𝑇 × 𝐷𝐷𝑇
𝑇𝐷𝑇 =
𝑆𝑦
2 × 𝐹𝑆 × 𝑒

Where:

Sy= Tensile Yield = 35,000 psi (from DME by V.M. Faires, Table AT 4, p.568)

F.S=Factor of Safety = 3 (for stainless steel from DME by V.M. Faires Table 1.1,

p.20)

e = efficiency of longitudinal joint = 0.95 (for welded joint)

30
 41.09 kPa × 4.57 𝑚
𝑇𝐷𝑇 = = 0.00123 𝑚 = 1.23 𝑚𝑚
35,000 psi 101.325𝐾𝑝𝑎
2 ×( × 14.7𝑝𝑠𝑖 ) × 0.95
3

SPECIFICATIONS OF DAY TANK

Diameter 15 ft (4.57 mm)
Height 16 ft (4.88 m)
Barrels 500
Weight 11,200lbs ( 5,080.23 kg)
Volume 80.13m3
Pressure 41.09 Kpa (5.96 psi)
Thickness 1.23 mm
Material Carbon Steel

DESIGN OF FUEL STORAGE TANK

Material: Carbon Steel

1039.3 𝐿 24 ℎ𝑟
ℎ𝑟
× 𝑑𝑎𝑦
× 3 𝑑𝑎𝑦𝑠(𝑓𝑜𝑟 𝑒𝑥𝑐𝑒𝑠𝑠) × 30 × 5 𝑢𝑛𝑖𝑡𝑠 = 11,224,440 𝐿 = 2,965,183.18 𝑔𝑎𝑙

Fuel consumption is multiplied by 30 representing the number of days in one

month. Theoretically, fuel storage tank capacity must be good for 1 month

supply.

Thus, use Standard API Tank Size Dimensions for 3,380,000gal as follows:

DIAMETER = 𝐷𝑆𝑇 = 120ft = 36.58 m

HEIGHT = 𝐻𝑆𝑇 = 40ft = 12.19 m

BARRELS = 80,600

31
 WEIGHT = 574,000lbs = 260,362.04 kg

Volume of Fuel Storage Tank

𝜋 𝜋
𝑉𝐷𝑇 = 𝐷𝑆𝑇 2 𝐻𝑆𝑇 = (120 𝑓𝑡)2 (40 𝑓𝑡) = 452,389.34 𝑓𝑡 3 = 12,820.08 𝑚3
4 4

Pressure of Fuel Storage Tank

𝑃𝑆𝑇 = 𝛾𝑓 𝐻𝑆𝑇

Where:

𝛾𝑓 =specific weight of fuel

𝐾𝑁
𝑃𝑆𝑇 = 8.42 × 12.19 𝑚 = 102.64 𝐾𝑃𝑎
𝑚3

Thickness of Fuel Storage Tank

𝑃𝑆𝑇 × 𝐷𝑆𝑇
𝑇𝑆𝑇 =
𝑆𝑦
2 × 𝐹. 𝑆. × 𝑒

32
 102.64 kPa × 36.58 𝑚
𝑇𝐷𝑇 = = 0.02457 𝑚 = 24.57 𝑚𝑚
35,000 psi 101.325𝐾𝑝𝑎
2 ×( × ) × 0.95
3 14.7

SPECIFICATIONS OF STORAGE TANK

Diameter 120ft (36.58 m)
Height 40ft (12.19 m)
Barrels 80,600
Weight 574,000lbs (260,362.04 kg)
Volume 12,820.08 m3
Pressure 102.64 Kpa
Thickness 24.57 mm
Material Carbon Steel

DESIGN OF HEAT EXCHANGER

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

Δ𝑡max − Δ𝑡𝑚𝑖𝑛
LMTD= Δ𝑡
𝑙𝑛 𝑚𝑎𝑥
Δ𝑡𝑚𝑖𝑛

Δtmax = (65.6 – 54.4) °C = 11.2 °C

Δtmin = (37.8 – 32.2) °C = 5.6 °C

33
 (11.2− 5.6)℃
LMTD= 11.2 = 8.08 ℃ = 46.54 ℉
𝑙𝑛
5.6

Qj= mj x cpj x Δtj

Where:

Qj = heat rejected from jacket water = 1399 KW (from catalogue)

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)

𝑘𝐽
𝑄𝑗 1399 𝑘𝑔 3600𝑠 𝑘𝑔
𝑠
𝑚𝑗 = = 𝑘𝐽 = 12.02 × = 43,272 ℎ𝑟
Λ𝑡𝑗 × 𝐶𝑝𝑗 (27.8 𝐾)(4.187 ) 𝑠 1 ℎ𝑟
𝑘𝑔−𝐾

𝑄𝑗
A= 𝑈(𝐿𝑀𝑇𝐷)

Where:

A = surface area of heat exchanger

U = overall coefficient of heat transfer

LMTD = log mean temp. Difference

Solving for U

̅ × 𝐹𝑡 × 𝐹𝑚 × 𝐹𝑐 × 𝐹𝑝
𝑈= 𝑈

Where:

̅ = coefficient of heat transfer

𝑈

Ft = temp. Correction factor

Fm = tube material and thickness correction factor

Fc = cleanliness factor

Fp = prime mover factor

34
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

𝑓𝑡 𝑓𝑡
̅ = 𝑐√𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = (270) × √9
𝑈 = 810
𝑠 𝑠

𝐵𝑇𝑈
𝑈 = 810 × 1.08 × 0.96 × 0.85 × 1.0 = 713.84
𝑓𝑡 2 − ℎ𝑟 °𝐹
𝑘𝐽 1 𝐵𝑇𝑈 3600 𝑠
1399𝑘𝑊 × × ×
𝑘𝑊−𝑠 1.055 𝐾𝐽 1 ℎ𝑟
A= 𝐵𝑇𝑈 = 143.69𝑓𝑡 2
713.84 2 × 46.54 ℉
𝑓𝑡 −ℎ𝑟 °𝐹

𝑇𝑜𝑡𝑎𝑙 𝑛𝑜. 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 𝑛𝑜. 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠/𝑝𝑎𝑠𝑠 × 𝑛𝑜. 𝑜𝑓 𝐻2 0 𝑝𝑎𝑠𝑠

Where:

𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑

𝑁𝑜. 𝑜𝑓𝑡𝑢𝑏𝑒𝑠/𝑝𝑎𝑠𝑠 =
𝑡𝑢𝑏𝑒𝑠/𝑝𝑎𝑠𝑠

𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 𝑚𝑐𝑤 × 𝜐

mcw = mj = 43,272 kg/hr

υ = specific volume of circulating water @ t

𝑡𝑗𝑜 + 𝑡𝑗𝑖 (65.6 + 37.8)°𝐶

𝑡= = = 51.7 °𝐶
2 2

From steam table @ 51.7 °C (by interpolation)

υ = 1.01295 L/kg

35
 𝑘𝑔 𝐿 1 ℎ𝑟 𝐿
𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = (43,272 ℎ𝑟 ) (1.01295 𝑘𝑔) (60min) = 730.54 𝑚𝑖𝑛

From PPT & D by P.J. Potter, p. 357

“For each ¾” No. 18 BWG tube will pass 1.042 GPM/1 fps”

𝐿 1 𝑔𝑎𝑙.
𝑁𝑜. 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 730.54 ×
= = 𝑚𝑖𝑛 3.785 𝐿 = 20.58 𝑡𝑢𝑏𝑒𝑠 ≈ 21 𝑡𝑢𝑏𝑒𝑠
𝑝𝑎𝑠𝑠 𝐺𝑃𝑀 𝐺𝑃𝑀 𝑝𝑎𝑠𝑠 𝑝𝑎𝑠𝑠
𝐻2 𝑂 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 ( ) × 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 1.042 × 9 𝑓𝑝𝑠
𝑓𝑡 𝑓𝑝𝑠

𝐴
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡𝑢𝑏𝑒 =
𝑡𝑢𝑏𝑒𝑠
(0.1963)
𝑝𝑎𝑠𝑠

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)

143.69𝑓𝑡 2 1𝑚
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡𝑢𝑏𝑒 = = 34.86 𝑓𝑡 × = 10.63 𝑚
21(0.1963) 3.28𝑓𝑡

𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡𝑢𝑏𝑒 34.86

𝑁𝑜. 𝑜𝑓 𝐻2 𝑂 𝑝𝑎𝑠𝑠 = = = 3.49 ≈ 4 𝑤𝑎𝑡𝑒𝑟 𝑝𝑎𝑠𝑠𝑒𝑠
𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑟𝑎𝑛𝑔𝑒 10

Note: use 2 shells for 4 water passes

𝑁𝑜.𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 𝑡𝑢𝑏𝑒𝑠 𝑡𝑢𝑏𝑒𝑠

Thus, = 21 × 2 = 42
𝑝𝑎𝑠𝑠 𝑝𝑎𝑠𝑠 𝑝𝑎𝑠𝑠

𝑇𝑜𝑡𝑎𝑙 𝑛𝑜. 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 42 × 2 = 84 𝑡𝑢𝑏𝑒𝑠

SPECIFICATIONS OF HEAT EXCHANGER

Mass of Jacket Water 43,272 kg/hr
Water Velocity 9 ft/s (2.74 m/s)
Area 143.69 ft2
Circulating Water 730.54 L/min

36
Length of Tube 10.63 m
No.of H2O pass 4
No. of Tubes 84

DESIGN OF COOLING TOWER

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)

37
Using the formula (from PPE by F.T Morse, eq. 6-16, p. 178)

𝑏ℎ𝑝
𝑤 = 674.58 ×
𝑡2 − 𝑡1

Where:

W = cooling water [1 / hr)

1𝐵ℎ𝑝
Bhp =Pb= rated brake horsepower =4,211.88 𝑏𝑘𝑊 × = 5,645.95𝐵ℎ𝑝
0.746 𝑏𝐾𝑊

t1 & t2 = inlet & outlet water temperatures [°C]

5,645.95 𝑏ℎ𝑝 1
𝑤 = 674.58 × = 137,001.62 ℎ𝑟
65.6−37.8

Let ww = water flow in the cooling tower circuit

(65.6−37.8) (65.6−37.8) 1 1 ℎ𝑟 𝑘𝑔
𝑤𝑤 = 𝑤 = (137,001.62) [ ] = 228,062.58 × = 3,801.04
(48.9−32.2) (48.9−32.2) ℎ𝑟 60 𝑚𝑖𝑛 𝑚𝑖𝑛

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

38
Using the formula (from PPE by F.T Morse, eq. 6-19 & 6-20, p. 182)

𝑝𝑠 𝑘𝐽 𝐽
𝑆𝐻 = 0.00625 𝑅𝐻 (𝑝 ) [𝑘𝑔 ] ℎ = 1013.4 𝑡𝑑 + 18015.7 + 𝑆𝐻 × ℎ𝑔 [𝑘𝑔]
𝑎 −𝑝𝑠 𝑑𝑎

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

0.0895
𝑆𝐻2 = 0.00625(90) [ ] = 0.0535 𝑘𝑔
1.03 − 0.0895

𝐽
ℎ2 = 1013.4 (43.4) + 18015.7 + 0.0535 × 2,580,140 = 200,933
𝑘𝑔

Using the formula (from PPE by F.T Morse, eq. 6-17 & 6-18, p. 177)

Mass balance for cooling tower:

kg make−up
Δw = SH2 − SH1 = 0.0535 − 0.0123 = 0.0412 kg air

Energy balance for cooling tower

hfa+ ha

h1 Cooling Tower h2

39
 hfb

h1 = air entering at 29.4 °C DB and 21.2 °C W B

h2 = air leaving at 43.4 °C

hfa = hf at 48.9 °C (max. state of humidified air)

hfb = hf at 32.2 °C

hf= hf at 15.6 °C

h1 + ww hfa + Δwhf = h2 + ww hfb

79098 + 204730ww + 65510 × 0.0412 = 200933 + 134986ww

W w = 1.7 kg water / kg dry air (from above equation)

𝑘𝑔 𝑤𝑎𝑡𝑒𝑟
4246.97 𝑘𝑔
𝑚𝑖𝑛
𝐴𝑖𝑟 𝑓𝑙𝑜𝑤 = 𝑘𝑔 𝑤𝑎𝑡𝑒𝑟 = 2,498.22
1.7 𝑚𝑖𝑛
𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟

From Psychometric Chart

Since υair @ 29.4 °C & 21.1 °C = 0.862 m3/kg

𝑘𝑔 𝑚3 𝑚3
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐴𝑖𝑟 𝑓𝑙𝑜𝑤 = 2,498.22 × 0.862 = 2153.46 𝑚𝑖𝑛
𝑚𝑖𝑛 𝑚𝑖𝑛

𝑘𝑔 kg make−up kg
𝑀𝑎𝑘𝑒 − 𝑢𝑝 𝑤𝑎𝑡𝑒𝑟 = 2,498.22 × 0.0412 = 102.93
𝑚𝑖𝑛 kg min

𝑎𝑐𝑡𝑢𝑎𝑙 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑟𝑎𝑛𝑔𝑒 𝑡𝑎 − 𝑡𝑏 48.9−32.2

𝜂𝑐𝑜𝑜𝑙𝑖𝑛𝑔 = = = = 60 %
𝑡ℎ𝑒𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑟𝑎𝑛𝑔𝑒 𝑡𝑎 − 𝑡𝑤 48.9−21.1

From PPE by F.T. Morse, p. 182

Recommended Type: Forced Draft Cooling Tower

Cooling Tower Pipe

40
 𝑄𝐶𝑇𝑃
𝐴𝐶𝑇𝑃 = ; QCTP = mcw (υf @ 32.2 °C)
𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦

From Steam Table (by interpolation)

υf = 1.00506 L/kg = 0.0010506 m3/kg

𝑘𝑔 1ℎ𝑟 𝑚3 𝑚3
𝑄𝐶𝑇𝑃 = (43,272 ) (3600 𝑠) (0.0010506 𝑘𝑔 ) = 0.0126
ℎ𝑟 𝑠

Velocity of water @ HX = Velocity of water at cooling tower

9 ft/s = 2.74 m/s

𝑚3
𝑄𝐶𝑇𝑃 0.0126 2
𝐴𝐶𝑇𝑃 = = 𝑠 = 0.0046 𝑚2 × (39.37 𝑖𝑛) = 7.13 𝑖𝑛2
𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑚 1 𝑚2
2.74 𝑠

𝜋 4(7.13 𝑖𝑛2 )
𝐴𝐶𝑇𝑃 = (𝐷𝐶𝑇𝑃 )2 ; 𝐷𝐶𝑇𝑃 = √ = 3 𝑖𝑛. ; 𝑢𝑠𝑒 3 𝑖𝑛. 𝑝𝑖𝑝𝑒
4 𝜋

Material Specification (from PSME code, p.200)

Size: 3 in. Inside Dia.: 2.9 in Wall thickness: 0.3 in

Schedule: 80x Outside Dia.: 3.5 in

Fan Power of Cooling Tower

3.75ℎ𝑝
Where: Fan Power is typically 𝑘𝑔 (From F.T. Morse, PPE Book) page 182
1000
𝑚𝑖𝑛

3.75 ℎ𝑝 3.75 ℎ𝑝 𝑚3 1000 𝐿 1𝑔𝑎𝑙 60 𝑠

𝐹𝑃 = × 𝑄𝐶𝑇𝑃 = 𝑔𝑎𝑙 × [0.0126 × × × ] = 0.75 𝑘𝑊
1000 𝐺𝑃𝑀 1000 𝑠 1 𝑚3 3.785 𝐿 1 𝑚𝑖𝑛
𝑚𝑖𝑛

Fan Capacity

QA = mAυA

41
Where:

mA = mass of air = 1.59 kg/s

υA = specific vol. of air

ρA = density of air @ standard condition = 1.2 kg/m3

𝑘𝑔 1 60 𝑠 𝑚3
𝑄𝐴 = (1.59 )( )( ) = 79.5
𝑠 𝑘𝑔 1 min 𝑚𝑖𝑛
1.2 3
𝑚

Cooling Tower Floor Area

Concentration of Water = 80 L/min-m2

𝑚3 1000 𝐿 60 𝑠
(0.0126 ) ( ) (
𝑄𝑤 𝑠 1𝑚 3 1 𝑚𝑖𝑛)
𝐴𝐶𝑇 = =
𝑤𝑎𝑡𝑒𝑟 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝐿
80
𝑚𝑖𝑛 − 𝑚2

= 9.45 𝑚2 × 5 𝑢𝑛𝑖𝑡𝑠 = 47.25 𝑚2

𝜋 4(47.25 𝑚2 )
𝐴𝐶𝑇 = (𝐷𝐶𝑇 )2 ; 𝐷𝐶𝑇 = √ = 7.75 𝑚
4 𝜋

SPECIFICATIONS OF COOLING TOWER

Water Flow 3,801.04 kg/min
Air Flow 2,498.22 kg/min
Volumetric Air flow 2153.46 m3/min
Make-up water Flow 102.93 kg/min
Percent Cooling 60%
Pipe Area 7.13 in2
Size of Pipe 3 in
Schedule 80x
Pipe Inside Diameter 2.9 in
Pipe Outside Diameter 3.5 in
Wall Thickness 0.3 in
Fan Power 0.75 kw
Fan Capacity 79.5 m3/min
Cooling Tower Floor Area 47.25 m2

42
Cooling Tower Floor Diameter 7.75 m

ANALYSIS OF DIESEL CYCLE

Bore of the cylinder 0.175 m

Stroke of the piston – mm (in) 0.220 m
No. of cylinders 20
Rounds per Minute (RPM) 1800
Displaced volume of one cylinder 0.00529 m3
Displaced volume of the engine (20 cylinders) 0.1058 m3
Number of suction strokes per minute 1800/2 = 900
Number of suction strokes per second 900/60 = 15
Theoretical air consumption (intake air) 0.106 x (900/60) = 1.59 m3/s
Compression Ratio 15.3:1

𝐾𝑗
Cp air = 1.0 𝑘𝑔−°𝐾
𝐾𝑗
Cv air = 0.716 𝑘𝑔−°𝐾

k air = 1.4
T1 = 25 ̊ C (ISO standard for ambient temperature for diesel engine)
T1 = 25 ̊ C + 273 = 298 ̊ K
P1 = 100 KPa (ISO standard)
Clearance:
1 1
c=𝑟 = 15−1 = 0.07
𝑘 −1

Clearance Volume:
Vc = cVd = 0.07 (0.1058 m3) = 0.00741 m3
𝑚𝑎𝑖𝑟 = 𝜌𝑎𝑖𝑟 𝑣𝑎𝑖𝑟

Where:

𝑚𝑎𝑖𝑟 = mass of air

43
𝜌𝑎𝑖𝑟 = density of air

𝑣𝑎𝑖𝑟 = volume of air

𝑣𝑎𝑖𝑟 = 339.1 m3/min (from catalogue)

𝜌air = 1.225 kg/m3

𝑚𝑎𝑖𝑟 = 𝜌𝑎𝑖𝑟 𝑣𝑎𝑖𝑟

𝑘𝑔 𝑚3 60𝑚𝑖𝑛 24ℎ𝑟
= (1.225 𝑚3 ) (339.1 𝑚𝑖𝑛 × × )
ℎ𝑟 𝑑𝑎𝑦

𝑚𝑎𝑖𝑟 = 598,172.4 kg/day = 6.923 kg/s

Process 1-2

V1
rk 
V2
15.3 V1

1 V2
V1  15.3V2

VD  V1  V2
0.1058  15.3V2  V2
V2  0.0074m3
V1  15.3(0.0074)  0.1132m3

T2
 (rk ) k 1
T1
T2  (298)(15.3)1.41  887.35K
1
V2 P
 ( 1 )k
V1 P2
1
0.0074 100 1.4
( )
0.1152 P2
P2  4454.71KPa

Process 2-3

44
Qa  mC p (T3  T2 )
KJ Kg KJ
4000  6.923 (1.0 )(T3  887.35K )
s s Kg  K
T3  1465.13K

T3
rc 
T2
1465.13
rc 
887.35
rc  1.65

V3  rcV2
V3  1.65(0.0074)
V3  0.0122m3
P3  P2 4554.71KPa

Process 3-4

T4  T1rc
k

T4  (298)(1.65)1.4
T4  600.75 K

V1  V4  0.1132m3

r 1
k
1
e  1  k 1 ( c )
rk K (rc  1)
1 1.651.4  1
e  1 ( )
15.31.41 1.4(1.65  1
e  0.625
e  62.5%

PERFORMANCE TEST

Brake Power (Pb)

45
 𝑃𝑏 = 2𝜋𝑇𝑁

Where:

T = 16,474 lb-ft (from Catalogue)

N = 1800 rpm (from Catalogue)

𝑟𝑒𝑣 1ℎ𝑝 0.746 𝐾𝑊

𝑃𝑏 = 2𝜋(16,474 lb − ft ) (1800 )× 𝑓𝑡−𝑙𝑏 × =
𝑚𝑖𝑛 33,000 1 ℎ𝑝
𝑚𝑖𝑛

4,211.88 𝐾𝑊

Mass of Fuel Consumed per Day:

𝑚𝑓 = 𝜌𝑓 × 𝑉𝑓𝑢𝑒𝑙

Where:

𝑉𝑓𝑢𝑒𝑙 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐹𝑢𝑒𝑙

𝑘𝑔 𝐿 24 ℎ𝑟 𝑚3 𝑘𝑔
𝑚𝑓 = (858.23 3
) (1039.3 × × ) = 21,407
𝑚 ℎ𝑟 𝑑𝑎𝑦 1000𝐿 𝑑𝑎𝑦

Heat Supplied by Fuel

141.5
𝑆. 𝐺. @15.60 𝐶 = 131.51+0 𝐴𝑃𝐼

141.5
0.85823 = 131.51+⁰𝐴𝑃𝐼

⁰API = 33.37

Qh = 41130 + 139.6 (⁰API)

= 41130 + 139.6 (33.37)

Qh = 45,788.452 KJ/Kg

46
Where:

Qh= heating value of fuel

Piston Speed

220𝑚 𝑟𝑒𝑣 𝑚𝑖𝑛

Piston speed = 2LN = 2 ( 1000 ) (1800 𝑚𝑖𝑛 × )
60𝑠

Piston speed = 13.2 m/s

Brake Force

1 𝑘𝑔 1𝑚 9.81 𝑚
𝑇 16,474 lb−ft× × × 2
2.2 𝑙𝑏 3.28 𝑓𝑡 𝑠
𝐹= = 175𝑚 = 255,954.93 N = 255.95 KN
𝑟 ( )
2(1000)

Where:

F = brake force or brake load

r = brake arm or torque arm

Indicated Mean Brake Pressure

𝐾𝑁. 𝑚
𝑃𝑏 4,211.88 𝑠
𝑃𝑚𝑏 = = = 2,648.98 𝐾𝑃𝑎
𝑉𝐷 𝑚3
1.59 𝑠

Where:

Pb = brake power

Pmb = indicated mean brake pressure

VD = piston displacement

47
Indicated Power

From:http://www.trucktrend.com/cool-trucks/1411-caterpillar-c175-20-diesel-

engine-by-the-numbers/, mechanical efficiency of CAT-175 is 70%

Use ηm = 70%

Pb 4211.88
Pind    6016.97 KW
nm 0.7

Friction Power

Pf  Pind  Pb
Pf  6016.97  4211.88
Pf  1805.09 KW

Indicated Mean Effective Pressure

Pind
Pmi 
Vd
KN
6016.97
Pmi  m2
m3
1.59
s
Pmi  3784.26 KPa

Generator Efficiency

𝑃𝑔𝑒𝑛 4000 𝐾𝑊
𝑒𝑔𝑒𝑛 = = × 100 = 94.97 %
𝑃𝑏 4211.88 𝐾𝑊

Thermal Efficiencies

48
 a. Indicated Thermal Efficiency, eti

KJ
6016.97
Pind s
eti  
m f Qh (21407 kg  day  hr )( 45788.452 KJ )
day 24hrs 3600s kg
eti  0.5304  53.04%

b. Brake Thermal Efficiency, etb

KJ
4211.8
Pb s
etb  
m f Qh (21407 kg  day  hr )( 45788.452 KJ )
day 24hrs 3600s kg
etb  0.3713  37.13%

c. Combined or Over-all Thermal Efficiency

KJ
Pgen 4000
etc   s
m f Qh (21407 kg  day  hr )( 45788.452 KJ )
day 24hrs 3600s kg
etc  0.3526  35.26%

Engine Efficiencies
a. Indicated Engine Efficiency, eti
eti 53.04
eei   100  84.86%
e 62.5

b. Brake Engine Efficiency

etb 37.13
eeb   100  59.41%
e 62.5

c. Combined or Over-all Engine Efficiency

etc 35.26
eec   100  56.42%
e 62.5

Specific Fuel Consumption

49
 a. Indicated Specific Fuel Consumption, mi

kg day
(21407  )
mf day 24hrs kg
mi    0.148
pind 6016.97 KW KW  hr

b. Brake Specific Fuel Consumption, mb

kg day
(21407  )
mf day 24hrs kg
mb    0.212
Pb 4211.8KW KW  hr

c. Combined or Over-all Specific Fuel Consumption, mc

kg day
(21407  )
mf day 24hrs kg
mc    0.223
Pgen 4000 KW KW  hr

Heat Rate, HR

a. Indicated Heat Rate, HRi

kg day KJ
(21407  )( 45788.452 )
m f Qh day 24hrs kg
HRi  
Pind 6016.97 KW
KJ
HRi  162904.82
KW  hr

b. Brake Head Rate, HRb

kg day KJ
(21407  )( 45788.452 )
m f Qh day 24hrs kg
HRb  
Pb 4211.8KW
KJ
HRb  9696.9
KW  hr

c. Combined or Over-all Heat Rate, HRc

50
 kg day KJ
(21407  )( 45788.452 )
m f Qh day 24hrs kg
HRc  
Pgen 4000 KW
KJ
HRc  10210.35
KW  hr

Piston Displacement

𝜋 2
𝑉𝑑 = 𝐷 𝐿𝑁𝑛𝑐 𝑛𝑝
4

Where:

Vd = piston displacement

D = bore or diameter of the piston

L = length of stroke

nc= no. of cylinders

np = no. of pistons actions

𝜋 2
𝑉𝑑 = 𝐷 𝐿𝑁𝑛𝑐 𝑛𝑝
4

𝜋 175𝑚 220𝑚 𝑟𝑒𝑣 𝑚𝑖𝑛 1

= 4 ( 1000 )2 ( 1000 )(1800 𝑚𝑖𝑛 × )(20)(1)(2) = 1.59m3/s
60𝑠

Air-Fuel Ratio

𝐶12 𝐻23 + 𝑎𝑂2 + 3.76𝑎𝑁2 → 𝑏𝐶𝑂2 + 𝑐𝐻2 𝑂 + 3.76𝑎𝑁2

C: 12 = b b = 12

51
H: 23 = 2c c = 11.5

O: 2a = 2b+c a = 17.75

N: 3.76a 3.76a

From engineeringtoolbox.com typical excess air for diesel fuel oil is 10% – 20%,

thus, use 20%.

𝐶12 𝐻23 + 17.7𝑂2 + 66.74𝑁2 → 12𝐶𝑂2 + 11.5𝐻2 𝑂 + 66.74𝑁2

𝐶12 𝐻23 + 1.2(17.75𝑂2 + 66.74𝑁2 ) → 12𝐶𝑂2 + 11.5𝐻2 𝑂 + 𝑑𝑂2 + 1.2(66.74𝑁2 )

1.2(17.75)(2) = 12(2) + 11.5 + 2𝑑

𝑑 = 3.55 𝑘𝑔 𝑚𝑜𝑙

𝐶12 𝐻23 + 21.3𝑂2 + 80.09𝑁2 → 12𝐶𝑂2 + 11.5𝐻2 𝑂 + 3.55𝑂2 + 80.09𝑁2

𝐴 21.3(32) + 80.09(28) 𝑘𝑔 𝑎𝑖𝑟

( )𝑎 = = 17.51
𝐹 12(12) + 1(23) 𝑘𝑔 𝑓𝑢𝑒𝑙

𝐴 𝐴
(𝐹 )𝑎 − (𝐹 )𝑡
%𝐸𝑥𝑐𝑒𝑠𝑠 𝐴𝑖𝑟 =
𝐴
( )𝑡
𝐹

𝐴
20% = 17.51 − (𝐹 )𝑡
𝐴
(𝐹 )
𝑡

𝐴 𝑘𝑔 𝑎𝑖𝑟
( )𝑡 = 14.59
𝐹 𝑘𝑔 𝑓𝑢𝑒𝑙

52
PERFORMANCE TEST
Brake Power 4,211.88 KW
Generator Power 4000 KW
Indicated Power 6,016.97 KW
Mass of Fuel Consumed per Day: 21,407 kg/day
Heating Value of Fuel 45,788.452 KJ/Kg
Piston speed 13.2 m/s
Brake Force 255.95 KN
Indicated Mean Brake Pressure 2,648.98 Kpa
Indicated Mean Effective Pressure 3,784.26 Kpa
I. Generator Efficiency 94.97%
Thermal Efficiencies
a. Indicated Thermal Efficiency 56.42%
b. Brake Thermal Efficiency, 37.13%
c. Combined or Over-all Thermal Efficiency 35.26%
II. Engine Efficiencies
a. Indicated Engine Efficiency 84.86%
b. Brake Engine Efficiency 59.41%
c. Combined or Over-all Engine Efficiency 56.42%
III. Specific Fuel Consumption
a. Indicated Specific Fuel Consumption, 0.148 kg/kw-hr
b. Brake Specific Fuel Consumption 0.212 kg/kw-hr
c. Combined or Over-all Specific Fuel Consumption 0.223 kg/kw-hr
IV. Heat Rate
a. Indicated Heat Rate 162,904.82 kj/kw-hr

53
 b. Brake Head Rate 9,696.9 kj/kw-hr
c. Combined or Over-all Heat Rate 10,210.35 kj/kw-hr
Piston Displacement 1.59m3/s
Air-Fuel Ratio 17.51 (kg air)/(kg fuel)

MASS BALANCE FOR THE COMBUSTION OF DIESEL FUEL

Input

100 mol C12H23

Process

mol air 12 mol CO2

0.21 mol O2/ mol 11.5 mol H2O
0.79 mol N2/ mol 3.55 mol O2

80.09 mol N2

VARIABLE LOAD CALCULATIONS

TIME LOAD (MW)

1:00 AM 6
2:00 AM 5.5
3:00 AM 5.25
4:00 AM 5.8
5:00 AM 6.5
6:00 AM 7.6
7:00 AM 8.7
8:00 AM 9.7
9:00 AM 11
10:00 AM 12.7
11:00 AM 13.2
12 NN 12.9
1:00 PM 12.2

54
 2:00 PM 12.1
3:00 PM 12.5
4:00 PM 15.6
5:00 PM 15
6:00 PM 16
7:00 PM 14
8:00 PM 12.6
9:00 PM 10
10:00 PM 7.9
11:00 PM 6
12 MN 6
TOTAL 250 MW
AVERAGE 10.42 MW
Table 3.1 Load Per Hour

Table 3.2 Load Curve

UNIT START STOP

GENERATOR 1 12:00 AM 12:00 AM

55
 GENERATOR 2 12:00 AM 12:00 AM
GENERATOR 3 7:00 AM 11:00 PM
GENERATOR 4 10:00 AM 10:00 PM
RESERVE UNIT
Table 3.3Schedule of Start Up and Stopping of Generators

Calculation of the Load Under the Curve

A  L W 1
A  bh
A  1MW  5.5MW 2
A  5.5MW 1
A  (1MW )(0.5MW )
2
A  0.25MW

AT  5.5MW  0.25MW
AT  5.75MW

1
A  bh
A  L W 2
1
2. A  1MW  5.25 A  (1MW )(0.25MW )
2
A  5.25MW
A  0.125MW

AT  5.25MW  0.125MW
AT  5.375MW

56
 A  L W
3. A  1MW  5.25MW
A  5.25MW

1
A  bh
A  L W 2
1
4. A  1 5.25 A  (1)(0.55)
2
A  5.25MW
A  0.275

AT  5.25  0.275
AT  5.525MW

1
A bh
A  L W 2
1
5. A  1 5.8 A  (1)(0.7)
2
A  5.8MW
A  0.35MW

AT  5.8  0.35
AT  6.15MW

1
A  bh
A  L W 2
1
6. A  1 6.5 A  (1)(1.1)
2
A  6.5MW
A  0.55MW

AT  6.5  0.55
AT  7.05

1
A  bh
A  L W 2
1
7. A  1 7.6 A  (1)(1.1)
2
A  7.6MW
A  0.55

57
AT  7.6  0.55
AT  8.15MW

1
A  bh
A  L W 2
1
8. A  1 8.7 A  (1)(1)
2
A  8.7 MW
A  0.5MW

AT  8.7  0.5
AT  9.2MW

1
A  bh
A  L W 2
1
9. A  1 9.7 A  (1)(1.3)
2
A  9.7 MW
A  0.65MW

AT  9.7  0.65
AT  10.35MW

1
A  bh
A  L W 2
1
10. A  111 A  (1)(1.7)
2
A  11MW
A  0.85MW

AT  11  0.85
AT  11.85MW

1
A bh
A  L W 2
1
11. A  112.7 A  (1)( 0.5)
2
A  12.7 MW
A  0.25

58
AT  12.7  0.25
AT  12.95MW

1
A bh
A  L W 2
1
12. A  113.2 A  (1)( 0.5)
2
A  13.2MW
A  0.25MW

AT  13.2  0.25
AT  13.45MW

1
A bh
A  L W 2
1
13. A  112.9 A  (1)( 0.3)
2
A  12.9MW
A  0.15MW

AT  12.9  0.15
AT  13.05

1
A bh
A  L W 2
1
14. A  112.2 A  (1)(0.7)
2
A  12.2MW
A  0.35MW

AT  12.2  0.35
AT  12.55MW

1
A  bh
A  L W 2
1
15. A  112.1 A  (1)(0.1)
2
A  12.1MW
A  0.05MW

59
AT  12.1  0.05
AT  12.15MW

1
A bh
A  L W 2
1
16. A  112.1 A  (1)( 0.4)
2
A  12.1MW
A  0.2 MW

AT  12.1  0.2
AT  12.3MW

1
A  bh
A  L W 2
1
17. A  112.5 A  (1)(3.1)
2
A  12.5MW
A  1.55MW

AT  12.5  1.55
AT  14.05

1
A bh
A  L W 2
1
18. A  115.6 A  (1)( 0.4)
2
A  15.6MW
A  0.2 MW

AT  15.6  0.2
AT  15.8MW

1
A  bh
A  L W 2
1
19. A  115 A  (1)(1)
2
A  15MW
A  0.5MW

60
AT  15  0.5
AT  15.5MW

1
A  bh
A  L W 2
1
20. A  114 A  (1)(1)
2
A  14MW
A  0.5MW

AT  14  0.5
AT  14.5MW

1
A  bh
A  L W 2
1
21. A  112.6 A  (1)(1.4)
2
A  12.6MW
A  0.7 MW

AT  12.6  0.7
AT  13.3MW

1
A bh
A  L W 2
1
22. A  110 A  (1)( 2.6)
2
A  10MW
A  1.3MW

AT  10  1.3
AT  11.3MW

1
A bh
A  L W 2
1
23. A  1 7.9 A  (1)( 2.1)
2
A  7.9MW
A  1.05MW

61
AT  7.9  1.05
AT  8.95MW

1
A  bh
A  L W 2
1
24. A  1 6 A  (1)(1.9)
2
A  6MW
A  0.95MW

AT  6  0.95
AT  6.95MW

AREA UNDER THE LOAD CURVE= 5.75 + 5.375 + 5.25 + 5.525 + 6.15 + 7.05

+ 8.15 + 9.2 + 10.35 + 11.85 + 12.95 + 13.45 + 13.05 + 12.55 + 12.15 + 12.3 +

14.05 + 15.8 + 15.5 + 14.5 + 13.3 + 11.3 + 8.95 + 6.95

Area under the load curve = 251.25 MW

𝑅𝑒𝑠𝑒𝑟𝑣𝑒 𝑂𝑣𝑒𝑟 𝑃𝑒𝑎𝑘 = 𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 − 𝑃𝑒𝑎𝑘 𝐿𝑜𝑎𝑑

= 20,000 – 15,800

𝑅𝑒𝑠𝑒𝑟𝑣𝑒 𝑂𝑣𝑒𝑟 𝑃𝑒𝑎𝑘 = 4200 KW (21%)

𝑇𝑜𝑡𝑎𝑙 𝐿𝑜𝑎𝑑 (𝑘𝑊−ℎ𝑟𝑠) 251,250 (𝑘𝑊−ℎ𝑟𝑠)

𝑑𝑎𝑦 𝑑𝑎𝑦
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐿𝑜𝑎𝑑 = 𝑛𝑜.𝑜𝑓 ℎ𝑜𝑢𝑟𝑠 = 24 ℎ𝑟𝑠 = 10,468.75 KW
𝑑𝑎𝑦 𝑑𝑎𝑦

𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐿𝑜𝑎𝑑 10,458.75 𝐾𝑊

𝐿𝑜𝑎𝑑 𝐹𝑎𝑐𝑡𝑜𝑟 = = = 0.6626 = 66.26%
𝑃𝑒𝑎𝑘 𝐿𝑜𝑎𝑑 15,800 𝐾𝑊

𝐴𝑛𝑛𝑢𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝐿𝑜𝑎𝑑 𝐹𝑎𝑐𝑡𝑜𝑟 × 𝑃𝑒𝑎𝑘 𝐿𝑜𝑎𝑑 × 8760

= 0.6626 x 15,800 x 8760

62
𝐴𝑛𝑛𝑢𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 =91,709,140.8 KW-hrs.

𝐴𝑛𝑛𝑢𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦 𝑃𝑟𝑜𝑑𝑢𝑐𝑒𝑑 91,709,140.8 KW−hrs

𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 = 𝐾𝑊 𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 ×8760
= 20,000 ×8760
= 0.5235 = 52.35%

𝐴𝑛𝑛𝑢𝑎𝑙 𝐾𝑊−ℎ𝑟𝑠 91,709,140.8

𝑈𝑠𝑒 𝐹𝑎𝑐𝑡𝑜𝑟 = = = 0.579 = 57.9%
𝐾𝑊 𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 ×𝑛𝑜.𝑜𝑓 ℎ𝑜𝑢𝑟𝑠 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 20,000 × 330 ×24

𝑃𝑒𝑎𝑘 𝐿𝑜𝑎𝑑 15,800 KW

𝐷𝑒𝑚𝑎𝑛𝑑 𝐹𝑎𝑐𝑡𝑜𝑟 = = 20,000 𝐾𝑊 = 0.79 = 79%
𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦

Table 3.4 Summary of Technical Catalogue

EQUIPMENT SPECIFICATION

Engine type : four-stroke, water cooled diesel

Displacement: 105.8L/6,456ci

Engine layout: V-20

Block Material: cast iron

Valvetrain: OHV four valves / cylinder (80 total)

CAT C175-20 Bore: 6.89 inches

Stroke: 8.66 inches

Compression ratio: 15.3:1

Induction: four parallel turbochargers

Air treatment: air-to-water intercooler

Air intake rate: 11,966 cubic feet/minute

63
 Fueling: common rail

Power: 4,000 KW at 1,800rpm

Torque: 16,474 lb-ft at 1,800 rpm

Standby power: 4 megawatts

Voltage: 12,470 volts

Frequency: 60 Hz

Engine operation speed: 1,8000 rpm

Max. Fuel consumption: 274.4gallons/hour

Exhaust gas stack temperature: 894 degrees

Oil capacity: 178.3 gallons

Economical Carbon steel

Diameter: 120 ft

Height: 40ft

Carrying Capacity up to 12,820.08 m3/ month

Fuel Storage Tank ISO 1496 Part 3 - Type 75 "Tank Container"

Baffled design allows partial payloads to be

carried

Sealed area around the valve to give product

bunding

Diameter: 15 ft

Height: 16 ft
Day Tank
Includes Rupture Basin And Instrumentation

80.13m 3/day Capacity

64
 UL Approved, NFPA 30 Compliant

Mounting Base: Structural Steel Channel

Metal Thickness: 1.23 mm

Exterior Finish: Chemical Resistant Gray

Enamel, Rust Resistant Primer

Manual Fill Port: 2" NPT

Inspection Port: 6" Square Gasketed Plate

1" NPT Pipe Connections: Tank Fill, Engine Fuel

Return, Overflow to Storage Tank, Engine Fuel

Supply, Plugged Drain

Approvals / Compliance: UL Approved, NFPA

30 compliant

Optional Rupture Basin Specifications

Mounting Base: Structural Steel Channel

Containment: 160% Of Tank Capacity Standard

Leak Detector: Preferred RBS Float Switch

Metal Thickness: Same As Companion Tank

Turned Edge Reinforcement

Finish: Chemical Resistant Gray Enamel Finish,

Rust Resistant Primer.

Drain: Plugged 1" NPT Coupling

Approvals / Compliance: UL Approved

Silencer Intake

65
 4 cycle: 4000 6000 FPM

Exhaust

Medium speed (350 to1200 RPM): 6000 to 9000

FPM

Pressure drop factor (PDF)

Model: 111

PDF: 4.4

Dynamic insertion loss (D.I.L) / Grade

Model: 111

Grade: industrial

D.I.L: 10dB

Volume: 113 cu ft

Volume operating: 85 cu ft

Dry weight: 1000 lbs

Operational weight: 15,500 lbs

Feeding capacity: 9.9-990 cu ft/hr

Surge Tank Hazardous area classification: non hazardous

EX certification type: optional ATEX, IECEx

Steel costruction: Carbon steel painted

Design temperature: +14 to +113 degrees

farenheit

Motors: 4.1 hp

66
 Instrumentation: level switch, pressure safety

valve, pressure transmitter, load cells (3 units)

Air consumption: 17.5 cu ft/min

Model: E4JS

Type: standard blade louver

Application: decorative, air exhaust, ventilation

Louver Free area: 50.4 %

Free area velocity: 888 fpm

Over all performance: 7157 cfm

Pressure loss: 0.15

Materials: stainless steel, carbon steel, hastelloy,

inconel, incoloy, duplex alloys,copper and

copper alloys, super austenitic stainless steels

Rated pressure: 3000 PSIG to full vacuum

Temperature rating: 1,200 to -325 degree

farenheit
Heat Exchanger
Simulation software: aspen shell & tube

exchanger, aspen shell & tube mechanical

Applications: condenser, evaporator, heater,

interchanger, product cooler, reactor

Services: sandblasting, painting, passivation,

post welded heat treatment, radiography, helium

67
 testing

Compliances: ASME code, API 660, TEMA

standards

Material: Ceramic

Structure type: plate type catalyst

SCR Catalyst Catalyst unit: Metal as carrier, the surface coated

with active ingredients.

Applicable scope: high or low smoke dust.

Design water flow: 102.93 kg/min

Basin water volume: 3,000 – 3,500 ltr

Water connections: 150mm camlock

Cooling Tower
Bulk air cooling

Volumetric Air flow 2153.46 m^3/min

Air flow 2,498.22 kg/min

Material: polycarbonate

Seal: lip seal

Prime volume: 45ml

Max. Pump speed: 3000 RPM

Fuel Injection Pump
Max. Outlet pressure: 800mmHg

Inlet/Outlet port size: 3/8”

Heat generation: condition: 5 L/min flow rate,

300mmHg generated pressure 138 cal/min

68
 Material: bronze

Impeller: neoprene compound

Seal: lip seal

Port: 3/8” female thread, ½” barbed fittings

included

Voltage: 12V

Amp draw: max. 10 amp

Gear Type Pump
Fuse size: 15 amp

Motor type: permanent magnet type fully

enclosed stainless steel shaft ball type shaft

bearing reversible.

Self priming: 3 m vertical lift

Pressure: can generate pressures up to 2 bar

Liquids: lubricants and viscous liquid

Body material: ASTM, ASME JIS

Cast steel / Forged steel

1Cr0.5Mo steel

2.5cr1Mo steel
Relief Valve
Fluid: water

Pressure class, size (standardized): 15mm-

50mm

*standardized according to set pressure

69
 Connection form: inlet end: butt weld, flanged

Outlet end: flanged

*the outlet end can be made to order.

Body material: ASTM, ASME, JIS

Cast steel / Forged steel

1Cr0.5Mo Steel

2.5Cr1Mo Steel

Fluid: water, steam

Safety Valve Pressure class, size (standardized): 40mm-

154mm

*standardize according to set pressure

Connection form: inlet end: butt weld, flanged

Outlet end: flanged

*the outlet end can be made to order.

Nominal pressure: 1.0 Mpa

Shell testing: 2.2 Mpa

Seal testing: 1.6 Mpa

Aie testing: 0.6 Mpa

Check Valve
Max. Temp: less than or equal to 425 degree

celcius

Medium: water

Lifting bolt: A3

70
 Disc: SS201

Body: WCB

Butterfly control valve

Diameter: 2”-24”

Type: wafer or lug butterfly valve

Nominal pressures: ANSI class 150-600

Control Valve Materials: carbon steel, stainless steel, chrome-

molly, alloy 20, monel, hastelloy B & C, titanium,

and others

Seats: soft, metal and dual

Actuator:

Technology: electronic, dynamic

Capacity: 500 kVA to 2000kVA

Efficiency: 99.90% to 99.93%

Response time: adjustable to suit site supply

Input voltage range: 11,000V nominal

Transformer Output accuracy: +- 1.25V single phase V output

Frequency: 60Hz

Conductor insulation class: class A/A

Temperature class: H

Operating temp: -10C +40C

Ingress protection: IP 54

71
 Standards: BSEN60076, BS2562

Model: K25

Power: 63 hp

Torque: 139 lb-ft

Power measured: 2700 rpm

Displacement: 152 cu.in

Torque measured: 1600rpm

Fuel type: gas

Operating weight: 7900 lb

Tire type: pneumatic

Number of front wheels: 2

Forklift Number of rear wheels: 2

Max. Speed: 11.5 mph

Load capacity: 5511.6 lb

Load center: 19.7 in

Mast tip forward: 6 degrees

Mast tip rear: 10 degrees

Max. Fork spread: 39.4 in

Lift speed: 130 ft/min

Lower speed: 98 ft/min

Length to fork face: 8.4 ft-in

Overall width: 3.8 ft-in

72
Overall height – mast lowered: 7 ft-in

Max fork height: 11 ft-in

Wheelbase: 5.2 ft-in

Turning radius: 7.3 ft-in

Height to top of overhead guard: 6.9 ft-in

Ground clearance: 4.6 in

73
 CHAPTER IV

ECONOMIC ANALYSIS

This chapter presents the power plant economics analysis including the

calculation of capital expenditures, operating expenditures, and the total project

cost.

Capital expenditures are money invested to acquire physical assets to

setup the power plant. This will include equipment cost, land cost, building cost,

piping cost, and miscellaneous costs. Majority of the money invested to capital

expenditures is for equipment cost. Table 4.4 shows the capital investment

needed in the foundation of the proposed design of a 20 MW Diesel Power Plant.

From this data, 60% of the total capital investment is to be loaned from a bank

and the remaining 40% is to be shouldered by the owners. On the other hand,

Table 4.2 shows the list of machineries and equipment according to their

equivalent cost and quantity needed for this design. The pricing of equipment

was based on the current market and selling price. The pricing for auxiliary

equipment and piping (20%), electrical equipment (20%) and building

construction 15% was based on PPT & D by P.J. Potter, page 590.

From researchgate website, the diesel power plant operating cost is

presented in the percentage analysis as follows: fuel (75%), operations and

maintenance (8%), spare parts (6%), chemicals (5%), and training expense

(3%).This analysis was used for the computation of operating cost as shown in

74
Table 4.19 and 4.20.The net present value is also stated in these tables shown

as net income after tax.

Payback period is the time in which the initial cash outflow of an

investment is expected to be recovered from the cash inflows generated by the

investment. It is one of the simplest investment appraisal techniques. Based on

the computation made for this design, the payback or payout period is 3.65 years

as shown in Table 4.21.

Return of investment is the ratio between the net profit and cost of

investment resulting from an investment of some resource. A high ROI means

the investment’s gains compare favorably to its cost. In this design, the ROI

computed is 24.69 for the average of ten years as shown in Table 4.22.

Sensitivity Analysis

Based on the evaluation, the following will be the expenses and earnings

of the company:

 Total Capital Investment = Php 377,774,248.89

 Amortization for 10 years = Php 36,888,611.59

 Revenue for the First Year = Php 484,605,000.00

 Salavage Value = Php 6,012,853.20

 Operating Cost for the First Year= Php 482,178,883.80

 Net Income for the First Year = Php 99,216,908.69

75
 Table 4.1

EMPLOYEES’ SALARY

ELECPRO CORPORATION
No.of Unit/Position Title Monthly Sub-Total Annual Salary
Total Annual
Position Salary (Php) (Php) from
Salary
(Php) www.payscale.com
Plant Manager/ Professional
1 55,000.00 55,000.00 660,000.00 660,000.00
Mechanical Engineer
3 Mechanical Shift Engineer 30,347.25 91,041.75 364,167.00 1,092,501.00
1 Instrumentation & Control Engineer 29,361.42 29,361.42 352,337.00 352,337.00
1 Admin/Logistics Supervisor 25,311.75 25,311.75 303,741.00 303,741.00
1 Financial Accountant 24,368.00 24,368.00 292,416.00 292,416.00
3 Electrical Shift Engineer 23,725.50 71,176.50 284,706.00 854,118.00
1 Warehouse Supervisor/ Purchaser 19,323.50 19,323.50 231,882.00 231,882.00
2 Maintenance Technician 15,146.42 30,292.83 181,757.00 363,514.00
2 Warehouse Man/ Storekeeper 10,590.00 21,180.00 173,300.00 346,600.00
2 Control Room Operator 14,159.00 28,318.00 169,908.00 339,816.00
3 Lineman 12,548.00 37,644.00 150,576.00 451,728.00
2 Helper 10,590.00 21,180.00 127,080.00 254,160.00
1 Safety Officer 14,441.67 14,441.67 127,080.00 127,080.00
1 Meter Reader/ Mail Courier 10,590.00 10,590.00 127,080.00 127,080.00
24 TOTAL 295,502.50 479,229.42 3,546,030.00 5,796,973.00

76
 Table 4.2

COST OF MACHINERIES AND EQUIPMENT

PRICE PER PC TOTAL

EQUIPMENT PCS
(PHP) PRICE(PHP)
CAT C175-20 5 19,796,400 98,982,000
Fuel Storage Tank 2 250,000 500,000
Day Tank 6 100,000 600,000
Silencer 6 25,000 150,000
Louver 12 6,750 81,000
Heat Exchanger 12 15,750 189,000
SCR Catalyst 7 112,500 787,500
Cooling Tower 2 117,500 235,000
Fuel Injection Pump 7 13,250 92,750
Gear Type Pump 7 8,750 61,250
Relief Valve 7 7,750 54,250
Safety Valve 7 7,800 54,600
Check Valve 7 22,000 154,000
Control Valve 7 14,250 99,750
Transformer 5 352,500 1,762,500
Forklift 1 550,000 550,000
TOTAL: 99 21,517,700 104,353,600

77
 Table 4.3

COST OF RAW MATERIALS

QUANTITY
PRODUCT PRODUCT
NEEDED TOTAL PRICE
DESCRIPTION DESCRIPTION SALE PRICE
ANNUALY
(Liter) (Php)
OIL-CAT 15W-40 OIL-CAT 15W-40
684 Php 3803.5 per 19L 136,926.00
DEO, 19L DEO, 19L
B20 Diesel Fuel B20 Diesel Fuel 8,500,000 Php 42.12 per L 300,900,000.00

Note:
𝑔𝑎𝑙 3.785 𝐿 𝐿
Consumption of OIL-CAT 15W-40 DEO Container = 178.3 × = 675
𝑦𝑟 1 𝑔𝑎𝑙 𝑦𝑟

675 𝐿 ÷ 19 𝐿 = 35.53 ≈ 36 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟𝑠 𝑜𝑓 𝑂𝐼𝐿 − 𝐶𝐴𝑇

𝐿 ℎ𝑟 𝐿
Consumption of B20 Diesel Fuel = 1039.3 ℎ𝑟
× 24 𝑑𝑎𝑦
× 330 𝑑𝑎𝑦𝑠 = 8,231,256 𝑦𝑟

 The values used in the table are rounded up, so that there will be excess amount in case of

emergency

78
 Table 4.4

CAPITAL INVESTMENT

PARTICULARS COST (PHP)

Purchased Equipment Delivered (45%) 104,353,600.00

Auxilliary Equipment & Piping (20%) 46,379,377.78
Electrical Equipment (20%) 46,379,377.78
Building Construction (15%) 34,784,533.33
Land (20,000 sq.meter) 5,000,000.00
Contingency (37%PED) 38,610,832.00
Contractor's Fee (19% PED) 19,827,184.00
Legal Expense (4% PED) 4,174,144.00
Fixed Capital Investment 299,509,048.89
Working Capital Investment (75%PED) 78,265,200.00

TOTAL CAPITAL INVESTMENT 377,774,248.89

Capitalization Schedule
Bank Loan 226,664,549.33
Owner's Equity 151,109,699.56

79
 Table 4.5

AMORTIZATION SCHEDULE

Principal at Periodic Principal at

Period the Beginning Interest (%) Amortization Payments to Interest the Ending of
of the Period the Principal the Period
1 226,664,549.33 10 36,888,611.59 14,222,156.65 22,666,454.93 212,442,392.68
2 212,442,392.68 10 36,888,611.59 15,644,372.32 21,244,239.27 196,798,020.36
3 196,798,020.36 10 36,888,611.59 17,208,809.55 19,679,802.04 179,589,210.81
4 179,589,210.81 10 36,888,611.59 18,929,690.51 17,958,921.08 160,659,520.30
5 160,659,520.30 10 36,888,611.59 20,822,659.56 16,065,952.03 139,836,860.75
6 139,836,860.75 10 36,888,611.59 22,904,925.51 13,983,686.07 116,931,935.23
7 116,931,935.23 10 36,888,611.59 25,195,418.06 11,693,193.52 91,736,517.17
8 91,736,517.17 10 36,888,611.59 27,714,959.87 9,173,651.72 64,021,557.30
9 64,021,557.30 10 36,888,611.59 30,486,455.86 6,402,155.73 33,535,101.44
10 33,535,101.44 10 36,888,611.59 33,535,101.44 3,353,510.14 0.00

𝑃 𝑥 𝑖 ( 1+𝑖 )𝑛 226,664,549.33𝑥 0.10 ( 1+0.10 )10

𝐴𝑚𝑚𝑜𝑟𝑡𝑖𝑧𝑎𝑡𝑖𝑜𝑛 = = = 36,888,611.59
( 1+𝑖 )𝑛 −1 ( 1+0.10)10 −1

𝐼𝑛𝑡𝑒𝑟𝑒𝑠𝑡 = 𝑃𝑥 𝑖

𝑃𝑒𝑟𝑖𝑜𝑑𝑖𝑐 𝑃𝑎𝑦𝑚𝑒𝑛𝑡𝑠 𝑡𝑜 𝑡ℎ𝑒 𝑃𝑟𝑖𝑛𝑐𝑖𝑝𝑎𝑙 = 𝐴𝑚𝑜𝑟𝑡𝑖𝑧𝑎𝑡𝑖𝑜𝑛 − 𝐼𝑛𝑡𝑒𝑟𝑒𝑠𝑡

𝑃𝑟𝑖𝑛𝑐𝑖𝑝𝑎𝑙 𝑎𝑡 𝑡ℎ𝑒 𝐸𝑛𝑑𝑖𝑛𝑔 𝑜𝑓 𝑡ℎ𝑒 𝑃𝑒𝑟𝑖𝑜𝑑 = 𝑃𝑟𝑖𝑛𝑐𝑖𝑝𝑎𝑙 𝑎𝑡 𝑡ℎ𝑒 𝐵𝑒𝑔𝑖𝑛𝑛𝑖𝑛𝑔 𝑜𝑓 𝑡ℎ𝑒 𝑃𝑒𝑟𝑖𝑜𝑑 − 𝑃𝑒𝑟𝑖𝑜𝑑𝑖𝑐 𝑃𝑎𝑦𝑚𝑒𝑛𝑡𝑠 𝑡𝑜 𝑡ℎ𝑒 𝑃𝑟𝑖𝑛𝑐𝑖𝑝𝑎𝑙

80
 Table 4.6

DEPRECIATION

Quantity Book Value Salvage Value Useful Life Depreciation Total Depreciation
Equipment
(Pcs) (Php) (Php) (Yr) (Php) (Php)
CAT C175-20 5 19,796,400 1,979,640.00 10 1,781,676.00 8,908,380.00
Fuel Storage
2 250,000
Tank 25,000.00 10 22,500.00 45,000.00
Day Tank 6 100,000 10,000.00 10 9,000.00 54,000.00
Silencer 6 25,000 2,500.00 10 2,250.00 13,500.00
Louver 12 6,750 675.00 10 607.50 7,290.00
Heat
12 15,750
Exchanger 1,575.00 10 1,417.50 17,010.00
SCR Catalyst 7 112,500 11,250.00 10 10,125.00 70,875.00
Cooling Tower 2 117,500 11,750.00 10 10,575.00 21,150.00
Fuel Injection
7 13,250
Pump 1,325.00 10 1,192.50 8,347.50
Gear Type
7 8,750
Pump 875.00 10 787.50 5,512.50
Relief Valve 7 7,750 775.00 10 697.50 4,882.50
Safety Valve 7 7,800 780.00 10 702.00 4,914.00
Check Valve 7 22,000 2,200.00 10 1,980.00 13,860.00
Control Valve 7 14,250 1,425.00 10 1,282.50 8,977.50
Transformer 5 352,500 35,250.00 10 31,725.00 158,625.00
Forklift 1 550,000 55,000.00 10 49,500.00 49,500.00
Building 1 38,610,832 3,861,083.20 20 1,737,487.44 1,737,487.44
TOTAL 100 60,128,532 6,012,853.20 3,674,080.44 11,129,311.44

81
 𝑜𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑐𝑜𝑠𝑡 − 𝑠𝑎𝑙𝑣𝑎𝑔𝑒 𝑣𝑎𝑙𝑢𝑒
𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 =
𝑠𝑒𝑟𝑣𝑖𝑐𝑒 𝑙𝑖𝑓𝑒

Table 4.7

ACCUMULATED DEPRECIATION

Accumulated
Annual
Year No. of Years Depreciation
Depreciation (Php)
(Php)

2020 11,129,311.44 1 11,129,311.44

2021 11,129,311.44 2 22,258,622.88

2022 11,129,311.44 3 33,387,934.32

2023 11,129,311.44 4 44,517,245.76

2024 11,129,311.44 5 55,646,557.20

2025 11,129,311.44 6 66,775,868.64

2026 11,129,311.44 7 77,905,180.08

2027 11,129,311.44 8 89,034,491.52

2028 11,129,311.44 9 100,163,802.96

2029 11,129,311.44 10 111,293,114.40

82
 Table 4.8

PROJECTED SALES OF YEAR 2020

Price (Php) per Daily Gross Annual Gross

TIME LOAD (MW) LOAD (kw-hr)
KW-hr Sales Sales
1:00 AM 6 6,000.00 6.00 36,000.00 11,880,000.00
2:00 AM 5.5 5,500.00 6.00 33,000.00 10,890,000.00
3:00 AM 5.25 5,250.00 6.00 31,500.00 10,395,000.00
4:00 AM 5.8 5,800.00 6.00 34,800.00 11,484,000.00
5:00 AM 6.5 6,500.00 6.00 39,000.00 12,870,000.00
6:00 AM 7.6 7,600.00 6.00 45,600.00 15,048,000.00
7:00 AM 8.7 8,700.00 6.00 52,200.00 17,226,000.00
8:00 AM 9.7 9,700.00 6.00 58,200.00 19,206,000.00
9:00 AM 11 11,000.00 6.00 66,000.00 21,780,000.00
10:00 AM 12.7 12,700.00 6.00 76,200.00 25,146,000.00
11:00 AM 13.2 13,200.00 6.00 79,200.00 26,136,000.00
12:00 NN 12.9 12,900.00 6.00 77,400.00 25,542,000.00
1:00 PM 12.2 12,200.00 6.00 73,200.00 24,156,000.00
2:00 PM 12.1 12,100.00 6.00 72,600.00 23,958,000.00
3:00 PM 12.5 12,500.00 6.00 75,000.00 24,750,000.00
4:00 PM 15.6 15,600.00 6.00 93,600.00 30,888,000.00
5:00 PM 15 15,000.00 6.00 90,000.00 29,700,000.00
6:00 PM 16 16,000.00 6.00 96,000.00 31,680,000.00
7:00 PM 14 14,000.00 6.00 84,000.00 27,720,000.00
8:00 PM 12.6 12,600.00 6.00 75,600.00 24,948,000.00
9:00 PM 10 10,000.00 6.00 60,000.00 19,800,000.00
10:00 PM 7.9 7,900.00 6.00 47,400.00 15,642,000.00
11:00 PM 6 6,000.00 6.00 36,000.00 11,880,000.00
12:00 MN 6 6,000.00 6.00 36,000.00 11,880,000.00
TOTAL 244.75 244,750.00 6.00 1,468,500.00 484,605,000.00

83
 Table 4.9

PROJECTED SALES OF YEAR 2021

Price (Php) per KW- Daily Gross Annual Gross

TIME LOAD (MW) LOAD (kw-hr)
hr Sales Sales
1:00 AM 6.12 6,120.00 6.18 37,821.60 12,481,128.00
2:00 AM 5.61 5,610.00 6.18 34,669.80 11,441,034.00
3:00 AM 5.36 5,355.00 6.18 33,093.90 10,920,987.00
4:00 AM 5.92 5,916.00 6.18 36,560.88 12,065,090.40
5:00 AM 6.63 6,630.00 6.18 40,973.40 13,521,222.00
6:00 AM 7.75 7,752.00 6.18 47,907.36 15,809,428.80
7:00 AM 8.87 8,874.00 6.18 54,841.32 18,097,635.60
8:00 AM 9.89 9,894.00 6.18 61,144.92 20,177,823.60
9:00 AM 11.22 11,220.00 6.18 69,339.60 22,882,068.00
10:00 AM 12.95 12,954.00 6.18 80,055.72 26,418,387.60
11:00 AM 13.46 13,464.00 6.18 83,207.52 27,458,481.60
12:00 NN 13.16 13,158.00 6.18 81,316.44 26,834,425.20
1:00 PM 12.44 12,444.00 6.18 76,903.92 25,378,293.60
2:00 PM 12.34 12,342.00 6.18 76,273.56 25,170,274.80
3:00 PM 12.75 12,750.00 6.18 78,795.00 26,002,350.00
4:00 PM 15.91 15,912.00 6.18 98,336.16 32,450,932.80
5:00 PM 15.30 15,300.00 6.18 94,554.00 31,202,820.00
6:00 PM 16.32 16,320.00 6.18 100,857.60 33,283,008.00
7:00 PM 14.28 14,280.00 6.18 88,250.40 29,122,632.00
8:00 PM 12.85 12,852.00 6.18 79,425.36 26,210,368.80
9:00 PM 10.20 10,200.00 6.18 63,036.00 20,801,880.00
10:00 PM 8.06 8,058.00 6.18 49,798.44 16,433,485.20
11:00 PM 6.12 6,120.00 6.18 37,821.60 12,481,128.00
12:00 MN 6.12 6,120.00 6.18 37,821.60 12,481,128.00
TOTAL 249.65 249,645.00 6.18 1,542,806.10 509,126,013.00

84
 Table 4.10

PROJECTED SALES OF YEAR 2022

LOAD Price (Php)

TIME LOAD (kw-hr) Daily Gross Sales Annual Gross Sales
(MW) per KW-hr
1:00 AM 6.24 6,242.40 6.37 39,735.37 13,112,673.08
2:00 AM 5.72 5,722.20 6.37 36,424.09 12,019,950.32
3:00 AM 5.46 5,462.10 6.37 34,768.45 11,473,588.94
4:00 AM 6.03 6,034.32 6.37 38,410.86 12,675,583.97
5:00 AM 6.76 6,762.60 6.37 43,046.65 14,205,395.83
6:00 AM 7.91 7,907.04 6.37 50,331.47 16,609,385.90
7:00 AM 9.05 9,051.48 6.37 57,616.29 19,013,375.96
8:00 AM 10.09 10,091.88 6.37 64,238.85 21,198,821.47
9:00 AM 11.44 11,444.40 6.37 72,848.18 24,039,900.64
10:00 AM 13.21 13,213.08 6.37 84,106.54 27,755,158.01
11:00 AM 13.73 13,733.28 6.37 87,417.82 28,847,880.77
12:00 NN 13.42 13,421.16 6.37 85,431.05 28,192,247.12
1:00 PM 12.69 12,692.88 6.37 80,795.26 26,662,435.26
2:00 PM 12.59 12,588.84 6.37 80,133.00 26,443,890.70
3:00 PM 13.01 13,005.00 6.37 82,782.03 27,318,068.91
4:00 PM 16.23 16,230.24 6.37 103,311.97 34,092,950.00
5:00 PM 15.61 15,606.00 6.37 99,338.43 32,781,682.69
6:00 PM 16.65 16,646.40 6.37 105,960.99 34,967,128.20
7:00 PM 14.57 14,565.60 6.37 92,715.87 30,596,237.18
8:00 PM 13.11 13,109.04 6.37 83,444.28 27,536,613.46
9:00 PM 10.40 10,404.00 6.37 66,225.62 21,854,455.13
10:00 PM 8.22 8,219.16 6.37 52,318.24 17,265,019.55
11:00 PM 6.24 6,242.40 6.37 39,735.37 13,112,673.08
12:00 MN 6.24 6,242.40 6.37 39,735.37 13,112,673.08
TOTAL 254.64 254,637.90 6.37 1,620,872.09 534,887,789.26

85
 Table 4.11

PROJECTED SALES OF YEAR 2023

Price (Php)
TIME LOAD (MW) LOAD (kw-hr) Daily Gross Sales Annual Gross Sales
per KW-hr
1:00 AM 6.38 6,379.73 6.56 41,827.84 13,803,186.44
2:00 AM 5.85 5,848.09 6.56 38,342.18 12,652,920.90
3:00 AM 5.58 5,582.27 6.56 36,599.36 12,077,788.14
4:00 AM 6.17 6,167.08 6.56 40,433.58 13,343,080.23
5:00 AM 6.91 6,911.38 6.56 45,313.49 14,953,451.98
6:00 AM 8.08 8,080.99 6.56 52,981.93 17,484,036.16
7:00 AM 9.25 9,250.61 6.56 60,650.36 20,014,620.34
8:00 AM 10.31 10,313.90 6.56 67,621.67 22,315,151.41
9:00 AM 11.70 11,696.18 6.56 76,684.37 25,305,841.81
10:00 AM 13.50 13,503.77 6.56 88,535.59 29,216,744.63
11:00 AM 14.04 14,035.41 6.56 92,021.24 30,367,010.17
12:00 NN 13.72 13,716.43 6.56 89,929.85 29,676,850.85
1:00 PM 12.97 12,972.12 6.56 85,049.94 28,066,479.10
2:00 PM 12.87 12,865.79 6.56 84,352.81 27,836,425.99
3:00 PM 13.29 13,291.11 6.56 87,141.33 28,756,638.42
4:00 PM 16.59 16,587.31 6.56 108,752.38 35,888,284.75
5:00 PM 15.95 15,949.33 6.56 104,569.59 34,507,966.10
6:00 PM 17.01 17,012.62 6.56 111,540.90 36,808,497.18
7:00 PM 14.89 14,886.04 6.56 97,598.29 32,207,435.03
8:00 PM 13.40 13,397.44 6.56 87,838.46 28,986,691.53
9:00 PM 10.63 10,632.89 6.56 69,713.06 23,005,310.74
10:00 PM 8.40 8,399.98 6.56 55,073.32 18,174,195.48
11:00 PM 6.38 6,379.73 6.56 41,827.84 13,803,186.44
12:00 MN 6.38 6,379.73 6.56 41,827.84 13,803,186.44
TOTAL 260.24 260,239.93 6.56 1,706,227.21 563,054,980.24

86
 Table 4.12

PROJECTED SALES OF YEAR 2024

Price (Php) per Daily Gross Annual Gross

TIME LOAD (MW) LOAD (kw-hr)
KW-hr Sales Sales
1:00 AM 6.52 6,520.09 6.75 44,030.49 14,530,062.24
2:00 AM 5.98 5,976.75 6.75 40,361.28 13,319,223.72
3:00 AM 5.71 5,705.08 6.75 38,526.68 12,713,804.46
4:00 AM 6.30 6,302.75 6.75 42,562.81 14,045,726.83
5:00 AM 7.06 7,063.43 6.75 47,699.70 15,740,900.76
6:00 AM 8.26 8,258.78 6.75 55,771.96 18,404,745.50
7:00 AM 9.45 9,454.13 6.75 63,844.21 21,068,590.25
8:00 AM 10.54 10,540.81 6.75 71,182.63 23,490,267.29
9:00 AM 11.95 11,953.49 6.75 80,722.57 26,638,447.44
10:00 AM 13.80 13,800.85 6.75 93,197.87 30,755,298.41
11:00 AM 14.34 14,344.19 6.75 96,867.08 31,966,136.93
12:00 NN 14.02 14,018.19 6.75 94,665.56 31,239,633.81
1:00 PM 13.26 13,257.51 6.75 89,528.67 29,544,459.89
2:00 PM 13.15 13,148.84 6.75 88,794.82 29,302,292.18
3:00 PM 13.58 13,583.51 6.75 91,730.19 30,270,963.00
4:00 PM 16.95 16,952.23 6.75 114,479.28 37,778,161.82
5:00 PM 16.30 16,300.22 6.75 110,076.23 36,325,155.60
6:00 PM 17.39 17,386.90 6.75 117,414.64 38,746,832.64
7:00 PM 15.21 15,213.54 6.75 102,737.81 33,903,478.56
8:00 PM 13.69 13,692.18 6.75 92,464.03 30,513,130.70
9:00 PM 10.87 10,866.81 6.75 73,384.15 24,216,770.40
10:00 PM 8.58 8,584.78 6.75 57,973.48 19,131,248.61
11:00 PM 6.52 6,520.09 6.75 44,030.49 14,530,062.24
12:00 MN 6.52 6,520.09 6.75 44,030.49 14,530,062.24
TOTAL 265.97 265,965.21 6.75 1,796,077.14 592,705,455.50

87
 Table 4.13

PROJECTED SALES OF YEAR 2025

Price (Php) per Daily Gross Annual Gross

TIME LOAD (MW) LOAD (kw-hr)
KW-hr Sales Sales
1:00 AM 6.66 6,663.53 6.96 46,349.14 15,295,215.32
2:00 AM 6.11 6,108.23 6.96 42,486.71 14,020,614.04
3:00 AM 5.83 5,830.59 6.96 40,555.50 13,383,313.40
4:00 AM 6.44 6,441.41 6.96 44,804.17 14,785,374.81
5:00 AM 7.22 7,218.82 6.96 50,211.57 16,569,816.59
6:00 AM 8.44 8,440.47 6.96 58,708.91 19,373,939.40
7:00 AM 9.66 9,662.12 6.96 67,206.25 22,178,062.21
8:00 AM 10.77 10,772.70 6.96 74,931.11 24,727,264.76
9:00 AM 12.22 12,216.47 6.96 84,973.42 28,041,228.08
10:00 AM 14.10 14,104.47 6.96 98,105.67 32,374,872.42
11:00 AM 14.66 14,659.76 6.96 101,968.10 33,649,473.70
12:00 NN 14.33 14,326.59 6.96 99,650.65 32,884,712.93
1:00 PM 13.55 13,549.18 6.96 94,243.25 31,100,271.14
2:00 PM 13.44 13,438.12 6.96 93,470.76 30,845,350.89
3:00 PM 13.88 13,882.35 6.96 96,560.70 31,865,031.91
4:00 PM 17.33 17,325.17 6.96 120,507.76 39,767,559.82
5:00 PM 16.66 16,658.82 6.96 115,872.84 38,238,038.29
6:00 PM 17.77 17,769.41 6.96 123,597.70 40,787,240.84
7:00 PM 15.55 15,548.23 6.96 108,147.99 35,688,835.74
8:00 PM 13.99 13,993.41 6.96 97,333.19 32,119,952.16
9:00 PM 11.11 11,105.88 6.96 77,248.56 25,492,025.53
10:00 PM 8.77 8,773.65 6.96 61,026.36 20,138,700.17
11:00 PM 6.66 6,663.53 6.96 46,349.14 15,295,215.32
12:00 MN 6.66 6,663.53 6.96 46,349.14 15,295,215.32
TOTAL 271.82 271,816.45 6.96 1,890,658.56 623,917,324.79

88
 Table 4.14

PROJECTED SALES OF YEAR 2026

Price (Php) per Daily Gross Annual Gross

TIME LOAD (MW) LOAD (kw-hr)
KW-hr Sales Sales
1:00 AM 6.81 6,810.13 7.09 48,316.19 15,944,344.25
2:00 AM 6.24 6,242.62 7.09 44,289.85 14,615,648.90
3:00 AM 5.96 5,958.86 7.09 42,276.67 13,951,301.22
4:00 AM 6.58 6,583.12 7.09 46,705.65 15,412,866.11
5:00 AM 7.38 7,377.64 7.09 52,342.54 17,273,039.61
6:00 AM 8.63 8,626.16 7.09 61,200.51 20,196,169.39
7:00 AM 9.87 9,874.68 7.09 70,058.48 23,119,299.17
8:00 AM 11.01 11,009.70 7.09 78,111.18 25,776,689.88
9:00 AM 12.49 12,485.23 7.09 88,579.69 29,231,297.80
10:00 AM 14.41 14,414.77 7.09 102,269.28 33,748,862.01
11:00 AM 14.98 14,982.28 7.09 106,295.63 35,077,557.36
12:00 NN 14.64 14,641.77 7.09 103,879.82 34,280,340.15
1:00 PM 13.85 13,847.26 7.09 98,242.93 32,420,166.65
2:00 PM 13.73 13,733.76 7.09 97,437.66 32,154,427.58
3:00 PM 14.19 14,187.76 7.09 100,658.74 33,217,383.86
4:00 PM 17.71 17,706.33 7.09 125,622.11 41,455,295.06
5:00 PM 17.03 17,025.32 7.09 120,790.49 39,860,860.64
6:00 PM 18.16 18,160.34 7.09 128,843.19 42,518,251.35
7:00 PM 15.89 15,890.30 7.09 112,737.79 37,203,469.93
8:00 PM 14.30 14,301.27 7.09 101,464.01 33,483,122.93
9:00 PM 11.35 11,350.21 7.09 80,526.99 26,573,907.09
10:00 PM 8.97 8,966.67 7.09 63,616.32 20,993,386.60
11:00 PM 6.81 6,810.13 7.09 48,316.19 15,944,344.25
12:00 MN 6.81 6,810.13 7.09 48,316.19 15,944,344.25
TOTAL 277.80 277,796.41 7.09 1,970,898.11 650,396,376.05
-

89
 Table 4.15

PROJECTED SALES OF YEAR 2027

Price (Php) per Daily Gross Annual Gross

TIME LOAD (MW) LOAD (kw-hr)
KW-hr Sales Sales
1:00 AM 6.96 6,959.95 7.24 50,366.73 16,621,022.22
2:00 AM 6.38 6,379.95 7.24 46,169.51 15,235,937.04
3:00 AM 6.09 6,089.96 7.24 44,070.89 14,543,394.45
4:00 AM 6.73 6,727.95 7.24 48,687.84 16,066,988.15
5:00 AM 7.54 7,539.95 7.24 54,563.96 18,006,107.41
6:00 AM 8.82 8,815.94 7.24 63,797.86 21,053,294.82
7:00 AM 10.09 10,091.93 7.24 73,031.76 24,100,482.23
8:00 AM 11.25 11,251.92 7.24 81,426.22 26,870,652.60
9:00 AM 12.76 12,759.91 7.24 92,339.01 30,471,874.08
10:00 AM 14.73 14,731.89 7.24 106,609.59 35,181,163.71
11:00 AM 15.31 15,311.89 7.24 110,806.81 36,566,248.89
12:00 NN 14.96 14,963.89 7.24 108,288.48 35,735,197.78
1:00 PM 14.15 14,151.90 7.24 102,412.36 33,796,078.52
2:00 PM 14.04 14,035.90 7.24 101,572.91 33,519,061.49
3:00 PM 14.50 14,499.89 7.24 104,930.70 34,627,129.63
4:00 PM 18.10 18,095.87 7.24 130,953.51 43,214,657.78
5:00 PM 17.40 17,399.87 7.24 125,916.84 41,552,555.56
6:00 PM 18.56 18,559.86 7.24 134,311.29 44,322,725.93
7:00 PM 16.24 16,239.88 7.24 117,522.38 38,782,385.19
8:00 PM 14.62 14,615.89 7.24 105,770.14 34,904,146.67
9:00 PM 11.60 11,599.92 7.24 83,944.56 27,701,703.71
10:00 PM 9.16 9,163.93 7.24 66,316.20 21,884,345.93
11:00 PM 6.96 6,959.95 7.24 50,366.73 16,621,022.22
12:00 MN 6.96 6,959.95 7.24 50,366.73 16,621,022.22
TOTAL 283.91 283,907.93 7.24 2,054,543.02 677,999,198.25

90
 Table 4.16

PROJECTED SALES OF YEAR 2028

Price (Php) per Daily Gross Annual Gross

TIME LOAD (MW) LOAD (kw-hr)
KW-hr Sales Sales
1:00 AM 7.11 7,113.07 7.45 53,019.05 17,496,285.26
2:00 AM 6.52 6,520.31 7.45 48,600.79 16,038,261.48
3:00 AM 6.22 6,223.93 7.45 46,391.67 15,309,249.60
4:00 AM 6.88 6,875.97 7.45 51,251.74 16,913,075.75
5:00 AM 7.71 7,705.82 7.45 57,437.30 18,954,309.03
6:00 AM 9.01 9,009.89 7.45 67,157.46 22,161,961.32
7:00 AM 10.31 10,313.95 7.45 76,877.62 25,369,613.62
8:00 AM 11.50 11,499.46 7.45 85,714.12 28,285,661.16
9:00 AM 13.04 13,040.62 7.45 97,201.58 32,076,522.97
10:00 AM 15.06 15,055.99 7.45 112,223.65 37,033,803.79
11:00 AM 15.65 15,648.75 7.45 116,641.90 38,491,827.56
12:00 NN 15.29 15,293.10 7.45 113,990.95 37,617,013.30
1:00 PM 14.46 14,463.24 7.45 107,805.39 35,575,780.02
2:00 PM 14.34 14,344.69 7.45 106,921.74 35,284,175.26
3:00 PM 14.82 14,818.89 7.45 110,456.35 36,450,594.28
4:00 PM 18.49 18,493.98 7.45 137,849.52 45,490,341.66
5:00 PM 17.78 17,782.67 7.45 132,547.62 43,740,713.14
6:00 PM 18.97 18,968.18 7.45 141,384.12 46,656,760.68
7:00 PM 16.60 16,597.16 7.45 123,711.11 40,824,665.60
8:00 PM 14.94 14,937.44 7.45 111,340.00 36,742,199.04
9:00 PM 11.86 11,855.11 7.45 88,365.08 29,160,475.43
10:00 PM 9.37 9,365.54 7.45 69,808.41 23,036,775.59
11:00 PM 7.11 7,113.07 7.45 53,019.05 17,496,285.26
12:00 MN 7.11 7,113.07 7.45 53,019.05 17,496,285.26
TOTAL 290.15 290,153.90 7.45 2,162,735.26 713,702,636.03

91
 Table 4.17

PROJECTED SALES OF YEAR 2029

Price (Php) per Daily Gross Annual Gross

TIME LOAD (MW) LOAD (kw-hr)
KW-hr Sales Sales
1:00 AM 7.27 7,269.56 7.68 55,811.03 18,417,639.64
2:00 AM 6.66 6,663.76 7.68 51,160.11 16,882,836.33
3:00 AM 6.36 6,360.86 7.68 48,834.65 16,115,434.68
4:00 AM 7.03 7,027.24 7.68 53,950.66 17,803,718.32
5:00 AM 7.88 7,875.35 7.68 60,461.95 19,952,442.94
6:00 AM 9.21 9,208.10 7.68 70,693.97 23,329,010.21
7:00 AM 10.54 10,540.86 7.68 80,925.99 26,705,577.47
8:00 AM 11.75 11,752.45 7.68 90,227.83 29,775,184.08
9:00 AM 13.33 13,327.52 7.68 102,320.22 33,765,672.67
10:00 AM 15.39 15,387.23 7.68 118,133.35 38,984,003.90
11:00 AM 15.99 15,993.02 7.68 122,784.26 40,518,807.20
12:00 NN 15.63 15,629.54 7.68 119,993.71 39,597,925.22
1:00 PM 14.78 14,781.43 7.68 113,482.43 37,449,200.59
2:00 PM 14.66 14,660.27 7.68 112,552.24 37,142,239.93
3:00 PM 15.14 15,144.91 7.68 116,272.98 38,370,082.58
4:00 PM 18.90 18,900.84 7.68 145,108.68 47,885,863.06
5:00 PM 18.17 18,173.89 7.68 139,527.57 46,044,099.09
6:00 PM 19.39 19,385.48 7.68 148,829.41 49,113,705.70
7:00 PM 16.96 16,962.30 7.68 130,225.73 42,974,492.49
8:00 PM 15.27 15,266.07 7.68 117,203.16 38,677,043.24
9:00 PM 12.12 12,115.93 7.68 93,018.38 30,696,066.06
10:00 PM 9.57 9,571.58 7.68 73,484.52 24,249,892.19
11:00 PM 7.27 7,269.56 7.68 55,811.03 18,417,639.64
12:00 MN 7.27 7,269.56 7.68 55,811.03 18,417,639.64
TOTAL 296.54 296,537.29 7.68 2,276,624.90 751,286,216.84

92
 Table 4.18

ANNUAL SALES

Daily Load (KW- Annual Load Price per KW-hr Daily Gross Sales Annual Gross
Year
hr) (MW-hr) (Php) (Php) Sales (Php)

2020 244,750 80,767,500 6.00 1,468,500.00 484,605,000.00

2021 249,645 82,382,850 6.18 1,542,806.10 509,126,013.00

2022 254,638 84,030,507 6.37 1,620,872.09 534,887,789.26

2023 260,240 85,879,178 6.56 1,706,227.21 563,054,980.24

2024 265,965 87,768,520 6.75 1,796,077.14 592,705,455.50

2025 271,816 89,699,428 6.96 1,890,658.56 623,917,324.79

2026 277,796 91,672,815 7.09 1,970,898.11 650,396,376.05

2027 283,908 93,689,617 7.24 2,054,543.02 677,999,198.25

2028 290,154 95,750,788 7.45 2,162,735.26 713,702,636.03

2029 296,537 97,857,306 7.68 2,276,624.90 751,286,216.84

93
 Table 4.19

INCOME STATEMENT (2020-2024)

2020 2021 2022 2023 2024

Gross Sales 484,605,000.00 509,126,013.00 534,887,789.26 563,054,980.24 592,705,455.50

Less Production Cost

B20 Diesel Fuel (75%) 300,900,000.00 309,927,000.00 319,224,810.00 328,801,554.30 338,665,600.93
C175-20 Engine Oil
136,926.00 141,033.78 145,264.79 149,622.74 154,111.42
(0.002%)
Operations and
32,096,000.00 33,058,880.00 34,050,646.40 35,072,165.79 36,124,330.77
Maintenance (8%)
Spare Parts (6%) 24,072,000.00 24,794,160.00 25,537,984.80 26,304,124.34 27,093,248.07
Chemicals (5%) 20,060,000.00 20,661,800.00 21,281,654.00 21,920,103.62 22,577,706.73
Training Expense (3%) 12,036,000.00 12,397,080.00 12,768,992.40 13,152,062.17 13,546,624.04
Utilities, Distribution,
Transmission Lines,
11,233,600.00 11,570,608.00 11,917,726.24 12,275,258.03 12,643,515.77
Office Supplies, etc.
(2.8%)
Depreciation (0.13%) 11,129,311.44 11,129,311.44 11,129,311.44 11,129,311.44 11,129,311.44
Annual Salaries with
5,796,973.00 5,970,882.19 6,150,008.66 6,334,508.92 6,524,544.18
Benefits (0.07%)
Total Production
417,460,810.44 429,650,755.41 442,206,398.73 455,138,711.35 468,458,993.35
Cost

Gross Income 67,144,189.56 79,475,257.59 92,681,390.53 107,916,268.89 124,246,462.15

Less Income After Tax
20,143,256.87 23,842,577.28 27,804,417.16 32,374,880.67 37,273,938.65
(30%)

NET INCOME AFTER

47,000,932.69 55,632,680.31 64,876,973.37 75,541,388.22 86,972,523.51
TAX

94
 Table 4.20

INCOME STATEMENT (2025-2029)

2025 2026 2027 2028 2029

Gross Sales 623,917,324.79 650,396,376.05 677,999,198.25 713,702,636.03 751,286,216.84

Less Production Cost

B20 Diesel Fuel (75%) 348,825,568.96 359,290,336.03 370,069,046.11 381,171,117.49 392,606,251.01
C175-20 Engine Oil
158,734.76 163,496.80 168,401.71 173,453.76 178,657.37
(0.002%)
Operations and
37,208,060.69 38,324,302.51 39,474,031.58 40,658,252.53 41,878,000.11
Maintenance (8%)
Spare Parts (6%) 27,906,045.52 28,743,226.88 29,605,523.69 30,493,689.40 31,408,500.08
Chemicals (5%) 23,255,037.93 23,952,689.07 24,671,269.74 25,411,407.83 26,173,750.07
Training Expense (3%) 13,953,022.76 14,371,613.44 14,802,761.84 15,246,844.70 15,704,250.04
Utilities, Distribution,
Transmission Lines,
13,022,821.24 13,413,505.88 13,815,911.05 14,230,388.39 14,657,300.04
Office Supplies, etc.
(2.8%)
Depreciation (0.13%) 11,129,311.44 11,129,311.44 11,129,311.44 11,129,311.44 11,129,311.44
Annual Salaries with
6,720,280.51 6,921,888.92 7,129,545.59 7,343,431.96 7,563,734.92
Benefits (0.07%)
Total Production Cost 482,178,883.80 496,310,370.97 510,865,802.76 525,857,897.50 541,299,755.08

Gross Income 141,738,440.98 154,086,005.08 167,133,395.49 187,844,738.53 209,986,461.76

Less Income After Tax

42,521,532.30 46,225,801.52 50,140,018.65 56,353,421.56 62,995,938.53
(30%)

NET INCOME AFTER

99,216,908.69 107,860,203.55 116,993,376.84 131,491,316.97 146,990,523.23
TAX

95
 Table 4.21

PAYOUT PERIOD

Fixed Capital Net Income After Annual

Year Investment Tax Depreciation
2020 299,509,048.89 47,000,932.69 11,129,311.44
2021 299,509,048.89 55,632,680.31 11,129,311.44
2022 299,509,048.89 64,876,973.37 11,129,311.44
2023 299,509,048.89 75,541,388.22 11,129,311.44
2024 299,509,048.89 86,972,523.51 11,129,311.44
2025 299,509,048.89 99,216,908.69 11,129,311.44
2026 299,509,048.89 107,860,203.55 11,129,311.44
2027 299,509,048.89 116,993,376.84 11,129,311.44
2028 299,509,048.89 131,491,316.97 11,129,311.44
2029 299,509,048.89 146,990,523.23 11,129,311.44

TOTAL 2,995,090,488.89 932,576,827.40 111,293,114.40

AVERAGE 299,509,048.89 93,257,682.74 11,129,311.44
PAYOUT PERIOD 3.65

𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

𝑃𝑎𝑦𝑜𝑢𝑡 𝑃𝑒𝑟𝑖𝑜𝑑 =
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑃𝑟𝑜𝑓𝑖𝑡 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟 + 𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟

96
 Table 4.22

RETURN OF INVESTMENT

Total Capital Net Income After

Year ROI (%) ROI
investment Tax
2020 377,774,248.89 47,000,932.69 0.12 12.44
2021 377,774,248.89 55,632,680.31 0.15 14.73
2022 377,774,248.89 64,876,973.37 0.17 17.17
2023 377,774,248.89 75,541,388.22 0.20 20.00
2024 377,774,248.89 86,972,523.51 0.23 23.02
2025 377,774,248.89 99,216,908.69 0.26 26.26
2026 377,774,248.89 107,860,203.55 0.29 28.55
2027 377,774,248.89 116,993,376.84 0.31 30.97
2028 377,774,248.89 131,491,316.97 0.35 34.81
2029 377,774,248.89 146,990,523.23 0.39 38.91
AVERAGE 24.69

97
 Table 4.23

BREAK-EVEN ANALYSIS (2020-2024)

Break-even Analysis 2020 2021 2022 2023 2024

Fixed Cost
Depreciation 11,129,311.44 11,129,311.44 11,129,311.44 11,129,311.44 11,129,311.44
Local Taxes 5,990,180.98 5,990,180.98 5,990,180.98 5,990,180.98 5,990,180.98
Amortization 36,888,611.59 36,888,611.59 36,888,611.59 36,888,611.59 36,888,611.59
Contingency 38,610,832.00 38,610,832.00 38,610,832.00 38,610,832.00 38,610,832.00
Total Fixed Cost 92,618,936.00 92,618,936.00 92,618,936.00 92,618,936.00 92,618,936.00

Variable Cost
B20 Diesel Fuel 300,900,000.00 309,927,000.00 319,224,810.00 328,801,554.30 338,665,600.93
C175-20 Engine Oil 136,926.00 141,033.78 145,264.79 149,622.74 154,111.42
Operations and
Maintenance 32,096,000.00 33,058,880.00 34,050,646.40 35,072,165.79 36,124,330.77
Spare Parts 24,072,000.00 24,794,160.00 25,537,984.80 26,304,124.34 27,093,248.07
Transmission &
Distribution Cost 20,060,000.00 20,661,800.00 21,281,654.00 21,920,103.62 22,577,706.73
Utilities, Office
Supplies, etc. 11,233,600.00 11,570,608.00 11,917,726.24 12,275,258.03 12,643,515.77
Depreciation 11,129,311.44 11,463,190.78 11,807,086.51 12,161,299.10 12,526,138.07

98
Annual Salaries with
Benefits 5,796,973.00 5,970,882.19 6,150,008.66 6,334,508.92 6,524,544.18
Total Variable Cost 405,424,810.44 417,587,554.75 430,115,181.40 443,018,636.84 456,309,195.94

TOTAL COST 498,043,746.44 510,206,490.76 522,734,117.40 535,637,572.84 548,928,131.95

NET SALES 484,605,000.00 509,126,013.00 534,887,789.26 563,054,980.24 592,705,455.50

NET WEIGHT
(Annual Load) 80,767,500 82,382,850 84,030,507 85,879,178 87,768,520
Selling Price per kw-
hr (net sales/net
weight) 6.00 6.18 6.37 6.56 6.75

BREAK EVEN
SELLING PRICE 6.17 6.19 6.22 6.24 6.25

99
 Table 4.24

BREAK-EVEN ANALYSIS (2025-2029)

Break-even Analysis 2025 2026 2027 2028 2029

Fixed Cost
Depreciation 11,129,311.44 11,129,311.44 11,129,311.44 11,129,311.44 11,129,311.44
Local Taxes 5,990,180.98 5,990,180.98 5,990,180.98 5,990,180.98 5,990,180.98
Amortization 36,888,611.59 36,888,611.59 36,888,611.59 36,888,611.59 36,888,611.59
Contingency 38,610,832.00 38,610,832.00 38,610,832.00 38,610,832.00 38,610,832.00
Total Fixed Cost 92,618,936.00 92,618,936.00 92,618,936.00 92,618,936.00 92,618,936.00

Variable Cost
B20 Diesel Fuel 348,825,568.96 359,290,336.03 370,069,046.11 381,171,117.49 392,606,251.01
C175-20 Engine Oil 158,734.76 163,496.80 168,401.71 173,453.76 178,657.37
Operations and
Maintenance 37,208,060.69 38,324,302.51 39,474,031.58 40,658,252.53 41,878,000.11
Spare Parts 27,906,045.52 28,743,226.88 29,605,523.69 30,493,689.40 31,408,500.08
Transmission
&Distrbution Cost 23,255,037.93 23,952,689.07 24,671,269.74 25,411,407.83 26,173,750.07
Utilities, Office
Supplies, etc. 13,022,821.24 13,413,505.88 13,815,911.05 14,230,388.39 14,657,300.04
Depreciation 12,901,922.22 13,288,979.88 13,687,649.28 14,098,278.76 14,521,227.12

100
Annual Salaries with
Benefits 6,720,280.51 6,921,888.92 7,129,545.59 7,343,431.96 7,563,734.92
Total Variable Cost 469,998,471.82 484,098,425.98 498,621,378.75 513,580,020.12 528,987,420.72

TOTAL COST 562,617,407.83 576,717,361.98 591,240,314.76 606,198,956.12 621,606,356.73

NET SALES 623,917,324.79 650,396,376.05 677,999,198.25 713,702,636.03 751,286,216.84

NET WEIGHT (Annual
Load) 89,699,428 91,672,815 93,689,617 95,750,788 97,857,306
Selling Price per kw-
hr (net sales/net
weight) 6.96 7.09 7.24 7.45 7.68

BREAK EVEN
SELLING PRICE 6.27 6.29 6.31 6.33 6.35

101
 CHAPTER V

ENVIRONMENTAL MANAGEMENT

Considering environmental impacts, the proposed plant is well-organized

when it comes to waste treatment. This chapter will discuss the social, political,

ethical benefits; health and safety requirements; and generated hazardous

materials and waste management.

I. Social, Political and Ethical Benefits

In this project, the type of fuel that will be used is biofuel which is the B20

diesel fuel, a blend of 20% biodiesel with 80% diesel fuel in accordance to

Republic Act 9367, also known as Philippines Biofuels Act of 2006. In some

cases, pure, unaltered vegetable oil can power standard diesel engines. Unlike

fossil fuels, biofuels are a renewable energy source. Because they are derived

from crops that can be harvested annually, or in the case of algae monthly,

biofuels are theoretically unlimited.

Policies, however, are not created by economists, but by politicians. The

analysis of policy choices by politicians is done using models of political

economy. This study takes a political economic approach to identifying some of

the key factors in the formulation of biofuel policies in the Philippines. Production

of ethanol and biodiesels has dramatically expanded since the beginning of the

new millennium. The use of biofuels is central to many of the proposed policies to

address climate change impacts. Most of the studies on the economics of climate

102
change policies employ a social welfare economic perspective. The common

conclusion of these studies is that the best policy to mitigate environmental

externalities while maximizing social welfare is to introduce incentives that nudge

producers of energy to pay the price of externalities associated with greenhouse

gas (GHG) emissions, which will favor clean biofuel products.

Biofuels are very similar to hydrocarbons and have some of the same

emissions problems that standard fossil fuels have. They can, however, be more

environmentally friendly if care is taken in how they are produced and distributed.

It is also the case that biofuels have an impact on the environment other than

emissions, so we must consider several different subcategories under this

heading. To reduce these emissions, the company will be using Selective

Catalytic Reduction (SCR), an advanced active emissions control technology

system that injects a liquid-reluctant agent through a special catalyst into the

exhaust stream of a diesel engine.

The government will benefit through revenue from taxes that can be

collected from the income of the company as well in its company. Positively, the

plant can provide employment from project planning, erection and actual

operation. Local people will be the beneficiaries since they are the most likely to

be given job opportunities. In the end, the improvement in the standard of living

of employees of the company and their families would be visible and eventually

cater changes to earn additional income.

103
II. Health and Safety Requirements

All portable generators for electrical power supplies fuelled by Diesel have

low noise emissions and can be fitted with Earth Leakage Circuit Breakers and

earth spikes conforming to BS 7430: 1991 Code of Practice for earthing.

In this project, generators will be sited so as to reduce the possibility of

noise nuisance and be silenced generator sets. Generators should also be sited

to ensure that exhaust fumes are dissipated into the atmosphere away from

populated venue areas and guarded from unauthorized persons. Dry Powder

Extinguishers will be located in each generator area.

The fuelling and/or re-fuelling of generators will only be carried out by

authorized personnel wearing the correct personal protective equipment and

following the engineer’s instructions. Suitable materials and equipment must be

kept at hand to deal with any possible fuel spillages.

Diesel fuel will be stored in no more than two metal containers with a

maximum capacity of 10 litre or two plastic containers of a maximum 5 litres

capacity. These containers will be designed and approved for the purpose,

correctly labeled as to their contents and will be fitted with a screw-cap or closure

to prevent leakage of liquid or vapour.

Fuel storage area will be well away from ignition sources and must be

secure, to protect against unauthorized access or the possibility of vandalism or

arson. Dry Powder Extinguishers will be located in each fuel storage area.

104
 Supply cables will be of the correct rating for the maximum possible load

with no damage to the insulation and fitted with the correct type of connectors for

external use.

Cables will be routed, placed with a cable protection system or buried so

that they will not cause a tripping hazard or be crushed by vehicular traffic.

Armored cabling will be installed for hazardous voltages e.g. those which could

cause electric shock if damaged, protecting against contact with sharp edges or

crushing by heavy loads.

III. Generated Hazardous Materials and Waste Management

In the operation of a Diesel Power Plant there are different wastes

materials that are being produced namely Carbon dioxide (CO2), Nitrogen oxides

(NOx); Hydrocarbons; and Suspended particulate matter (SPM). In which CO2,

NOx are greenhouse gases (GHGs) that contributes to global warming and other

environmental problems.

Since NOx concentration level is high in diesel power plant which affects the

environment to great extent, the company will be using Selective Catalytic

Reduction (SCR) method for controlling this emission. Ammonia (NH3) is making

use of reagent in SCR technique and it is inject to the exhaust stream. NH3

reacts with NOx present in the exhaust and it will be converted into Nitrogen (N2)

and water (H2O). It is proposed that, if SCR system is installed in Diesel Power

Plant, NOx concentration level is expected to reduce from 1100 ppm to 132 ppm.

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 CHAPTER VI

DESIGN TRADE-OFFS

A formal method which allows designers to explicitly make a decision on

which is the best design is done on the design trade-off method. The

methodology can be used when an engineer wishes to rate the design by the

weakest aspect, or by cooperatively considering the overall performance or

combination of these strategies.

The topic given to the group was randomly selected with a given capacity

and type of power plant from which it turns out that the design shall be a 20MW

diesel power plant. To make this design possible, several deliberation of

knowledge was made which resulted to three multiple realistic constraints.

On the first design option, the group decided to use two (2) generators

with a capacity of 10 MW each. However, the generators available are from the

country where most of the products are not firmly built. If the designers will

choose to use these sub-standard generators, it will be risky technically,

economically and environmentally. According to the studies made, these

substandard materials not only degenerate to losses of energy, equipment and

revenue but sometimes it involves loss of life. The safety of the equipment and

the staff that will operate the facility will be at stake and could result to the loss of

life and major equipment and or lines that will lead to system collapse.

Substandard materials used in most of the other systems are vulnerable to faults

because they are weak and cannot withstand the specified current capacity

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which original materials can withstand, secondly they are less sensitive to fault

which prolongs the stress of the fault current thereby resulting to fire outbreak.

Thus, this design option was not taken into consideration because aside from the

increase cost of maintenance and operation of the network, the use of this design

will be dangerous to life and to environment.

On the second design option, the group decided to use six (6) generators

with a capacity of 4 MW each. There will be five (5) generators that will be used

for the production of electricity and the remaining generator will be used as

reserve. Each generator will operate at an interval of 4.8 hours. However, it turns

out that if the group used six (6) generators even though one from these will be

used as a reserve, the capacity of the plant will be 24 MW. Thus, this design will

not conform to the design objective. Additionally, because more generators will

be used in this design, there will be disadvantages technically, economically and

environmentally. The technical and economic disadvantages of this design are

due to the reason that there will be more equipment and auxiliary devices

needed during the operation which shall be maintained and operated and thus

making it costly. Because there will be more units that will be operated in this

design, more undesirable emissions will be produced which can add up to the

environmental problems of the earth.

On the third design option, the group decided to use five (5) generators

with a capacity of 4 MW each. One from these generators will be used as reserve

when there is defective unit and during maintenance schedule. The generators

that will be used in this design is from a trusted brand, Caterpillar, where

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products are made with compliance to the standard and is one of the leading

manufacturer of diesel engines in the world. Because Caterpillar conforms to the

standard, its environmental impact is lesser compared to other brands.

Additionally, these generators are set together with an engine making it more

convenient than buying a separate engine which may not be suitable for the

generator. Also, the use of oil is less in this type of generator set making it more

economical.

The group used several formulas and references on this study for the

following essential aspects such as: machine foundation, fuel tank, heat

exchanger, and cooling tower. The references used by the group include different

books and search engines. Among the books used by the group are: PSME code

of 1993; ARPN Journal of Engineering and Applied Sciences; Design of Machine

Elements by Virgil Morning Faires; Power Plant Engineering in MKS Units by

Frederick T. Morse; and Power Plant Theory and Design by Philip J. Potter. On

the other hand, the search engine used by the group is Google.

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 CHAPTER VII

PROJECT CONSTRUCTION EXECUTION PLAN

This chapter shall discuss the construction management and strategy,

quality control and assurance, work scheduling and overall management and

commissioning of the project that must be undertaken in the proposed 20 MW

Diesel Power Plant.

I. Project Construction Management and Strategy

The construction of the 20 MW Diesel Power Plant would have a

construction program of 24 months and will undergo different phases

namely Project Planning, Project Engineering and Design,

Construction and Start up and Commissioning.

The Project Planning phase includes the conceptual studies of

the proposed Diesel Power Plant which involves the Design Study, Site

Selection, Infrastructure Development Plan, Preparation of a Detailed

Project Report and Environmental Impact Assessment.

After the Project planning phase the Project Engineering and

Design phase will begin. It involves the accomplishment of the Site

Arrangement Drawing, Plant Arrangement Drawing, Process

Diagrams, Equipment List Denoting all Major Project Mechanical,

Electrical, and Controls Equipment, Plant Descriptions and other

technical input for the permitting process.

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 The Pre-Construction phase is started after approval of

construction budget. The construction budget includes labor, material,

contractors, construction administration, miscellaneous construction

items and contingencies.

When construction documents are complete the project is ready

to "put out for bid". This phase includes procurement of labor, materials

and finalization of budget. The bid process is the industry standardized

method of selecting and hiring contractors and other professional

services. Qualified construction companies and contractors are

provided with bid documents, which they use to determine the costs

and prices for their bid package. The bid submissions are reviewed

and accepted based on completeness of the bid package, compliance

with the terms in the bid documents, construction suitability and the bid

cost.

After all bids are received and reviewed, it is sometimes the

case that all of the submitted bid costs exceed the authorized project

budget. For the construction to progress the project budget must be

increased or changes shall be made according to the scope or quality

of the project.

The Construction Phase is concerned with the following:

 Monitoring of the project by facilities management staff.

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  Continuation of preparation and documentation by all

professional service contractors.

 Changes to drawings or specifications.

 Periodic reviews.

The construction phase completes the building and the scope of the

project.

The facilities management staff—including project architects,

project engineers, interior designers and construction administrators—

monitor and manage the project during the Construction Phase. Typically

there is a contract with a construction manager or a construction

contractor who manages the project, schedules the work and hires and

schedules the sub-contractors.

Functional performance tests will be established and all designated

systems will be tested against the performance criteria. Results will be

recorded, and corrective actions initiated if required which will complete

the turnover activity.

Towards the end of construction, the project’s staff will assemble a

"punch list", or a list of items that need to be corrected or completed. Once

the work is complete enough to allow satisfactory operation of the building,

the project becomes "substantially complete". This may occur even if

some work remains to be done.

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II. Quality Control and Assurance

This stage is also known as the Project Quality Management that is

comprised of the processes to ensure that the project will satisfy the

needs for which it was undertaken. This is performed by the following

procedures.

1. Identifying relevant quality standards and knowing how to satisfy them.

2. Evaluating the overall project performance to ensure that the project

will satisfy quality standards.

3. Monitoring the project results for compliance with the quality standards.

4. Identifying ways to eliminate causes of the unsatisfactory performance.

III. Commissioning of the Project / Project Execution

For a successful development, selection of the best technology and

site, receive the required permits and construct the plant in a timely

and cost-effective manner is important.

Project commissioning is the process of assuring that all systems

and components of a building or industrial plant are designed,

installed, tested, operated, and maintained according to the operational

requirements of the owner or final client. A commissioning process

may be applied not only to new projects but also to existing units and

systems subject to expansion, renovation or revamping.

In practice, the commissioning process comprises the integrated

application of a set of engineering techniques and procedures to

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 check, inspect and test every operational component of the project,

from individual functions, such as instruments and equipment, up to

complex amalgamations such as modules, subsystems and systems.

Commissioning activities, in the broader sense, are applicable to all

phases of the project, from the basic and

detailed design, procurement, construction and assembly, until the final

handover of the unit to the owner, including sometimes an assisted

operation phase.

Constructing this type of power plant provides opportunities that are

a great help for developing the community. Building a foundation of

genuine thrust and support with the community and partnership with

the local government is relevant. This is being done by improving the

level of awareness of the residents, improving the quality of education

through construction or rehabilitation of schools, awarding scholarship

grants to students and teachers, providing on-the-job training

opportunities to graduating students, and uplifting literacy in

information technology.

IV. Project Development Timeline

In project development timeline, a schedule is a listing of

a project's milestones, activities, and deliverables, usually with

intended start and finish dates. Those items are often estimated by

other information included in the project schedule of resource

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allocation, budget, task duration, and linkages of dependencies and

scheduled events. A schedule is commonly used in the project

planning and project portfolio management parts of project

management. Elements on a schedule may be closely related to

the work breakdown structure (WBS) terminal elements, the Statement

of work, or a Contract Data Requirements List.

The first process to be considered will be the gathering and

evaluating of data, gathering of maps, reports and literature, site visit

for first estimate, preparing the licenses, environmental, social and

legal aspects. Starting in the planning stage, the designer will

modularize the parts to be installed with the objectives of shortening

the construction period, ensuring safety and quality, and improving

work efficiency. Also the designer should have developed equipment

for transporting modules and other large components to their

installation locations.

The scope and arrangement of construction from the site include

the selection of the plant until the preventive maintenance of the

equipment. In the design the construction of the plant and contractor is

included in this scope. The surface exploration and environmental

assessment are also taken into consideration.

The installation of the parts and equipment of the plant are also

included in the scope and then the test run to see if the plant works

efficiently.

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 ELECPRO Corporation Development Timeline

V. Organization and Management Aspect

This part of the study represents the organizational setup of the proposed

20 Megawatt Diesel Power Plant.

ELECPRO organization structure will be composed of the following

personnel:

1. Plant Manager/ Professional Mechanical Engineer – A power plant

manager is responsible for supervising all aspects of the safe and efficient

operation of an electricity generating power plant. These energy facilities

can of various fuel types, but the role of the power plant manager is

generally the same: they must ensure that the plant operates safely for all

workers and employees at the facility, as well oversee all environmental

compliance.

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 Power Plant managers typically oversee a number of teams which

performs the many functions for the facility to operate. They often review

inspection and process safety reports filed by the plant’s safety teams to

examine any areas where equipment must be repaired or replaced or

operating teams may need further training.

2. Mechanical Shift Engineer –A mechanical shift engineer must have good

knowledge and practical skills in mechanical and maintenance systems.

He must also have the ability to work well in teams.

3. Instrumentation & Control Engineer –is responsible for designing,

developing, installing, managing, and maintaining equipment which is

used to monitor and control engineering systems, machinery and

processes.

4. Admin/ Logistics Supervision - ensure the administrative aspects of a

business running and organized. He/she must perform administrative

tasks like documentation, editing, filing, organization, and sales support.

He/she also manage other administrative employees to ensure

administrative tasks are done; these managers also train subordinates.

He/she must have a strong attention to detail. He/she also need to have

great communication skills (verbal and written), be able to efficiently work

as a team and on their own, and be able to delegate important tasks to

employees. He/she should also have a good knowledge of computers and

technology, since most of their tasks rely on computer systems and

programs.

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5. Financial Accountant - Financial accountability is pivotal to maintaining a

healthy business, and financial accountants conduct a number of functions

to ensure this is possible. They manage payroll, taxes, income, spending,

and educating their employer on financial information. Work days for

financial accountants can be a bit longer than a standard 9-to-5 job,

because of strict deadlines on all projects that financial accountants are

given. Generally, financial accountants do not need to work directly with

employees; if they discover discrepancies with posted reports, they inform

management.

Financial accountants need a strong background in math and must be

ready to examine financial figures on a daily basis. An associate's or

bachelor’s degree in accounting is needed for this job, as is knowledge of

statistics, arithmetic, and algebra. The ability to use computers and

accounting software programs is important, and financial accountants

must be able to use computers to perform mathematical computations and

create presentations. Different employers will use different accounting

software, so it is good for financial accountants to be able to adapt quickly

to new programs.

6. Electrical Shift Engineer – A mechanical shift engineer must have good

knowledge and practical skills in electrical systems. He must also have the

ability to work well in teams.

7. Warehouse Supervisor/ Purchaser – is in charge off all the incoming

and outgoing products of the particular warehouse they work in. He/ she is

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 also in charge for coordinating purchases of various products and services

for the company. He/ she must order supplies, inventory, equipment, and

services for all departments in the company.

8. Maintenance Technician – often work in shifts and can also be required

to supply “on call” support to their facility, depending upon the specifics of

the job role.

9. Safety Officer - Safety officers are responsible for monitoring activities in

the workplace and ensuring that nobody is violating safety regulations.

The essential aim of their job is to minimize occupational injuries,

accidents, and health problems. Their job requires more than simply

watching the behavior of coworkers and correcting unsafe conduct; they

must also provide employees with safety training to ensure that they are

fully aware of safety standards. This may involve circulating reading and

instructional material on the matter, as well as running or organizing

educational programs.

10. Warehouse Man / Storekeeper – responsible for receiving, storing, and

distributing material from the warehouse and storage room.

11. Control Room Operator - A power plant control operator works in a plant

which is dedicated to providing electricity to a particular area. The operator

must oversee the electrical grid-lines and ensure that they are functioning

properly; when they are not, the operator should work to find a switch for

the lines. Sometimes, emergency situations may cause blackouts to

occur, so they must be able to stay calm under pressure and follow proper

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 emergency guidelines regarding who should be called, whether

maintenance workers or law enforcement.

These control room operators often work indoors, but may also venture

outside to monitor the workings of the power plant. Some periodic

maintenance and troubleshooting may be necessary for the machinery

and equipment involved, and another common task involves operating the

"flue gas cleaning scrubber," along with the bag-house, to ensure the

plant's efficient operation.

12. Lineman –He must install, repair and maintain overhead and electrical

power lines and auxiliary equipment.

13. Helper - help production workers by performing duties that require less

skill, such as supplying or holding materials or tools, and cleaning work

areas and equipment.

14. Meter Reader/ Mail Courier -Read electric consumption meters and enter

data in route books or hand-held computers. He is also primarily

responsible for driving a designated route each day and picking up and

delivering mail and packages.

Employees’ Benefits

ELECPRO employees will be entitled with the following benefits as

mandated by Department of Labor and Employment’s (DOLE) Labor Code:

● 13th month pay

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 ● Retirement pay

Upon the age of 60 years or more, the employee who has served at the

establishment for at least five years may be granted a retirement pay equivalent

to at least one-half month of salary for every year of service. A fraction of at least

six months is considered as one whole year.

The “one-half month salary” includes:

1. 15 days salary based on the latest salary rate;

2. Cash equivalent of 5 days of service incentive leave;

3. One-twelfth (1/12) of the 13th month pay

● Overtime pay

The employee who renders overtime will be given additional

compensation equivalent to his regular wage plus at least 25% premium.

Overtime pay for holiday or rest day shall be paid an additional

compensation from the rate of the first eight hours on a holiday or rest day plus at

least 30%.

On a Special Non-Working day, or rest day, an additional compensation of

30% premium will be paid in addition to the rate of the first eight hours on holiday

or rest day.

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 ● Night shift differential (NSD)

Applies to employees who work between 10:00 p.m. and 6:00 a.m. An

additional 10% premium is applied for every hour at work.

● Leave Benefits

While sick leave and vacation leave benefits are not specifically stated

under the law, it stipulates that private employees are allowed to provide

employees a yearly Service Incentive Leave of five days with pay. This applies to

employees with work tenure of at least one year within the company.

●Maternity Leave

Any pregnant woman employee who has worked with the company for at

least six months will be granted a maternity leave of at least two weeks prior to

her due date (expected date of delivery) and four weeks after normal delivery or

miscarriage with full pay based on her regular salary.

A total of 60 days is granted for government employees, and 60 to 80

days for employees in the private sector.

The Maternity Leave benefit is effective up to the first four deliveries of the

woman employee working in the company.

However, Senate Bill 2982, or the Expanded Maternity Leave Law of

2015, has been approved on its third (3rd) reading on January 18, 2016. If

121
enacted into law, will grant 100 days of maternity leave for employees in the

government and private sector, regardless of the type of delivery.

● Paternity Leave

The R.A No. 8187, or Paternity Leave Act of 1996, grants seven days of fully

paid leave to married fathers. This is effective up to the first four deliveries of the

legitimate spouse.

● Parental Leave for Solo Parents, or Solo Parenting Leave (SPL)

Seven days leave with pay for every year of service, on top of other leave

privileges, e.g. Maternity or Paternity Leave.

● Special Leave Benefits for Women

This entitles women who underwent surgery due to gynecological

disorders to two months’ leave with full pay, as stipulated in R.A. 9710 or the

Magna Carta of Women. This applies to employees who have rendered at least

six months of service with the company.

On the other hand, victims of violence against women, as stipulated in

R.A. 9262 or the Anti-Violence Against Women and Their Children Act of 2004,

are entitled to 10 days leave with full pay.

● Mandatory Government Benefits and Contributions

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The following government contribution will be automatically deducted from

regular employees based on their salary, with the following benefits:

● Social Security System (SSS) benefits

The SSS Employees’ Compensation (EC) program has been in place to

help workers who encounter work-related illnesses or injury resulting in disability

or death. This includes compensation for: medical services, appliances, and

supplies in an accredited hospital; rehabilitation services, including medical,

surgical, and hospital treatment; and income cash benefit. More information can

be found here.

● Pag-IBIG benefits

This entitles employees to avail of a Housing Loan, Calamity Loan, and Multi-

Purpose Loans that aim to provide financial assistance to their needs. For a full

list of Pag-IBIG benefits and membership requirements, visit their website.

● PhilHealth benefits

Provides financial assistance for inpatient and outpatient hospitalization, as well

as Z Benefit Packages for patients undergoing prolonged hospitalization and

expensive treatments and suffering from Millennium Development Goal (MDG)-

related illnesses.

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 ELECPRO Table of Organization Overview

Plant Manager/ Professional

Mechanical Engineer

Mechanical Shift Instrumentation & Admin/Logistics Electrical Shift Warehouse

Engineer Control Engineer Supervisor Engineer Supervisor/
Purchaser

Control Room Financial Lineman

Operator Safety Officer Accountant Warehouse Man/
Storekeeper

Maintenance Meter Reader/

Technician Mail Courier

Helper

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125
PLANT LAYOUT

126
 Legend

1 Power House 11 Cooling Tower

2 Purifier & Pump House 12 Piping Installation

3 Tank Farm 13 Warehouse

4 Substation & Transmission 14 Storage Room

5 Switch Gear Room 15 Canteen

6 Transformer 16 Clinic

7 Machine Shop 17 HSSE Office

8 Admin Building 18 Guard House

9 Internal Switch Gear Room & Control Room 19 Gate 1

10 Parking Area 20 Gate 2

127
128
POWERHOUSE LAYOUT

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 CHAPTER VIII

SUMMARY OF FINDINGS, CONCLUSIONS AND RECOMMENDATIONS

This chapter shows the summary, conclusion and recommendation drawn

in this research study.

Summary of Findings

This project discusses the concept of a diesel power plant with a twenty

megawatt (20MW) capacity.

The company will be named as "Electricity Provider Corporation”, or

ELECPRO Corp. for short, since the main objective of this design is to provide

electricity for several areas in Batangas where cost of electricity is high.

ELECPRO Corp. is intended to be established at Dela Paz Proper,

Batangas City. The plant's location is an advantage being near the coast line

where the delivery of fuel oil is easier because it will be deliver via ship and not

via truck. For this reason, the company will not face delays in fuel delivery due to

heavy traffic.

The proposed diesel power plant will have a total land area of two (2)

hectares. This would include: power house, pump house, control room, machine

shop, admin building, transmission line, tank farm, canteen, warehouse, and

storage room. There will be a vacant space in power house readily available in

case of expansion. The plant will maintain a safe and conducive working area for

the workers by installing safety and sanity facilities, cleanliness, proper

ventilation and good lighting shall be given top priority and consideration.

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 Production shall be three-hundred thirty (330) days a year from which

employees will work on shifting schedule (3 shift a day) for twenty-four (24) hours

daily. Plant shut down shall be twice a year ̶ during December season and mid-

year ̶ to accommodate clean-out schedule, and repair and overhaul of

machineries and equipment.

To avoid noise problems during the production, a silencer will be installed

on the chimney. Also, a Selective Catalytic Reduction (SCR) will be installed on

the chimney to avoid too much emission of carbon dioxide (CO2) into the

atmosphere.

From this design, the cost of electricity production per kw-hr will be P6.00

on its starting year. It is lesser compared to other electricity provider such as

MERALCO, where cost of electricity is P9.2587/kwh, and BATELEC where cost

of electricity is P8.2966/kwh. Due to increasing cost of living in the Philippines

annually, the cost of electricity production per kw-hr is projected to increase by

3% from year 2021 according to Philippine Statistics. The projected cost from

year 2020-2029 is shown in Appendix B.

The total capital investment of the plant is PHP 377,774,248.89 from

which 60% of it will be loan from the bank and the remaing 40% will be

shouldered by the owners.

Upon analyzing the financial aspects of this design, the group have come

up that expected financial return from an investment over a given period of time,

also known as pay-out period, will be 3.65 years. The expected return of

investment for ten years has an average of 24.69 %.

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Conclusion

The establishment of proposed 20 MW diesel power plant will offer a very

bright future of Philippine economy and will provide job opportunities to many

Filipinos, specially the Batangueños.

The company will employ 24 personnel that will be working as one to meet

the company’s goal and mission.

Because electricity consumption is a necessity to humans, it is expected

to increase yearly, making it feasible to put up a power plant.

The total capital investment of the plant is PHP 377,774,248.89. The

company will loan 60% of the total capital investment from the Bank of the

Philippines Islands to be amortized for 10 years at 10% interest. Based on the

financial study, the amortization is amounting to Php 36,888,611.59. On the other

hand, the remaining forty percent (40%) will come from the owners.

The pricing of equipment was based on the current market and selling

price. The pricing for auxiliary equipment and piping (20%), electrical equipment

(20%) and building construction 15% was based on PPT & D by P.J. Potter, page

590. Land cost is based Dela Paz land rate of P180/m2 but in this study, the

group used P250/m2 because the power plant is be established on April 2020

when land cost is expected to increase due to inflation. The cost of Caterpillar

GenSet Diesel Engine Oil (OIL-CAT 15W-40 DEO) is based on its current rate of

Php 3,803.50/19L. Because oil change of Caterpillar GenSet is every 12 months

and oil capacity is 178.3 gallons, it is expected that 675L of DEO will be used per

unit annually. The current cost of B20 Diesel Fuel is Php 35.40 but the cost used

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in this design is Php 42.12 per liter because according to business.inquirer.net,

the cost of fuel is expected to increase by Php 6.72 per liter on year 2020. On the

other hand, the pricing for the production cost is based on researchgate.net as

shown in Appendix D.

Based on the deliberation of technical, financial and socio-economic

aspect of the design, the project is beneficial, viable and feasible.

Recommendation

Based on the evaluation of the research design results, the group

recommends the following:

o The proposed plant must be updated with the latest developments

regulations under prescribed law.

o The proposed plant must extend its electricity distribution network

to expand the marketing and sales of its products.

o The proposed plant must ensure that there is preventive

maintenance to reduce long term cost.

o The proposed plant must maintain a safe and conducive working

area for the workers by installing safety and sanity facilities,

cleanliness, proper ventilation and good lighting

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 BIBLIOGRAPHY

http://www.choicesmagazine.org/choices-magazine/theme-articles/economic-

and-policy-analysis-of-advanced-biofuels/political-economy-of-biofuel

http://biofuel.org.uk/advantages-of-biofuels.html

https://auto.howstuffworks.com/fuel-efficiency/biofuels/10-edible-biofuels.htm

http://indjst.org/index.php/indjst/article/view/85777

https://www.batangascity.gov.ph/web/about-the-city/city-profile/social-aspects

https://www.researchgate.net/publication/316659100

http://www.trucktrend.com/cool-trucks/1411-caterpillar-c175-20-diesel-engine-by-

the-numbers/

134
PSME code, Table 2.4. 2.3 (4) P.11

Power Plant Theory and Design by P.J. Potter, p.

135
DME by V.M. Faires, Table 1.1 p.20

PPE by F.T. Morse, eq. 6-16, p.178

PPE by F.T. Morse, eq. 6-19 & 6-20, p.182

136
Power Plant Theory and Design by P.J. Potter, Table 8-1 p.353

137
PPE by F.T. Morse, eq. 6-17 & 6-18, p.177

Measured and Calculated Values Of Specific Gravity For Blend

Diesel Power Plant Operating Cost

(From https://www.researchgate.net/publication/316659100)

138
PSME code, p.200

139
Standard API Tank Size

140
141