Department of Mechanical Engineering

College of Engineering and Design

Silliman University

Pencil Lead

In Partial Fulfillment of the Requirements in ME 58 – Industrial Plant Design

Submitted to:

Engr. Rufwin Pabu-aya

Faculty of the College of Engineering and Design

Department of Mechanical Engineering

Silliman University

Submitted by:

Corwyn C. Banogon

BSME - V

i
List of Figures

Chapter I

Figure 1.1 Site Location and Area 1

Figure 1.2 Industrial Plant Layout 2

Figure 1.3 Industrial Plant Layout (Floor Plan) 3

Figure 1.4 Schematic Diagram 8

Figure 1.5 Industrial Mixer Machine 15

Figure 1.6 Press Lead Machine 15

Figure 1.7 Pencil Lead Cutting Machine 15

Figure 1.8 High Quality Curing Machine 15

Figure 1.9 Automatic Pencil Lead Packaging 16

Figure 1.10 Industrial Plant Load Curve 17

Figure 1.11 Fire Protection System 19

Figure 1.12 Firefighting System Layout with Dimensions 20

Figure 1.13 Lighting Layout 22

Figure 1.14 Lighting Layout with Dimensions 23

Figure 1.15 Organizational Chart 24

Figure 2.1: Psychometric Chart 31

Figure 2.2 Air Condition Layout 42

Figure 2.3 Air Condition Layout with Dimension 43

Figure 3.1 Power Plant Load Curve 48

Figure 3.2 Operational Schedule 51

ii
 Figure 3.3 Infanite Diesel Generator 15kW 59

Figure 3.4 Side view Infanite Diesel Generator 15kW 59

Figure 3.5 Infanite Diesel Generator 10kW 60

Figure 3.6 Side view Infanite Diesel Generator 10kW 60

Figure 3.7 Daiden Diesel Generator 7kW 61

Figure 3.8 Side view Daiden Diesel Generator 7kW 61

Figure 3.9 Chimney Height and Inside Diameter 67

Figure 3.10 Chimney Height and Inside Diameter 67

Figure 3.11 Chimney Height and Inside Diameter 68

Figure 3.12 Storage tank Dimension 80

Figure 3.13 Storage tank dimensions 80

Figure 3.14 Storage tank dimensions 81

Figure 3.15 Power Plant Layout 84

Figure 3.16 Power Plant Layout with Dimensions 85

List of Tables

Table 1.1 Raw Materials 4

Table 1.2 List of Equipment 5

Table 1.3 Approximate Weight of Building Materials 9

Table 1.4 Safe Bearing Power of Soils 10

Table 1.5 Data on Concrete Mixes to Yield 1 m3 Concrete 11

Table 1.6 Machine Foundation Calculations 13

Table 1.7 Machine Foundation Measurements 14

iii
Table 1.8 Work Schedule and Load Curve 17

Table 1.9 Sprinkler Calculations 18

Table 1.10 Lighting Calculations 21

Table 1.11 Total Cost 25

Table 2.1 Hourly Schedule of Door 27

Table 2.2 Weekend Schedule 27

Table 2.3 Doors and Windows Conditions 28

Table 2.4 Wall Composition 29

Table 2.5 CLTD For Walls 32

Table 2.6 CLTD of Doors 33

Table 2.7 CLTD of Flat Roofs 34

Table 2.8 Wall Load Calculations 34

Table 2.9 Door Load Calculations 35

Table 2.10 Ceiling and Roof Load Calculation 36

Table 2.11 Glass load Calculation 37

Table 2.13 Miscellaneous Load Calculations 38

Table 2.14 Moisture Content Difference from Psychometric Chart 39

Table 2.15 Sensible Gain & Latent Gain 39

Table 2.16 Solar Heat Gain Calculations 40

Table 2.17 People Load Calculations 41

Table 2.18 Split Type Inverter Aircon 44

Table 2.19 Financial expenses 44

Table 3.1 Energy Generated 49

iv
Table 3.2 Generating Units Operational Schedule 50

Table 3.3 Generating Units Operational Hours 51

Table 3.4 Equipment specification 52

Table 3.5 Approximate Weight of Building Materials 54

Table 3.6 Safe Bearing Power of Soils 55

Table 3.7 Data on Concrete Mixes to Yield 1 m3 Concrete 57

Table 4.1 Cost of Equipment 86

Table 4.2 Cost Operation 86

Table 4.3 Turnover 87

v
 TABLE OF CONTENTS

PAGE NO.
Title Page i
List of Figures ii
List of Tables iii
Chapter 1
Background Information 1
Industrial Plant Layout 3
Raw Materials 4
List of Equipment 5
Process Definition 7
Material Balance 7
Schematic Diagram 8
Machine Foundation Calculations 9
Machine Foundation Layout 18
Work Schedule and Load Curve 19
Fire Fighting System 20
Fire Fighting System Layout 21
Lighting Calculations 22
Lighting Layout 23
Organizational Chart 26
Financial Expenses 27
Chapter 2
Door and Window Schedule 28
Door and Window Condition 30
Wall Composition 31

vi
 Heat Load Calculations 31
Indoor Air Quality 32
Cooling load Temperature Difference Calculations 34
Conduction Heat Gain 36
Convection Heat Gain 40
Moisture Content 41
Sensible and Latent Convective Heat Gain 41
Solar Heat Gain 42
Internal Heat Gain 42
People Heat Gain 43
Conditioning Layout 44
List of Equipment 45
Financial Expenses 45
Chapter 3

Power Plant Design 48

Load Curve 48
Power Plant Consumption 49
Load Factor calculations 50
Operational Schedule 51
Plant Capacity Calculations 52
List of Equipment 52
Machine Foundation Calculations 53
Chimney Design 62
Cooling Tower Design 69
Mass Flow Rate of Dry Air Calculations 71
Fuel tank, Storage tank, and Transfer pump 76
Power Plant Layout 83

vii
 Power Plant Layout with Dimensions 84

Chapter 4

Economic Analysis 86
Total Costs of Equipment 86
Operating Cost 86
Payback Period 87
Reference 89
Appendix 90

viii
CHAPTER 1

INDUSTRIAL POWER PLANT

Background information

Pencil lead is one of the oldest and important material on this planet. It was discovered in
1565 from a large deposit of graphite from the hamlet of Seathwaite in Borrowdale parish,
Cumbria, England. Pencil lead is widely used to provide visual design, knowledge, and
creativity. Eventually, technology became more popular ensuring lesser time demand and
efficiency. But sometimes technology isn’t always better, drawing with pencil can kickstart the
creative process concentrating on the challenge at hand and allow it to its purest form when
technology fall short. This project will Design an Industrial plant of pencil lead to establish an
industrial plant that will create a visually impactful project.

Figure 1.1 Site Location and Area

The Industrial Power Plant for the production is located at Barangay 7, Lawton, Tanjay
City along Nono Limbaga seen in figure 1.1. The area is about 6,100 square meters; with a plant
area of 5, 976 which is enough area for the manufacturing plant.

1
Industrial Plant Layout

Figure 1.2 Industrial Floor Plan

2
Figure 1.3 Industrial Floor Plan with Dimensions

3
 Figure 1.2 Shown above its whole area of the Pencil lead manufacturing plant. The plant
area is about 5,976 square meters. In figure 1.3 shows the floor plan of the industrial plant
together with the power plant. Each Department has different dimensions.

Raw Materials
Table 1.1 Raw Materials for Pencil Lead

Main Material

Pencil Lead

Other Materials

Graphite Powder

Clay Powder

Water

4
 As seen in Table 1.1 shown above is the raw materials is needed for making pencil lead.
Mixing the raw materials with the help of Industrial Mixer to ensure its quality and shorter cycle
times. After mixing it produces thick mud and will be process on the another machine.

List of Equipment

Table 1.2 Machine and Specification

SPECIFICATIONS
Model no. YXPA750
Dimensions 1.5m x 2m x 1.9m
Barrel volume 10000L
Max. Volume 10000L
Machine Weight(kgs) 8900
Power (KW) 7.5
Price ₱500,000
Industrial Mixer Quantity 1
SPECIFICATIONS
Model no. -
Dimensions 500x1000x1200mm
Barrel volume 15in3
Machine Weight(kgs) 2000
Power (KW) 3
Price ₱ 442,500
Press Lead Pencil Machine Quantity 1
SPECIFICATIONS
Model no. -
Dimensions 1.5m x 2m x 1.9m
Barrel volume -
Max. Volume -
Machine Weight(kgs) 750
Power (KW) 3
Price ₱ 250,000
Pencil Lead Cutting Machine Quantity 1

5
 SPECIFICATIONS
Model no. -
Dimensions 500x1000x1200mm
Barrel volume -
Machine Weight(kgs) 1000
Power (KW) 7.5
Price ₱ 1,220,000.00
High Quality Curing Machine Quantity 2
SPECIFICATIONS
Model no. Ls-d
Dimensions 1400 x 1500 x 3420mm
Barrel volume -
Max. Volume -
Machine Weight(kgs) 75
Power (KW) 6
Price ₱ 200,000
Automatic Pencil lead Packing Quantity 1
Machine

The list of equipment’s is shown in Table 1.2. These machines are useful because they
reduce effort, extend the ability of people to perform task beyond their normal capabilities.
Generally, speeds up the process time of the production.

Process Definition
Process is started by chunks of graphite (a soft, dark mineral) and clay are placed inside a
huge rotating drum. Large rocks inside the drum crush the graphite and clay into a fine powder.
Then water is added, and the mixture is blended in the drum for up to 35 minutes. Then a
hydraulic press squeezes all the water out of the mixture leaving behind a cylindrical block grey
sludge and set it aside for a week to cure. Each cured block is load again into a horizontal
hydraulic press which pushes it through a forming dye, producing one long continuous lead.
Different dye gives different sizes of leads by cutting machine which cuts the continuous lead
into a pencil length. Workers load the leads into a rotary dryer at 160 degrees Celsius up to 12
hours. After drying it will be cured up 1,000 degrees Celsius up to 10 hours. This will be
strengthening the leads into final harness. Lastly the quality control, factory put samples quality
testing to check hardness break resistance, diameter and writing quality.

6
Material Balance
Production Rate = 100,000pcs/week Working hours = 8hrs/day Working days =
5days
Production/day = 20,000 Total Production Rate = 100,000 pcs/week
Pencil Type:
No. 2/ HB – graphite 68% clay 26% water 5%
Below is the quantity of raw materials needed in generating one-unit pencil lead:
Graphite Powder 0.142 kg
Clay Powder 0.072 kg
Water 0.09 L

Below the weight needed to produce 100,000pcs of pencil lead.

Graphite Powder Water
1 pencil lead 100,000 1 pencil lead 100,000
0.142 kg
= kg
= 14,200 kg 0.09 L
= L
= 9,000L

Clay Powder
1 pencil lead 100,000
0.072 kg
= kg
= 7,200 kg

7
Schematic Diagram

Figure 1.4 Schematic Diagram

Figure 1.4 shows the graphical process of the Pencil Lead Manufacturing Plant, by
providing a different element of process and understand the interrelationships among the various
steps to obtain the finish product.

8
Machine Foundation Design
Length of the Foundation Calculations:
L=L B +2 c
Where: L = length of the foundation, LB = length of the bedplate, c = clearance
The clearance of the distance of the edge of the foundation from the bedplate must be 120 mm to
300 mm to secure the belts imbedded within the foundation.
Upper Width of the Foundation Calculations:
a=w+ 2 c
Where: a = upper width of the foundation, w = width of the bedplate, c = clearance
The clearance of the distance of the edge of the foundation from the bedplate must be 120 mm to
300 mm to secure the belts imbedded within the foundation.
Weight of the Foundation Calculations:
W f =5 (W m )
Where: Wf = weight of the foundation, Wm = weight of the machine
Volume of the Foundation Calculations:
Wf
Vf=
ρ
Where: Vf = volume of the foundation, Wf = weight of the foundation, ρ = density of
building materials.
The building material that will be used for the machine foundation is reinforced concrete.
From table 6.1 (Approximate Weight of Building Materials) below, we can obtain its
approximate
density which is: ρ=2,802 kg/m3
Table 1.3 Approximate Weight of Building Materials

Approximate Weights of Building Materials

Building Material kg/m³
Plain concrete, stone 2323 - 2403
Plain concrete, slag 2082
Plain concrete, cinder 1602
Reinforced concrete, stone 2403
Brick masonry, pressed 2243
Brick masonry, common 1922
Ashlar masonry, granite 2643
Ashlar masony, limestone 2563
Ashlar masonry, sandstone 2243
Sand and gravel 1602 - 1762 9
Cinder fill 641 - 721
Lower Width of the Foundation Calculations:
S b W m +W f
=
N bL
N (W m +W f )
b=
Sb L
Where: b = lower width of the foundation, Sb = soil bearing capacity, N = factor of safety,
Wm = weight of the machine, Wf = weight of the foundation, L = length of the foundationThe bed
soil is found to be compact clay soil. From Table 6.2 (Safe Bearing Power of Soils) below, the
safe bearing power of a compact clay soil is given as follows:
Sb =50t /m ²
Table1.4 Safe Bearing Power of Soils

Safe Bearing Power of Soils

Soil Tonnes/m²
Native rock 1950 up
Ashlar masonry 245 - 290
Best brick masonry 145 - 195
Common brick masonry 50 - 98
Clay, compact 50 - 78
Clay, soft 9.5 - 19.5
Gravel and sand 78 - 98
Sand 19.5 - 58.5
Quicksand, loam, etc. 5 - 9.5

However, since this is a machine foundation, the safe bearing power of soil will be
halved, given an allowable unit of soil stress as follows:
Sb =25,000 kg/m ²
Note that if b < a, then let b = a, which means that the foundation is a rectangular cross
section. Also, the safe bearing capacity is computed using a factor of safety of 5.
Since b1,2,3 < a, therefore, make b equal to a making the foundation a rectangular cross section.
Depth of the Foundation Calculations:

Vf= ( a+b2 ) hL
2Vf
h=
( a+b ) L

10
 Where: h = depth of the foundation, Vf = volume of the foundation, a = upper width of
the foundation, b = lower width of the foundation, L = length of the foundation
Safe Bearing Stress Calculations
Using the common flexure formula:
Mx
fb=
I

M 1= ( W3 )( Width2 )
m m

Substituting the value obtained in the following equation:

S b W m +W f
= +f b
N bL
Therefore, the extreme soil stress is less than the allowable soil stress ensuring a safe
operation.
Concrete Mixture Calculations:
Table 1.5 Data on Concrete Mixes to Yield 1 m3 Concrete
Data on Concrete Mixes to Yield 1 m³ Concrete
Cement, Safe Comp.
Mixture Sand, m³ Stone, m³ Application Weight, t/m³
sacks Stress, t/m²
Roofs, sills,
1:2:3 9.2 0.51 0.77 tanks, 2.66 382.78
tunnels
R. C. floors,
1:2:4 7.8 0.44 0.88 beams, 2.66 328.1
columns
Building
1:2.5:4 7.3 0.52 0.83 2.66 273.42
walls
Foundations
1:3:5 6.2 0.52 0.86 2.66 218.73
and footings
Cinders,
1:2:4 8.6 0.49 R. C. floors 1.99 153.11
cu yd 0.98
Slag,
1:2:4 8.6 0.49 R. C. floors 2.13 153.11
cu yd 0.98

Based on Table 1.5 (Data on Concrete Mixes to Yield 1 m 3 Concrete) above, using the
mixture 1:2:4, having 1 part cement, 2 parts sand and 4 parts stone, to produce 1 m3 of concrete,
the following are needed: 7.8 sacks of cement, 0.44 m3 of sand and 0.88 m3 of stone.

11
Cement Sacks=V f
( 7.81sacks
m )
3

0.44 m3
Sand=V f ( 1m3 )
0.88 m3
Stone=V f ( 1m 3 )
Weight of Steel Bar Reinforcements Calculations:
W SB=0.01(W f )
Where: WSB = weight of the steel bar, Wf = weight of the foundation

12
 Table 1.6 Machine Foundations Calculations

Machin Machin Machin

Foundatio Foundatio Foundatio Foundation Foundatio
Equipment/ e e e Foundatio
n Length, n Upper n Weight, Lower Width,   n Volume,
Machine Length, Width, Weight, n Depth, m
m Width, m m m m3
m m kg

b<a
b= N(Wm+Wf)/ h= 2Vf/
  Lb w Wm L= Lb + 2c a= w + 2c Wf= 5Wm , Vf= Wf/ ρ
SbL (a+b)/L
b'=a
Industrial Mixer 1.5 2 8900 1.9 2.3 44500 145.372051 - 21.3736792 1.57232
Press Lead Pencil
0.5 1 2000 0.9 1.3 10000 68.9655172 - 4.80307397 1.39033
Machine
Pencil Lead
1.5 2 750 1.9 2.3 3750 12.2504537 - 1.80115274 0.473233
Cutting Machine
High Quality
0.5 1 1000 0.9 1.3 5000 34.4827586 - 2.40153698 0.903233
Curing Machine
Automatic Pencil
Lead 1.4 1.5 750 1.8 1.8 3750 12.9310345 - 1.80115274 0.852523
Packing Machine
Table 1.6 shows the dimension and weights of the machines. The values of each machine will be used for calculating the
depth of the concrete foundation. These values will be applied when placing the machines.

13
Table 1.7 Machine Foundation Volume Calculations

Steel Bar
Foundation Cement,
Equipment/ Machine Foundation Weight, m Sand, m3 Stone, m3 Reinforcements
Volume, m3 sacks
Weight, kg
Cement Sand Stone
  Wf Vf
= Vf (7.8) = Vf(0.44) = Vf (0.88) Wsb= 0.01Wf
0.62439961 0.27473583
Industrial Mixer 44500 4.870317003 0.549471662 445
6 1
6.00384245 2.64169068
Press Lead Pencil Machine 10000 46.82997118 5.283381364 100
9 2
Pencil Lead Cutting 7.20461095 3.17002881
3750 56.19596542 6.340057637 37.5
Machine 1 8
High Quality 2.40153698 1.05667627
5000 18.73198847 2.113352546 50
Curing Machine 4 3
Automatic Pencil 3.60230547 1.58501440
3750 28.09798271 3.170028818 37.5
Lead Packing Machine 6 9

Table 1.7 shown above are the volume needed for the cement, sand and stone. Steel bar needed to make a reinforced concrete.;
to ensure its safety and superior quality of the reinforced concrete.

14
Machine Foundation Layout

Figure 1.5 Industrial Mixer Machine Figure 1.7 Pencil Lead Cutting Machine

Figure 1.6 Press Lead Machine Figure 1.8 High Quality Curing Machine

15
 Figure 1.9 Automatic Pencil Lead Packaging
Figures 1.5 1.6, 1.7, 1.8 and 1.9 each shows the placement of reinforced concrete
foundation. Each machine has different measurements which depends on its dimensions and
weights. The reinforced concrete will absorb shocks and vibration - this will ensure superior
quality of construction and prevents cracks.

16
Work Schedule and Load Curve

Table 1.8 Plant Operational Schedule

Time 8:00 9:00 10:00 11:00 12:00 1:00 2:00 3:00 4:00 5:00
process AM AM AM AM AM PM PM PM PM PM
Start of
operation
Mixing
Forming
Press
Cutting
Drying
Curing
Packagin
g
Dry Clean

In table 1.8, the plant schedule starts at 8:00 am in the morning until 4:00 pm in the
afternoon. Working is essential for workers to keep organized and get the job well done and
manage the costs effectively. Each day toward the deadline goal, the project becomes
manageable and more easily achieved.

Load Curve

LOAD CURVE
35
30
25
20
LOAD (KW)

15
10
5
0
. . . . . . . . . . . . . . . . . . . . .
M M M M M M M M M M M . M M M M M M M M M M M .M M
A . A . A . A . A . A . A . A . A . A . A . 0 P 0 P . 0 P . 0 P . 0 P. 0 P . 0 P. 0 P . 0 P. 0 P. 0 P. 0 P 0 0 A
00 00 00 00 00 00 00 00 00 00 00 :0 0 0 0 0 0 0 0 0 0 0 :0 2:
1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11 1

TIME (HRS)

Figure 1.10 Industrial Plant Load Curve

17
 It is shown in Figure 1.10 the load requirement within a 24-hour period. At 3:00 PM,
higher demand of energy consumption is evident due to drying the pencil lead. The peak load
starts at 12:00 noon and ends at 4:00 in the afternoon. During 5-6:00 PM, it will slowly increase
again due to dry cleaning that needs a light.

Fire Fighting System

Square
Length Width Area Heads
Area Meter per Heads
[m] [m] [m²] Needed
Head
Office Room 6 9 54 18.5806 2.69 4
Restroom 5 8 40 18.5806 0.32 2
Conference Room 11 9 99 18.5806 2.15 3
Raw Material Storage Room 25 6 150 18.5806 1.29 2
Production Room 25 20 500 12.0774 4.14 6
Utility Room 33 6 198 18.5806 0.32 2
Hallway 44.5 13 579 18.5806 3.77 31
The firefighting system in this industrial plant design will be using the sprinkler system
and portable fire extinguishers will be placed on places where the hazards are around. It is a
requirement in every building to be equipped with sprinkler system, portable fire extinguishers
and fire alarms to keep buildings, workers and clients safe. In Figure 1.13, the layout for the
sprinklers and fire extinguishers are shown with its legends. In the table below (Table 1.8), the
calculations for the number of sprinklers to be installed in every section of the industrial plant are
calculated.

Table 1.9 Sprinkler Calculations

Table 1.9 shows the calculations for the number of sprinklers to be installed in every
section of the industrial plant is calculated. The amount of sprinkler heads for every room is
shown in Table 1.9 above where it is calculated using the following formula:

Floor Area[m2 ]
Sprinkler Head=
m2
Sprinkler Spacing Requirements [ ]
head

18
Firefighting Layout

Figure 1.11 Fire Protection System Sprinkler Head Locations

19
Figure 1.12 Fire Protection System Sprinkler Head Locations with Dimensions

20
 Figure 1.11 and Figure 1.12 show that sprinklers are used for factory safety in case of
emergency especially when a fire has occurred inside the establishment. Several sprinkler heads
are strategically placed in each room to ensure the welfare of the employees.

Lighting Calculations

In industrial settings where safety is a primary concern, many engineers acknowledge the
significance of proper lighting. Adequate illumination is also a key factor in maintaining high
worker productivity.

Table 1.10 Lighting Calculations

SPACE AREA LUX RECOMMENDED BULB NO. TOTAL

[m2] LUMENS WATTAGE OF LUMENS
[Watts] BULB
Office Room 54 300 1600 18 10 1600
Restroom 40 100 1600 18 3 1600
99 100 1600 18 6 1600
Conference
Room
150 100 1600 18 9 1600
Storage Room
500 100 1600 18 31 1600
Production
Room
Utility Room 198 100 1600 18 12 1600
Hallway 579 100 2300 30 25 2300

Table 1.10 shows the exact lumens, no. bulbs and wattage that will be use. Area has been
calculated to determine the recommended lumens in order to light up the room.

( Floor Area[m2 ]) Recommended Lux lumen

No .of Bulbs=
( 2 [ m ])
lumen
Bulb Illumination [ bulb ]
The recommended light levels or lux (lumen/m 2) for each type of room are obtained from
the IESNA Lighting Handbook and LPD levels from the IECC 2015 table below

21
Lighting Layout

Figure 1.13 Lighting Layout

22
Figure 1.14 Lighting Layout with Dimenions

23
 CEO

Manager
Manager(Marketing)
(Production)

Foreman Officer Maintenance

Foreman(assembly) Financial Accoutant Security Manager
(fabrication) Personnel

Workers I Workers I Sales Manager Security Officer Utility Personnel I

Workers II Worker II Advertising Manager Security I Utility Personnel II

Worker III Worker III Sales Officer Security II Utility Personnel III

24
 Figure 1.13 and 1.14 shows the lighting layout. Having a layout and calculation can be
seen on table 1.10, will illuminates spaces and to provide better consistency on working.
Specially dealing with machine is higher risk of accident specially when there is no light. The
plant has a total of 96 led bulbs that illuminates all room and with a specific wattage of led bulb.

Organizational Chart

Figure 1.15 Organizational Chart for the Pencil Lead Manufacturing Plant
An organizational chart is a diagram that shows the structure of an organization and the
relationships and relative ranks of its parts and positions/jobs. The General Manager acts as the
head of every department. Under the General Manager, the Administration Center, Production
Center, Financial Center and Quality Control Center can be found.

Financial Expenses

Table 1.11 Total Cost of the Pencil Lead Plant

Partial expenses
Category Unit Quantity Unit Price Total Amount
(Php) (Php)
Industrial 1 ₱510,000 ₱500,000
mixer
Horizontal 1 ₱436,050 ₱872,100
hydraulic press
machine
Pencil Lead 1 ₱255,000 ₱255,000
Cutting
Machine
Conveyor belt 1 ₱204,000 204,000

25
 pencil lead
trasporter
High quality 1 ₱1,122,000 ₱1,122,000
Curing
Machine
Automatic 1 ₱1,785,000 ₱1,785,000
Pencil lead
Packing
Machine
Digital 2 ₱14,535 ₱28,700
Rebound Leeb
Hardness
Tester
Impact rebound 2 ₱102,000 ₱204,000
resilience
Elasticity
Tester
Hydraulic 2 ₱499,800 ₱999,600
Cylindrical
Press

Equipment
Fire Protection Sprinklers & 377 ₱ 4,000 ₱1,508,000
System Pipe
Computers 20 ₱ 50,000 ₱1,000,000
Water 10 ₱10,000 ₱100,000
Appliances Despenser
Aircon 4 ₱ 50,000 ₱200,000
Fan 15 ₱1,000 ₱15,000
Construction Industrial Plant 1 ₱30,000,000 ₱30,000,000
Labor
Grand Total ₱54,866,400

Table 1.11 specify each price of the material needed for the pencil lead manufacturing
plant. Having a grand total of fifty-four million eight hundred sixty-six thousand and four
hundred pesos.

26
CHAPTER 2

REFRIGERATION AND AIR CONDITIONING DESIGN

Door and Window Schedule

    Off = Off-Peak; N = Normal-Peak; M = Mid-Peak; P = Peak

27
 Table 2.1 Hourly Schedule of Door
Hou
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23
r
Valu
Off Off Off Off Off Off Off Off P N N N P M N N N M P N Off Off Off Off
e

Table 2.2 Weekend Schedule

Hou
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23
r
Valu
Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off
e

Table 2.1 and Table 2.2 show the time and day of the door opening schedule. Since the
industrial plant will start to operate at 8am, it is labeled as Peak because most of the employee
will enter and scan for biometric. During weekend the factory is closed, because the required
working days only takes 5 days.

Door and Window Condition

Windows and doors are currently highly engineered in order to optimize energy
performances. Windows and doors have significant roles in the energy profile of a home. Frame
material issues, although important as part of an overall environmentally responsible approach,
play only a small role due to their small size/area. Performance of these products is important in
durability and maintenance, as well as energy.

Table 2.3 Doors and Windows Conditions

Conditions
Interior doors and
Exterior
Doors door have adequate
undercut

28
 to maintain balance
in HVAC system.
Conditions
All windows are
tested and certified
Windows and have air
infiltration
qualities of less than
0.50 CFM per linear
foot crack.

Table 2.3 shows the required design doors and windows to be installed. Having an
excellent quality material of doors and windows has a good impact on refrigeration design,
having their small size and area. Having a good insulation of door of at least 0.25 BTU/hr.ft 2 is
energy efficient same as the window that has a shading that will reduce its solar thermal load.
Thus, having a good insulation for windows and door even though it has a small area it can make
difference in consuming energy.

29
Wall Composition

U-value Heat
Thickness
Structure Insulation Material (BTU/hr- Capacity
(in.)
  ft2-F) (BTU/ft2-F)
1. Concerete 4
(HardiFlex)
1.Roof& 2. Polyisocynaurate 2
Ceiling
(Suspended 0.2 12.5
Ceilling –  
6m.)

  1. Concrete Block 8
Hollow Core
2. Air Space 1
Exterior
0.112 38.4
Walls

   

2
1. Conventional
Doors 0.23 0.7
Wood

Window 1. Single Glass with 1/4

Glass 0.55 Negligble
(Clear) Shading
 

Table 2.4 Wall Composition with Corresponding Heat Transmission Coefficients

Shown above in Table 2.4 are the respective make-up of the wall, roof, door, and
window, together with their respective heat Thermal Transmittance. All values were taken from
ASHRAE 1980 HANDBOOK.

Heat Load Calculations

30
1. Location of Site
a. Name: Tanjay City, Negros Oriental
b. Latitude: 9.4958° N, 122.9663° E
c. Designing Date July
d. Designing Time 16hr (4pm)
2. Summer Climate Conditions
a. Outdoor: 92 ˚F dry bulb, 81 ˚F wet bulb
3. Summer Indoor Design Conditions
a. Indoor: 78 ˚F dry bulb, 50% RH
4. Mean Daily Range: 20 ˚F db
5. Rooms required air-conditioning
a. Office Room
b. Conference Room
c. Utility Room

31
Indoor Air Quality

Figure 2.1 Psychometric Chart

Figure 2.1 represents graph that can be used to assess the physical and thermodynamics
properties of moist air; for the indoor quality air given. The dry bulb 78 ˚F temperature and its
relative humidity 50% as mentioned on design criteria, these 2 air properties value will be used
to find other air properties using the psychometric chart. There are 7 air properties dry bulb
temperature, wet bulb temperature, dewpoint temperature, enthalpy, relative humidity and
specific volume. Since dry bulb temperature is given and relative humidity. The given values
will be used to find the 5 unknown air properties. Green is the dry bulb temperature, wet bulb
temperature is blue, dew point temperature is dark blue, enthalpy is black, relative humidity is
red, specific humidity is violet, and lastly the specific volume is yellow. Now each air properties
are 78 ˚F(DBT), 18 ˚F (WBT), 15˚F (DPT), 55 J/g (H), 50% (RH), 1.2% (SH) and 0.86 m3/kg.

32
Cooling Load Temperature Difference

CLTD= [ ( CLTD+ LM ) x K + (78−Tr ) + ( T 0−92 ) ]

Legend
Where:
a. LM = Latitude Month
b. ( 78 – TR ) = Indoor Design Temperature Correction
c. ( T0 – 92 ) = Outdoor Design Temperature Correction
LM = 0 (for 9oN Latitude month is July and Designing time 16hrs)
K = 0.83 (Medium aged building)

Table 2.5 CLTD For Walls

CLTD correction for Latitude Month Applied to Walls

 
NNE NE ENE E ENE SSE
Latitude Months N S
NNW NW WNW W WSW SSW
Dec -3 -5 -5 -5 -2 0 3 9
Jan/Nov -3 -5 -4 -4 -1 0 2 7
Feb/Oct -3 -2 -2 -2 -1 -1 0 0
9 Mar/Sept -3 0 1 -1 -1 -3 -3 -8
April/Aug 5 4 3 0 2 -5 -10 -8
May/Jul 7 7 5 0 -3 -7 -9 -8
Jun 12 9 5 0 -3 -9 -10 -8

33
 Table 2.5 shown above the reference table for acquiring the values of CLTD. This value was taken from ASHRAE 1980
HANDBOOK .Below is a sample calculation of CLTD.
Cooling Load Difference Temperature of Wall facing North Side
CLTD Corr={ ( 7+7 ) x 0.83+ ( 78−78 )+ ( 92−80 ) }
CLTD Corr=81.72

Table 2.6 CLTD of Doors

CLTD correction for Latitude Month Applied to Walls

  Solar Time (Hr.)
Latitude 10 12 13 13 15 16
N 6 6 7 8 10 24
S 14 17 20 22 23 43
E 12 17 22 27 35 29
W 8 12 17 30 32 67

Table 2.6 shown above is a reference table for acquiring the values of CLTD. This value was taken from ASHRAE 1980
HANDBOOK.

Below a sample calculation of CLTD.

Cooling Load Difference Temperature of Door facing North Side

CLTD Corr={ ( 24−7 ) x 0.83+ ( 78−78 ) + ( 92−80 ) }
CLTD Corr=151.44

34
 Cooling Load Temperature Difference of Calculating Flat Roofs
Suspended Ceiling
Description Weight U-value Solar time
Construction Lb/ft2 BTU/hr-ft2-F (Hr.)
  12 13 14 15 16
4in Concrete
20 0.134 39 48 56 62 34
+ 2in insulation
Table 2.7 CLTD of Flat Roofs

Table 2.7 shown above the reference table for acquiring the values of CLTD. This value was taken from ASHRAE 1980
HANDBOOK.
Below is a sample calculation of CLTD.
Cooling Load Difference Temperature Ceiling and Roofs Orientation is Horizontal
CLTD Corr={ ( 34−5 ) x 0.83+ (78−78 ) + ( 92−80 ) }
CLTD = 153.1
Conductive Heat Gain of Wall Calculations
Table 2.8 Wall Load Calculations

Wall Load Calculations

Q = A*U*CLTD
Dimensions Values
Wall 78
Length Height Area U CLTD L To - QTOTAL
Orientatio K - CLTDtotal Q (BTU/hr)
(m) (m) (ft2) (BTU/hr.ft2.F) (F) M 80 (BTU/hr)
n Tr
North 58 12 7487.8 0.275 12 -7 0.83 78 92 81.72 168274.3721 526869.59
5

35
 7487.8
South 58 12 0.275 20 -8 0.83 78 92 128.2 263984.0248
5
3485.7
East 27 12 0.275 29 2 0.83 78 92 60.14 57648.60668
2
3485.7
West 27 12 0.275 16 -8 0.83 78 92 38.56 36962.59185
2
Table 2.8 shows the Cooling Load Temperature Difference Calculations as solving each value given. Each Orientation of the
wall has different value of latitude month due to the angle where the sun is facing. The total conductive heat gain of the wall is
526,869.5955 BTU/hr.

Conductive Heat Gain of Door Calculations

Table 2.9 Door Load Calculations
Door Load Calculations
Q = A*U*CLTD

Dimensions Values

78 To
Length Height Area U CLTD Q Q (BTU/hr)
Direction LM K - - CLTDtotal
(m) (m) (ft2) (BTU/hr.ft2.F) (F) (BTU/hr) Total
Tr 80
North 5 9.8 49 0.23 24 7 0.83 78 92 151.44 1706.7288
South 5 9.8 49 0.23 43 -8 0.83 78 92 261.83 2950.8241
10890.0883
East 5 9.8 49 0.23 29 2 0.83 78 92 60.14 677.7778
West 10 19.6 196 0.23 67 -8 0.83 78 92 123.22 5554.7576

36
 Table 2.9 shows the Cooling Load Temperature Difference Calculations as solving each value given. Each Orientation of the
door has different value of latitude month due to the angle where the sun is facing. The total conductive heat gain of the wall is
10890.0883 BTU/hr.

Conductive Heat Gain of Ceiling and Roof

Table 2.10 Ceiling and Roof Load Calculation

Ceiling & Roof Load Calculations

Q = A*U*CLTD
Dimension
s Values
Length Width Area U CLTD L 78 - To - CLTDtota Qtotal
Room K
(m) (m) (ft2) (BTU/hr.ft2.F) (F) M Tr 80 l (BTU/hr)
Production 0.8 130451.19
18 22 4260.33 0.2 34 5 78 92 153.1
room 3 4
Storage 0.8
6 24 1549.21 0.2 34 5 78 92 44.37 13747.686
room 3
Office 0.8 7733.0733
9 9 871.43 0.2 34 5 78 92 44.37
room 3 7
Conference 0.8 9451.5341
9 11 1065.08 0.2 34 5 78 92 44.37
room 3 2
Utility 0.8
7 11 828.397 0.2 34 5 78 92 44.37 7351.1932
room 3
0.8 3818.8016
5 8 430.336 0.2 34 5 78 92 44.37
Restroom 3 6
Total 172553.48

37
 3

Table 2.10 shows the Cooling Load Temperature Difference Calculations as solving each value given. Orientation of the
ceiling is Horizontal. The total conductive heat gain of the wall is 172,553.483 BTU/hr.

Conductive Heat Gain of Glass

Table 2.11 Glass Load Calculations

Glass Thermal Load

Q= A*U*Δt

Dimensions Values

U Qtotal
Direction Length (m) Width (m) Area (ft2) Δt (92F-78F) Q
(BTU/hr.ft2.F) BTU/hr
BTU/hr
North 16 0.127 21.86107 1 14 306.055 306.055
South 10 0.127 13.66317 1 14 191.284 191.284
East 0 0 0 1 14 0 0
West 10 0.127 13.66317 1 14 191.284 191.284

38
 Total 688.624

Table 2.11 shows the Glass thermal load as solving each value given. Change in temperature is taken from indoor and outdoor.
The thermal transmittance of glass is understandable because it has no delay on absorbing heat when its expose to sunlight leading to
have higher U-Value. The total conductive heat gain of the glass is 688.624 BTU/hr.

39
Convection Heat Gain

Table 2.12 Lightning Calculation

Lightning Load Calculations

Q= qi*3.41*Fa*Fs*CLF
Q total
  qi Fa Fs CLF
BTU/hr
Production
5285.5 1 1.3 0.08
room 549.692
Office
613.8 1 1.3 0.08
room 63.8352
Conference
368.28 1 1.3 0.08
room 38.3011
Storage
552.42 1 1.3 0.08
room 57.4517
Utility room 736.56 1 1.3 0.08 76.6022
Restroom 184.14 1 1.3 0.08 19.1506
Total 805.033

Table 2.12 each area of the room was taken its area and number of lights needed to use
see (table 1.10) for the lightning recommend lux. Sensible load is multiplied by the wattage of
each bulbs. The total thermal load of 806.033 BTU/hr

Table 2.13 Miscellaneous Load Calculations

Miscellaneous Load Calculations

Qs = qs*CLF & QL = qL
qs Qstotal Qltotal
Appliances Quantity CLF
BTU/hr BTU/hr BTU/hr
TV 2 682 0.8 545.6 330
Computer 25 51150 1 51150 400
Printer 5 852.5 0.5 426.25 155
Router 4 81.84 1 81.84 140
Water
despenser 5 1534.5 1 1534.5 122
Total 53738.2 1147

Table 2.13 shows the appliances that are commonly used by the employees. The
computer has the highest output power and it has 10 working hours or more because computer is
reliable and fast can finish task easily also it is a vital for the company to have a fast data and

40
finish its job quickly. Each appliance has a different sensible load depending on the power of the
appliance. The total thermal load is 1147 BTU/hr.

Moisture Content

Table 2.14 Moisture Content Difference from Psychometric Chart

Moisture Content Difference

First Floor
9 8
Wo (Outdoor) 2 DB 1 62.35 % RH 0.0204 lb moisture/lb of dry air
7 5
Wi (Outdoor) 8 DB 0 50 % RH 0.0102 lb moisture/lb of dry air
Δw = 0.0102 lb moisture/lb of dry air

Table 2.14 shows the computation of Δw and is shown above on the table using
Psychometric Chart. Dry bulb has also been obtained.

Sensible and Latent Convective Heat Gain

Table 2.15 Sensible Gain & Latent Gain

Total Heat Gain

Sesible Heat Gain Latent Heat Gain Total Heat Gain
Heat Gain
BTU/hr BTU/hr BTU/hr

Conduction 537759.6783 0 537759.678

Total 537759.678
Covection 227785.34 1952.033 229737.373
Total 229737.373
Solar 26487.7957 0 26487.7957
Total 26487.7957
People 26424.8 48020 74444.8
Total 74444.8
Total Heat Gain 868429.647
20% increase 173685.929

Table 2.15 shown above is the total heat gain from the whole manufacturing plant. The
total obtained is 173,685.929 BTU/hr thus, will be used for converting into ton of refrigeration or
into horsepower. Below is example calculation for converting BTU/hr to HP.

41
1 btu/hr =0.00039hp

0.00039 hp
173,685.929 BTU/hr x = 65.5 hp
1

Solar Heat Gain

Table 2.16 Solar Heat Gain Calculations

Solar Load
Q= A*SC*SHGF*CLF
Dimensions Values
Q Qtotal
Windows Length (m) Width (m) Area (ft2) SC SHGF
BTU/hr BTU/hr
North 16 0.127 21.8611 0.39 0.75 6.39436 40.8879
South 10 0.127 13.6632 0.39 0.35 1.86502 3.47831
East 0 0 0 0 0 0 0
West 10 0.127 13.6632 0.39 0.81 4.31619 18.6295
Total 62.9957

Qtotal
Doors Length (m) Width (m) Area (ft2) SC SHGF
BTU/hr

North 5 9.8 49 0 0 1706.7288

South 5 9.8 49 0 0 2950.8241
East 5 9.8 49 0 0 677.7778
West 10 19.6 196 0 0 5554.7576
Total 10890.008

Table 2.16 shown above are the Solar load values that are exposed to sun radiation in
each orientation of the windows and door has different value, because of the sun direction and
depending on how long. The total thermal load of windows is 62.9957 BTU/hr and for the doors
is 10,890.008 BTU/hr.

42
People Heat Gain

Table 2.17 People Load Calculations

People Load Calculations

Qs = qs*N.(persons)*CLF &
QL = qL*N.(persons)
 
qs qL Qstotal QLtotal
Location N. of persons CLF
BTU/hr BTU/hr BTU/hr BTU/hr
Production
room 565 1035 25 1 14125 25875
Office room 230 190 20 1 4600 3800
Conference
room 255 325 25 0.01 63.75 8125
Storage room 345 435 10 1 3450 4350
Utility room 345 435 10 1 3450 4350
Restroom 230 190 8 0.4 736 1520
Total 26424.8 48020

Table 2.17 shows the peoples’ sensible load and Latent load of each designated area. It’s
noticeable that Production room and storage room and utility room has the higher value of latent
load because of the amount of work they had in that area compared to the office room and
conference room where the employees are only working on paper works. The total sensible load
and latent load is 26.424.8 BTU/hr and 48,020 BTU/hr.

Summary of Heat Gain Calculations

The total thermal load of an exterior load and internal load were obtained by each table
shown above. The total thermal load is 173685.929 BTU/hr - in horsepower is 68.5. However,
the plant is not required to fully condition all designated room. Only room that are needed to be
air-conditioned is office room, conference room and utility room. The production room, storage
room and restroom will have a good ventilation since, it has a suspended ceiling of 2 meters, this
will help to ensure better air ventilation, quality and moisture; also, for comfortable working
place

43
Air Conditioning Layout

44
Figure 2.2 Airconditioning Layout

45
Figure 2.3 Airconditioning Layout Visible Dimension

46
 In figure 2.1 and 2.2 shows the aircon installed, mounted on the wall of the office room,
utility room and conference room. The rest of the room are not needed to be centralize but it’s
had a proper ventilation. Having a good circulation of air is vital for comfortable working and
keeps the moisture out. The split type aircon inverter will be installed in the room that have been
mentioned; having a power of 2.5 hp or 1,620 watts.

List of Equipment

Table 2.18 Split Type Inverter Aircon

Machine specifications
Brand: Samsung
Model: AR18TYHYEWKNTC
Airconditioned Rated Capacity (BTUs):
19000
Power Consumption: (W):1,720
Weight (Kg) Indoor unit: 7.73 kg

Split Type Air Conditioning unit Outside unit: 24.8 kg

Table 2.19 Shows the specification of the Split Type Inverter Aircon. The unit will be
used for air-conditioning the Office room, Conference room, and Utility room to reduce heat and
humidity, thus reducing the impact on our ability to perform and complete work task. The power
needed to air-condition all the room is 1,720 Watts.
Financial Expenses

Table 2.22 Financial expenses

Appliance Cost Qty. Total Cost

Split Type Air ₱ 30,995.00 4 ₱ 123,980.00
Conditioning
unit

Table 2.22 Shows the financial expenses for the split type air conditioning unit. In order
to control the finances and to show the exact amount of the expenses. The total cost for the 4
units is ₱123,980.00

47
CHAPTER III
POWER PLANT DESIGN

Definition

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. The diesel engine drives alternator which
converts mechanical energy into electrical energy. As the generation cost is considerable due to
high price of diesel and power stations that are only used to produce small power. The proposed
Design of Diesel Power Plant is to power the industrial design and will be constructed. This will
help to boost the production of the plant and have a stable energy needed to complete its
production.

Load Curve

LOAD CURVE
35
30
25
20
LOAD (KW)

15
10
5
0
. . . . . . . . . . . M
.M M M M M M M M M M M P.
A A. A. A. A. A. P. P. P. P. P.
0 0 00 00 00 00 :0
0
:0
0
:0
0
:0
0 00 00
1 :0 3 :0 5: 7: 9: 1: 1 3 5 7 9: 1 1:
1

TIME (HRS)

Figure 3.1 Power Plant Load Curve

Figure 3.1 shown above is the illustration of the variations in demand energy load over a
specific time. This curve will be an information to plan how much power will be needed to
generate at given time.

48
Power Plant Consumption

Table 3.1 Energy Generated

Energy Generated
Time Power Duration Energy Generated
(hr) (kW) (kWh)
1 8.73 1 AM – 2 AM 9.22
2 9.72 2 AM – 3 AM 10.92
3 12.13 3 AM – 4 AM 12.37
4 12.62 4 AM – 5 AM 14.56
5 16.5 5 AM – 6 AM 17.47
6 18.44 6 AM – 7 AM 19.65
7 20.87 7 AM – 8 AM 22.08
8 23.3 8 AM – 9 AM 23.78
9 23.78 9 AM – 10 AM 24.51
10 25.24 10 AM – 11 AM 25.97
11 26.7 11 AM – 12 PM 27.67
12 28.64 12 PM – 1 PM 29.12
13 29.61 1 PM – 2 PM 29.85
14 30.1 2 PM – 3 PM 30.22
15 30.34 3 PM – 4 PM 29.24
16 28.159 4 PM – 5 PM 26.64
17 25.24 5 PM – 6 PM 23.74
18 22.33 6 PM – 7 PM 22.81
19 23.3 7 PM – 8 PM 23.04
20 23.78 8 PM – 9 PM 22.08
21 20.39 9 PM – 10 PM 15.77
22 11.16 10 PM – 11 PM 10.43
23 9.71 11PM – 12 AM 8.49
24 7.28 12 AM –1AM 8.00
TOTAL 487.63

Sample Calculation at Time 1:00 AM

(8.73 kW + 9.72 kW )
Area= (1 hr−0 hr)
2
Area=9.22 kW −hr
EGEN =∑ 487.63 kW −hr

Suitable Generating Units to Supply the Load:

1. One (1) unit of 15 kW capacity diesel generator

49
 2. One (1) unit of 10 kW capacity diesel generator

3. One (1) unit of 5 kW capacity diesel generator

4. One (1) unit of 10 kW capacity diesel generator (for standby)

Load Factor Calculations:

Energy Generated
Average Load=
24 hours

487.63 kWhr
Average Load=
24 hours

Average Load=20.31 kW

Based on the given load requirements from Table 2.1, the maximum load can be obtained:

Maximum Load=30.34 kW

Average Load
Load Factor =
Maximum Load

20.31 kW
Load Factor=
30.34 kW

Load Factor =0.66

Operational Schedule of different Generating Units

Table 3.2 Generating Units Operational Schedule
Operational Schedule
Time Operation
Indefinite Unit 1 (6 kW) Operation
5:00 AM Start Unit 2 (6 kW)
9:00 AM Start Unit 3 (7 kW)
9:00 PM Stop Unit 2 (6 kW)
5:00 PM Stop Unit 3 (7 kW)

Table 3.3 Generating Units Operational Hours

Operational Hours
Generating Unit Duration/Day
Unit 1 24 hours
Unit 2 20 hours (5AM – 10PM)

50
 Unit 3 9 hours (9AM – 5PM)

Table 3.2 and 3.3 shown above is the working hours of diesel generator. Each unit are
assigned to a specific time to start. Unit 1 is indefinitely work as a base load, Unit 2 will start at 5
am which medium demand of energy and Unit 3 will start at 9am which is the high demand of
energy.

Figure 3.2 Operational Schedule – Unit 1 (Green), Unit 2 (Yellow) and Unit 3 (Red)

Figure 3.2 shown above the generating hours. The base load has a normal demand of
electricity and the medium peak increases its demand of electricity and lastly highest point on
that curve indicates the maximum demand of electricity.

Plant Capacity Calculations:

Plant Capacity=( 1 unit x 15 kW ) +(1 unit x 10 kW )+(1 unit x 7 kW )+(1 standby unit x 10 kW )

Plant Capacity=42 kW

Plant Capacity Factor Calculations:

Energy Generated
Plant Capacity Factor =
Plant Capacity x Operating Hours

487.63 kWhr
Plant Capacity Factor=
( 15 kw x 24 hrs ) + ( 10 kw x 20 hrs ) + ( 7 kw x 9 hrs )

51
Plant Capacity Factor=.78∨78 %

List of Equipment

Table 3.4 Equipment Specification

Specification
Brand Hi-earns or OEM
Capacity 15 kW
Model GF2-12KVA
Weight 600kg
Dimensions
1650x850x1002mm
(LxWxH)
Quantity 1
Brand infanite
Capacity 10 kW
Model IF10T
Weight 280 kg
Dimensions
1275x740x790mm
(LxWxH)
Quantity 1
Brand Daiden
Capacity 7 kW
Model 188FBE
Weight 171 kg
Dimensions
950x510x680mm
(LxWxH)
Quantity 1

Machine Foundation Design

Unit (1) 15 kW Diesel Generator, Unit (2) 10 kW Diesel Generator and Unit (3) 7 kW Diesel
Generator
Length of the Foundation Calculations:
L=L B +2 c
Where: L = length of the foundation, LB = length of the bedplate, c = clearance

52
 The clearance of the distance of the edge of the foundation from the bedplate must be 120
mm to 300 mm to secure the belts imbedded within the foundation.

L 1¿ 1.65 m+ 2 ( 0.2 m ) L 2¿ 1.27 m+2 ( 0.2 m ) L 3¿ .95 m+ 2 ( 0.2 m )

L 1¿ 2.05 m (Unit 1) L 2¿ 1.67 m (Unit 2) L 3¿ 1.35 m (Unit 3)

Upper Width of the Foundation Calculations:

a=w+ 2 c
Where: a = upper width of the foundation, w = width of the bedplate, c = clearance
The clearance of the distance of the edge of the foundation from the bedplate must be 120
mm to 300 mm to secure the belts imbedded within the foundation.

a1 ¿ .85 m+ 2(0.2 m) a2 ¿ .74 m+2(0.2 m) a3 ¿ .51 m+2(0.2m)

a 1 ¿ 1.15 m (Unit 1) a 2 ¿ 1.14 m (Unit 2) a 3 ¿ .91 m (Unit 3)

Weight of the Foundation Calculations:

W f =5 (W m )

Where: Wf = weight of the foundation, Wm = weight of the machine

W f 1=5(600 kg) W f 2=5(280 kg) W f 3=5(165 kg)

W f 1=3,000 kg (Unit 1) W f 2=1,400 kg (Unit 2) W f 3=855 kg (Unit 3)

Volume of the Foundation Calculations:

Wf
Vf=
ρ
Where: Vf = volume of the foundation, Wf = weight of the foundation, ρ = density of
building materials
The building material that will be used for the machine foundation is reinforced concrete.
From Table 6.1 (Approximate Weight of Building Materials) below, we can obtain its
approximate density which is: ρ=2,802 kg/m 3
Table 3.5 Approximate Weight of Building Materials

53
 Approximate Weights of Building Materials
Building Material kg/m³
Plain concrete, stone 2323 - 2403
Plain concrete, slag 2082
Plain concrete, cinder 1602
Reinforced concrete, stone 2403
Brick masonry, pressed 2243
Brick masonry, common 1922
Ashlar masonry, granite 2643
Ashlar masony, limestone 2563
Ashlar masonry, sandstone 2243
Sand and gravel 1602 - 1762
Cinder fill 641 - 721

3000 kg 1400 kg 825 kg

V f 1= 3
V f 2= 3
V f 3=
2,802 kg /m 2,802 kg /m 2,802 kg/m 3
V f 1=1.07 m3 (Unit 1) V f 2=.67 m3 (Unit 1) V f 3=.29 m3 (Unit 1)
Lower Width of the Foundation Calculations:

S b W m +W f
=
N bL

N (W m +W f )
b=
Sb L
Where: b = lower width of the foundation, Sb = soil bearing capacity, N = factor of safety,
Wm = weight of the machine, Wf = weight of the foundation, L = length of the foundation
The bed soil is found to be compact clay soil. From Table 6.2 (Safe Bearing Power of
Soils) below, the safe bearing power of a compact clay soil is given as follows:
Sb =50t /m ²

Table 3.6 Safe Bearing Power of Soils

54
 Safe Bearing Power of Soils
Soil Tonnes/m²
Native rock 1950 up
Ashlar masonry 245 - 290
Best brick masonry 145 - 195
Common brick masonry 50 - 98
Clay, compact 50 - 78
Clay, soft 9.5 - 19.5
Gravel and sand 78 - 98
Sand 19.5 - 58.5
Quicksand, loam, etc. 5 - 9.5

However, since this is a machine foundation, the safe bearing power of soil will be
halved, given an allowable unit of soil stress as follows:
Sb =25,000 kg/m ²
Note that if b < a, then let b = a, which means that the foundation is a rectangular cross
section. Also, the safe bearing capacity is computed using a factor of safety of 5.

5 ( 600 kg+3000 kg )
b 1=
( 25,000 kg / m2 ) (2.05 m )
5 ( 280 kg+1400 kg )
b 2=
( 25,000 kg / m2 ) (1.67 m)

5 (171 kg+ 855 kg)

b 3=
(25,000 kg /m ²)(1.35 m)

b1¿ 0.35m (unit 1) b2¿ .20 m(Unit 2) b3¿ 0.15m (Unit 3)

Since b1,2,3 < a, therefore, make b equal to a making the foundation a rectangular cross section.
b 1¿ 0.35m b 2¿ .20 m b 3¿ 0.15m

Depth of the Foundation Calculations:

Vf= ( a+b2 ) hL
2Vf
h=
( a+b ) L

55
 Where: h = depth of the foundation, Vf = volume of the foundation, a = upper width of
the foundation, b = lower width of the foundation, L = length of the foundation

2(1.07 m3 ) 2(.67) 2(.29 m3)

H1¿ H2¿ H3¿
(1.15 m+1.15 m ) (2.05 m) (1.04 m+1.04 m )(1.67 m) (.91 m+.91 m) (1.35 m)
h1¿ 0.45 m (Unit 1) h1¿ 0.38 m (Unit 2) h1¿ 0.23 m (Unit 3)

Safe Bearing Stress Calculations

Using the common flexure formula:
Mx
fb=
I
Wm Width m 600 kg .85 m 280 kg .74 m
M 1= ( )(
3 2 )(
=
3 2)( M 2= ) 3 ( 2 )( )
M 3= ( 1713kg )( .51m
2 )
M 1=85 kgm (Unit 1)M 3=34.53 kgm (Unit 2)M 3=14.3 kgm (Unit 3)
Length m 1.65 m Lengthm 1.27 m Length m .95 m
x 1= = x 2= = x 3= =
2 2 2 2 2 2
x 1=0.8 m (Unit 1)x 2=0.63 m (Unit 2)x 3=0.47 m (Unit 3)

b Length 3m
I 1= =( 1.65 m ) ¿ ¿
12

I 3=0.80 m4 (Unit 1) I 2=0.177 m 4 (Unit 2) I 3=0.061 m 4 (Unit 3)

(92.08 kgm)(.9 m) (34.53 kgm)(.63 m) (15.3 kgm)(.47 m)

fb 1= 4
fb2= 4
fb 3=
.528 m 0.177 m 0.061m4

kg kg kg
fb 1=156.9 (Unit 1) fb 2=122.90 2 (Unit 2)
fb 3=117.88 2 (Unit 3)
m2 m m
Substituting the value obtained in the following equation:

56
S b W m +W f
= +f b
N bL
kg
50,000
m2 650 kg +3250 kg kg
Unit 1= = +156.9 2
5 ( 1.15 m )( 2.2 m ) m
kg
50,000
m2 280 kg +1400 kg kg
Unit 2= = +122.90 2
5 ( 1.15 m )( 1.67 m ) m
kg
50,000
m2 165 kg+ 855 kg kg
Unit 3= = +117.8 2
5 (1.15 m)(1.35 m) m
kg kg
10,000 2
> 1,698.40 2 (Unit 1)
m m
kg kg
10,000 2
> 997.67 2 (Unit 2)
m m
kg kg
10,000 2
> 774.48 2 (Unit 3)
m m

Therefore, the extreme soil stress is less than the allowable soil stress ensuring a safe
operation and considered by builders to be adequate for building on which means they are better
than clay but worse than sand.
Concrete Mixture Calculations:

Table 3.7 Data on Concrete Mixes to Yield 1 m3 Concrete

57
 Data on Concrete Mixes to Yield 1 m³ Concrete
Cement, Safe Comp.
Mixture Sand, m³ Stone, m³ Application Weight, t/m³
sacks Stress, t/m²
Roofs, sills,
1:2:3 9.2 0.51 0.77 tanks, 2.66 382.78
tunnels
R. C. floors,
1:2:4 7.8 0.44 0.88 beams, 2.66 328.1
columns
Building
1:2.5:4 7.3 0.52 0.83 2.66 273.42
walls
Foundations
1:3:5 6.2 0.52 0.86 2.66 218.73
and footings
Cinders,
1:2:4 8.6 0.49 R. C. floors 1.99 153.11
cu yd 0.98
Slag,
1:2:4 8.6 0.49 R. C. floors 2.13 153.11
cu yd 0.98

Based on Table 6.3 (Data on Concrete Mixes to Yield 1 m 3 Concrete) above, using the

mixture 1:2:4, having 1 part cement, 2 parts sand and 4 parts stone, to produce 1 m3 of concrete,

the following are needed: 7.8 sacks of cement, 0.44 m3 of sand and 0.88 m3 of stone.

V f =1.5 m3

7.8 sacks
Cement Sacks=V f
( 1 m3 )
Cement Sacks=1.07 m 3
( 7.81sacks
m ) 3
Cement Sacks=8.3∨8 sacks(Unit 1)

Cement Sacks=.67 m3
( 7.81sacks
m ) 3
Cement Sacks=5.2∨5 sacks (Unit 2)

7.8 sacks
Cement Sacks=.29 m3
( 1 m3 )
Cement Sacks=2.26 sacks∨2 sacks (Unit 3)

0.44 m3
Sand=V f ( 1m 3 )
0.44 m 3 3 3
3 0.44 m 3 0.44 m
Sand 1.07 m 3 ( 1 m3 )
Sand .67 m
1 m3 (
Sand )
.29 m
1 m3 ( )
Sand=.47 m 3 (Unit 1) Sand=.29 m3 (Unit 2) Sand=.12 m3 (Unit 3)

58
 0.88 m3
Stone=V f ( 1m 3 )
0.88 m3 3 3
3 0.88 m 3 0.88 m
Stone=1.07 m3 ( 1m3 )Stone=.67 m ( 1m 3 ) Stone=.29 m ( 1 m3 )
Stone=0.94 m3 Stone=.58 m3 Stone=.25 m3

Weight of Steel Bar Reinforcements Calculations:

W SB=0.01(W f )
Where: WSB = weight of the steel bar, Wf = weight of the foundation

W SB 1=0.01(3000 kg)W SB 2=0.01(1400 kg)W SB 3=0.01(855 kg)

W SB=30 kg (Unit 1)W SB=14 kg (Unit 2)W SB=8.55 kg (Unit 3)

Machine Foundation Layout

Figure 3.3 Infanite Diesel Generator 15kW (Unit 1) Front Elevation View with Machine
Foundation

59
Figure 3.4 Infanite Diesel Generator 15kW (Unit 1) Side Elevation View with Machine
Foundation

Figure 3.5 Infanite Diesel Generator 10kW (Unit 1) Front Elevation View with Machine
Foundation

60
Figure 3.6 Infanite Diesel Generator 10kW (Unit 1) Side Elevation View with Machine
Foundation

Figure 3.7 Daiden Diesel Generator 7kW (Unit 1) Front Elevation View with Machine
Foundation

61
 Figure 3.8 Daiden Diesel Generator 7kW (Unit 1) Side Elevation View with Machine
Foundation

Figure 3.3-3.8 shown above the 3D layout. The size and depth are based from the
machine’s dimensions. Having a 3D layout of machine foundation will help to understand easily.

CHIMNEY DESIGN

The light hot flue gas is confined by the chimney column and the draft produced is

proportional to the height and difference in density of air and gas. Therefore, the draft of a

chimney is expressed by:

D=( Height ) x( Difference ∈density of flue gas∧air)

When this equation is written for height = 30 m, incorporating certain factors needed to convert

draft to inches of water, and allowing for cooling and friction in the chimney, it has the form of:

V5
D30=K ( ρa −ρg ) −0.5413 f ρ g
√ Qg

62
Where D = available draft per 30 m of chimney (cm H 2O), K = constant for steel or brick

chimneys (2.7 for brick and 2.4 for steel), ρ a = density of air, ρg = density of flue gas, V = gas

velocity in the chimney, Qg = gas flow, f = friction coefficient.

The actual height of the chimney is obtained by:

Required Chimney Draft

H= x 30
D 30

Where the required chimney draft is obtained by:

Required Chimney Draft=Σ ( Friction Losses )+ Velocity Head−Effective Draft

Where velocity head loss of gas discharged from the chimney is given by:

D 1=0.004 V 2 ρ g

The density of the flue gas can be determined using Table (Variation of air and flue gas densities

with temperatures), where in order to be conservative, chimney heights are commonly designed

to give the maximum required draft with 15.6˚ C ambient air temperature. In southern climates

where loads can occur in hot weather, gas temperatures are around 232˚ C or less. Flue gas

density is determined and is approximately equal to:

ρ g=0.69 kg /m3

Air Density Calculations:

P
ρa =
RaT a

Where: ρa = density of air, P = barometric pressure (assumed at sea level), R a = gas

constant of air, Ta = absolute temperature of air.

101.325 kPa
ρa =
kJ
( 0.287
kg . K)( 15.6+273 ) K

63
ρa =1.2233 kg/m 3

Chimney Height Calculations

The chimney is to be constructed of brick. The Q g (volume flow rate of exhaust gas) Unit
(1) 15kW is 8.88 m3 / min., Unit (2) 10kW is 5.92 m3 / min. and Unit (3) 7kW is 2.96 m3 / min
(obtained from table 5.1, 5,2 and 5.3) and Ds (static draft) = 2.007 cm H2O. The friction
coefficient that will be used is 0.04. Solving for the required draft:

Unit 1 (15kW) = 8.88 m3/ min = 0.146 m3/ sec

Unit 2 (10kW) = 5.92 m3/ min = 0.098 m3/ sec

Unit 3 (7kW) = 2.96 m3/ min = 0.049 m3/ sec

kg 2
(
Required Chimney Draft=2.007 cm H 2 O+ ( 0.004 ) 0.69
m3 )
V

Required Chimney Draft=2.007 cm H 2 O+ 0.00276V 2 cm H 2 O

kg kg kg V5
(
D 30=2.4 1.2233
m
3
−0.69
m
3 )
−( 0.5413)(0.04 )(0.69
m
3
)
√ 3
0.146 m /sec

D30=1.27992−0.03909 √ V 5 cm H 2 O(Unit 1)

kg kg kg V5
( m m )
D 30=2.4 1.2233 3 −0.69 3 −(0.5413)(0.04 )(0.69 3 )
m
3
√
0.098 m /sec

D30=1.27992−0.0477 √V 5 cm H 2 O(Unit 2)
kg kg kg V5
(
D 30=2.4 1.2233
m
3
−0.69
m
3 )
−( 0.5413)(0.04 )(0.69
m
3
)
√ 3
0.049 m /sec

D30=1.27992−0.0674 √V 5 cm H 2 O(Unit 3)

2.007 cm H 2 O+0.00276 V 2
H= x 30(Unit 1)
1.27992−0.0390 √ V 5 cm H 2 O

2.007 cm H 2 O+0.00276 V 2
H= x 30(Unit 2)
1.27992−0.0477 √V 5 cm H 2 O

64
 2.007 cm H 2 O+0.00276 V 2
H= x 30 (Unit 3)
1.27992−0.0674 √ V 5 cm H 2 O

4 Qg Qg
Inside Chimney Diameter=
√ πV
=1.13
V √
0.146 m3 /sec
Inside Chimney Diameter=1.13
√ V
0.431
Inside Chimney Diameter= m(Unit 1)
(√ V )

0.098 m3 / sec
Inside Chimney Diameter=1.13
√ V
0.353
Inside Chimney Diameter= m( Unit 2)
( √V )

0.049 m3 / sec
Inside Chimney Diameter=1.13
√ V
0.250
Inside Chimney Diameter= m(Unit 3)
( √V )
The equations above give height and diameter functions of chimney gas velocity. By assuming
various velocities, the corresponding height and diameter are obtained.

0.431
Inside Chimney Diameter= m(Unit 1)
( √ 1.2 )

Inside Chimney Diameter=0.39 m (unit 1)

Height (1 st cond .)x Diameter=19.4 m2 unit (1)

0.353
Inside Chimney Diameter= m(Unit 2)
( √ 1.2 )

Inside Chimney Diameter=0.32m (unit 2)

Height (1 st cond .) x Diameter=16.02 m2 unit (2)

0.250
Inside Chimney Diameter= m(Unit 3)
( √ 1.2 )

Inside Chimney Diameter=0.22m (unit 3)

65
Height (3 rd condi.) x Diameter=8.3 m2 unit (3)

1st Condition: V = 1.2 m/s

2.007 cm H 2 O+( 0.00276)(1.2)2

H= 5
x 30
1.27992−0.0390 √(1.2)

H=49.515 m (Unit 1)

2.007 cm H 2 O+( 0.00276)(1.2)2

H= 5
x 30
1.27992−0.0477 √(1.2)

H=50.07 m (Unit 2)

2.007 cm H 2 O+( 0.00276)(1.2)2

H= 5
x 30
1.27992−0.0674 √( 1.2)

H=51.40 m (Unit 3)

2nd Condition: V = 3.2 m/s

2.007 cm H 2 O+(0.00276)( 3.2)2

H= 5
x 30
1.27992−0.0390 √ (3.2)

H=107.96 m (unit 1)

2.007 cm H 2 O+(0.00276)( 3.2)2

H= 5
x 30
1.27992−0.0477 √(3.2)

H=150.33 m (unit 2)

2.007 cm H 2 O+(0.00276)( 3.2)2

H= 5
x 30
1.27992−0.0674 √(3.2)

H=1347.98 m (unit 3)

3rd Condition: V = 4.2 m/s

2.007 cm H 2 O+(0.00276)( 4.2)2

H= 5
x 30
1.27992−0.0390 √ (4.2)

66
H=155.97 m(Unit 1)

2.007 cm H 2 O+(0.00276)( 4.2)2

H= 5
x 30
1.27992−0.0477 √(4.2)

H=138.74 m(Unit 2)

2.007 cm H 2 O+(0.00276)( 4.2)2

H= x 30
1.27992−0.0674 √(4.2)5

H=38.17 m(Unit 3)

Therefore, for Units 1 (15kW). 1st condition is used with the gas velocity of 1.2 m/s with
H = 49.515 m and D = 0.39m. Unit 2 (10kW). 1st condition was also used with the gas velocity
of 1.2 m/s with H= 50.07 m and D = 0.32m. lastly for Unit 3 (7kW). 3rd condition was used with
the gas velocity of 4.2 m/s with H = 38.17m and D = 0.22m. since it yields the least value when
the height of the chimney is multiplied by its diameter.

Unit 2 (15kW) Chimney Design

Figure 3.9 Chimney Height and Inside Diameter

Unit 2 (10kW) Chimney Design

67
 Figure 3.10 Chimney Height and Inside Diameter

Unit 3 (7kW) Chimney Design

68
 Figure 3.11 Chimney Height and Inside Diameter

Figure 3.9-3.11 shows the 2D layout of each Unit has a different diameter and height
because it’s based from the power output of the diesel generator. The designing of chimney is
important to have a proper vent and combustion from the power plant.

Cooling Tower Design

The following temperatures are to be followed in the calculations necessary to determine
the mass flow rates of cooling water. For the temperatures from the engine to the heat exchanger,
where: 𝑡i (inlet water temperature) = 26.7 °C to 32.2 °C and 𝑡o (outlet water temperature) = 43.3
°C to 54.4 °C. For the temperature from the heat exchanger to the cooling tower, where: ta (inlet
water temperature) = 50 ℃ and tb (outlet water temperature) = 28 ℃. (Powerplant Engineering,
Morse)

Mass Flow Rate of Cooling Water in the Engine Jacket Calculations

bhp
w e =674.58 Equation 13
t o−t i

Where: we = engine cooling water (l per hour)

bhp = rated brake horsepower

ti = inlet water temperature

to = outlet water temperature

69
Unit 1 (15 kW)

Solving for the rated brake horsepower of a 15kW diesel engine and using the maximum
temperature range:

1 bhp
bhp=15 KW ( 0.746 Kw )
=31.51 bhp(Unit 1)

31.51
w e =674.58 ( 54.4−32.2 )
L 1hr 1 m3
w e =956.65 (
hr 60 min )( 1000 L )( 1000
1m )
3
kg

kg
w e =15.94 ( Unit 1)
min
Unit 2 (10 kW)
Solving for the rated brake horsepower of a 10kW diesel engine and using the maximum
temperature range:

1 bhp
bhp=10 KW ( 0.746 Kw )
=13.40 bhp(Unit 2)

13.40
w e =674.58 ( 54.4−32.2 )
L 1 hr 1 m3
w e =407.17 (
hr 60 min )( 1000 L )( 1000
3
kg
1m )

kg
w e =6.78 (Unit 2)
min
Unit 3 (7kW)
Solving for the rated brake horsepower of a 7 KW diesel engine and using the maximum
temperature range:

1 bhp
bhp=7 KW ( 0.746 Kw )
=6.70 bhp( Unit 3)

6.70
w e =674.58 ( 54.4−32.2 )
70
 L 1hr 1m 3
w e =203.58 (
hr 60 min )( 1000 L )( 1000
1m )
3
kg

kg
w e =3.39 (Unit 3)
min
Mass Flow Rate of Cooling Water in the Cooling Tower Calculations

The amount of heat released by the water is equal to the heat absorbed by the air, thus,

the corresponding heat balance is:

w t ( cpw ) ( t a−t b ) =w e ( cpw ) ( t o−t i )

we ( t o−t i )
w t=
( t a−t b )
Where: wt = tower cooling water, we = engine cooling water, ti = engine inlet water

temperature, to = engine outlet water temperature, ta = cooling tower inlet water temperature, tb =

cooling tower outlet water temperature.

15.94 ( 54.4−32.2 )
w t=
( 50−28 )
kg
w t=7.03 (Unit 1)
min

6.78 ( 54.4−32.2 )
w t=
( 50−28 )
kg
w t=2.99 (Unit 2)
min

3.39 ( 54.4−32.2 )
w t=
( 50−28 )
kg
w t=1.49 (Unit 3)
min
Mass Flowrate of Dry Air Calculations

Air Entering:

71
Tdb1 = 25 °C

RH1 = 60%

W1 = 0.012 kgmoisture / kgair

h1 = 55 kJ/kg

Air Leaving:

Tdb2 = 33 °C

RH2 = 85%

W2 = 0.0275 kgmoisture / kgair

h2 = 104 kJ/kg

Using the steam table, the dry saturated enthalpies of the cooling tower inlet temperature,

cooling tower outlet temperature and tap water values are obtained, respectively:

At ta = 50 °C, hfa = 209.33 kJ/kg

At tb = 28 °C, hfb = 117.43 kJ/kg

At tw = 15 °C, hf’ = 62.99 kJ/kg

An equation of mass balance for the cooling tower is:

1 kg air +SH 1 + ww +∆ w=1 kg air + SH 2+ ww

The corresponding heat balance of the equation above is:

h1 + ww hfa +∆ w hf '=h2 +w w hfb

Calculating for the water circulated per kilogram of air using the heat balance equation:

kJ kJ kJ kJ kJ
55
kg (
+w w 209.33
kg ) (
+ ( 0.0275−0.012 ) 62.99
kg )
=104 + ww (117.43 )
kg kg

w w =104 kJ /kg−55 kJ /kg−( 0.0275−0.012 ) kgmoisture / kgair ¿ ¿ ¿¿

kg water
w w =0.5226
kg air

72
Calculating for the mass flow rate of dry air:

kg
7.03
min
w dry air =
kg
0.5226 water
kg air

w dry air =13.45 kg /min(Unit 1)

kg
2.99
min
w dry air =
kg
0.5226 water
kg air

w dry air =5.72 kg /min(Unit 2)

kg
1.49
min
w dry air =
kg
0.5226 water
kg air

w dry air =2.85 kg /min(Unit 3)

Volume of Make-Up Water Tank Calculations

Calculating for the flow rate of make-up water:

ṁmw =(w dry air )( ∆ w)
kg air kg moisture
(
ṁ mw = 13.45
min )
( 0.0275−0.012 ) (
kg air )
ṁ mw =0.20 kg /min (Unit 1)
kg air kg moisture
(
ṁ mw = 5.72
min )( 0.0275−0.012 ) (kgair )
ṁmw =0.088 kg /min (Unit 2)
kg air kg moisture
(
ṁ mw = 2.85
min )( 0.0275−0.012 ) (kg air )
ṁ mw =0.044 kg/min (Unit 3)

73
 Obtained from the steam table, the specific volume of water at 15 °C is v f = 1.0009 x 10-3

m3/kg. Calculating the volume of the make-up water tank:

kg 60 min 24 hrs 1.0009 x 10−3 m3

(
V tank = 0.20
min )( hr )( day )( kg )
V tank =0.28 m3 (Unit 1)

kg 60 min 24 hrs 1.0009 x 10−3 m3

(
V tank = 0.088
min )( hr )( day )( kg )
V tank =0.126 m3 (Unit 2)

kg 60 min 24 hrs 1.0009 x 10−3 m 3

(
V tank = 0.044
min )( hr )( day )( kg )
V tank =0.063 m3 (Unit 3)

Minimum Power Requirement to Maintain the Flow of Water Calculations

Calculating for the capacity of the pump needed, where: Q = pump capacity:

kg 1.0009 x 10−3 m3
(
Q̇=( ṁmw ) ( v f ) = 0.20
min )( kg )( 60hrmin )
m3
Q̇=0.012 (Unit 1)
hr

kg 1.0009 x 10−3 m3
(
Q̇=( ṁ mw ) ( v f ) = 0.088
min )( kg )( 60hrmin )
m3
Q̇=0.004 .80 ( Unit 2)
hr

kg 1.0009 x 10−3 m3
(
Q̇=( ṁmw ) ( v f ) = 0.044
min )( kg )( 60hrmin )
m3
Q̇=0.00264 (Unit 3)
hr

74
 Calculating for the minimum brake power required for the pump to transport for Unit 1,

Unit 2 and Unit 3 of make-up water, assuming that the head is 20 m and the efficiency of the

pump is 80%, where: H = head, ƞp = pump efficiency and 𝛾 = specific weight.

γ Q̇ H
P=
ƞp

kN 0.012 m3 1 hr

P=
( 9.81 3
m )( hr )(
3600 sec
( 20 m ) )
0.8

P=0.0008175 kW (Unit 1)

kN 0.004 m3 1 hr

P=
( 9.81
m3 )( hr )(
3600 sec
( 20 m ) )
0.8

P=0.000275 kW (Unit 2)

kN 0.0026 m3 1 hr

P=
( 9.81
m3 )( hr )(
3600 sec
( 20 m) )
0.8

P=0.00771kW (Unit 3)

Minimum Power Capacity Required of the Induce Draft Fan Calculations

Obtained from the psychrometric chart, the specific volume of the air can be obtained.

Calculating for the volume flow rate of the air entering the cooling tower:

At Tdb1 = 25 °C and RH = 60%, v = 0.861 m3/kgair

kgair 60 min 0.861 m3

(
V̇ = ( w dry air ) ( v )= 0.20
min )( hr )( kgair )
m3
V̇ =10.33 (Unit 1)
hr

kgair 60 min 0.861 m3

(
V̇ = ( w dry air ) ( v )= 0.088
min )( hr )( kgair )
75
 m3
V̇ =4.54 (Unit 2)
hr

kgair 60 min 0.861m3

(
V̇ = ( w dry air ) ( v )= 0.044
min )( hr )( kg air )
m3
V̇ =2.2 (Unit 3)
hr

With an air flow rate can be shown above, assume that the head of the fan is 5 m and

efficiency of 80%, where specific weight of air is 11.8 N/m3, calculating for the required capacity

of the fan that will supply air to the cooling tower where: H = head, ƞ f = fan efficiency, 𝛾 =

specific weight of air at saturated atmospheric pressure:

γ Q̇ H
P=
ƞf

kN 10.33 m3

P=
( 0.0118
m3 )( hr )( 36001 hrsec ) ( 5 m )
0.8

P=0.000169 kW (Unit 1)

kN 4.54 m3

P=
( 0.0118
m3 )( hr )( 36001 hrsec ) ( 5 m)
0.8

P=0.0000744 kW (Unit 2)

kN 2.2 m3 1 hr

P=
( 0.0118
m3 )( hr )(
3600 sec
( 5 m) )
0.8

P=0.000036 kW (Unit 3)

Area and Height of Cooling Tower Calculations

76
 Obtained from KENT’s ME Handbook, at t a = 50 °C and tb = 28 °C, water concentration

is 2.3 gpm/ft2 and the cooling tower height is 22 m. Calculating the required area of the cooling

tower:

wt
A=
2.3 gpm /ft 2

kg 264.172 gal 0.001012 m3

A=
( 0.20
min )( m3 kg)( )
2
2.3 gpm/ft

1 m2
A=( 0.0232 ft 2 ) ( 10.7639 ft 2 )
A=0.002.219 m 2 (Unit 1) H=22 m

Note: this formula will also be applied on Unit 2 and Unit 3.

Fuel Tank, Storage tank and Transfer Pump

Fuel Tank or Day Tank Calculations

For Unit 1 (15kW) from the Hi-earns or OEM Diesel Power Generator Specification

Sheet, the fuel installation supply must accommodate fuel consumption rate at 100% load of the

prime power, this would be applied to all generator sets, the point wherein it uses the most fuel,

is at 12.2 liters per hour. For Units 2 (10kW) and Unit 3 (7kW) from Infinite Diesel Power

Generator Specification Sheet and Daiden Diesel Power Generator Specification Sheet at

Appendix, it will use 5 liters per hour. Calculating the fuel consumption per day:

L L L 24 hrs 1 m3
Fuel Consumption per day= 12.2 ( hr
+ 12.2 + 12.2
hr hr )( day )( 1000 L )
Fuel Consumption per day=0.87 m 3 (Unit 1)

77
 L L L 24 hrs 1 m3
Fuel Consumption per day= 8.1 ( hr
+8.1 +8.1
hr hr )( day )( 1000 L )
Fuel Consumption per day=.58 m3 (Unit 2)

L L L 24 hrs 1 m3
Fuel Consumption per day= 4.3 ( hr
+ 4.3 +4.3
hr hr )( day )( 1000 L )
Fuel Consumption per day=.30 m3 (Unit 3)

Fuel delivery is every 15 days however the calculations should have at least a 4-day
allowance in case of delays in the delivery. Calculating the volume of fuel per delivery:
0.87 m 3
Volume of Fuel per delivery= (19 days ) ( day )
Volume of Fuel per delivery=16.53m3 (Unit 1)

0.58 m3
Volume of Fuel per delivery= (19 days ) ( day )
Volume of Fuel per delivery=11.2 m3 (Unit 2)

0.30 m 3
Volume of Fuel per delivery= (19 days ) ( day )
Volume of Fuel per delivery=5.7 m3 (Unit 3)
Calculating the volume of the day tank of the 15 kW Infanite Diesel Generator with an air
allowance of 10%:
l 24 hrs 1 m3
(
V f = 12.2
hr )( day )( 1000 l )
V f =0.29 m3
V tank =V f +0.10 V f

V tank =0.29 m3 +(0.10)(0.29 m 3)

V tank =0.31 m3

Calculating the volume of the day tank of the 10 kW Infanite Diesel Generator with an air

allowance of 10%:

78
 l 24 hrs 1m 3
(
V f = 8.1
hr )( )(
day 1000 l )
V f =0.19 m 3

V tank =V f +0.10 V f

V tank =0.19 m3 +(0.10)(0.19 m 3)

V tank =0.20 m3

Calculating the volume of the day tank of the 7 kW Daiden Diesel Generator with an air

allowance of 10%:

l 24 hrs 1 m3
(
V f = 4.3
hr )( day )( 1000 l )
V f =0.10 m 3

V tank =V f +0.10 V f

V tank =0.10 m3 +(0.10)(0.10 m 3)

V tank =0.11m 3

Calculating the dimensions of the cylindrical day tank of a Infanite Diesel Generator

15kW with a height diameter ratio of 1.5:

π D2
V tank = H
4

H=1.5 D

4 V tank
D=
√
3

π 1.5

4 (0.29 m3)
D=
√
3

π 1.5

D=0.62m

H=0.94 m

79
 Calculating the dimensions of the cylindrical day tank of a Infanite Diesel Generator

10kW with a height diameter ratio of 1.5:

π D2
V tank = H
4

H=1.5 D

4 V tank
D=
√
3

π 1.5

4 (0.19 m3)
D=
√
3

π 1.5

D=0.54 m

H=0.81m

Calculating the dimensions of the cylindrical day tank of a Daiden Diesel Generator 7kW

with a height diameter ratio of 1.5:

π D2
V tank = H
4

H=1.5 D

4 V tank
D=
√
3

π 1.5

4 (0.10 m3)
D=
√
3

π 1.5

D=0.43 m

H=0.65 m

Storage Tank of unit 1 (15kW)

80
 Figure 3.12 Storage tank Dimension

Storage Tank of unit 2 (10kW)

Figure 3.13 Storage tank dimensions

81
Storage Tank of unit 3 (7kW)

Figure 3.14 Storage tank dimensions

Figure 3.12-3.14 shown above the tank design and the actual dimension based from each unit of
Diesel Generator.

82
Transfer Pump Calculations

Calculating for the amount of fuel to be transferred per second:

l l l
(
Q̇= 12.2
hr
+12.2 +12.2
hr hr )( 36001hrsec )
l
Q̇=0.010166 (Unit 1)
sec

l l l
(
Q̇= 8.1
hr
+8.1 + 8.1
hr hr )( 36001 hrsec )
l
Q̇=0.00675 (Unit 2)
sec

l l l
(
Q̇= 4.3
hr
+4.3 + 4.3
hr hr )( 36001hrsec )
l
Q̇=0.003583 (Unit 3)
sec

Using a simplified Bernoulli’s Equation:

h p =z 1−z 2=8 m

Calculating for the minimum brake power required for the fuel transfer pump to transport

diesel fuel with a density of 0.832 kg/l, assuming that the head is 8 m where: h p = head, ρ =

density, Q = fuel transferred per second, g = acceleration due to gravity.

P=h p ρ Q̇ g=( 8 m) ( 0.832l kg )(0.010166 secl )( 9.81s m )

2

P=0.66W (Unit 1)

P=h p ρ Q̇ g=( 8 m) ( 0.832l kg )(0 .00675 secl )( 9.81s m )

2

P=0.44 W (Unit 2)

P=h p ρ Q̇ g=( 8 m) ( 0.832l kg )(0.003583 secl )( 9.81s m )

2

83
P=0.23W (Unit 3)

84
Power Station Layout

Figure 3.15 Power Plant Layout

85
Figure 3.16 Power Plant Layout with Dimensions

86
 Figure 3.15 & 3.16 shown above is the Power Plant Layout that will provide consistent
and reliable energy throughout the year to The Pencil Lead Industrial Plant. The plant has a
different Department room, each department has different task in order to have better maneuver
of the plant. Having a reliable energy is important when it comes to industrial. Industrial plant
has higher electricity demand due to machines.

87
CHAPTER 4

ECONOMIC ANALYSIS

Total Cost of Equipment

Table 4.1 Cost of Equipment

Total Cost of Equipment PRICE

Industrial Mixer ₱510,000

Horizontal hydraulic press machine ₱436,050

Pencil Lead Cutting Machine ₱255,000

High quality Curing Machine

₱1,122,000
Automatic Pencil lead Packing Machine
₱1,785,000
Conveyor belt pencil lead trasporter 204,000
TOTAL ₱4,307,000

Table 4.1 shows the price of each equipment used in manufacturing Pencil lead. The cost
of these machines is based on the prices prevailing at the time of proposed project preparation.

Operating Cost

Table 4.2 Cost Operation

Cost Operation per Annum

  PRICE
Depreciation on Machinery @ 10%
₱500,300.00
Depreciation on Office Equipment and Furnitures @
20% ₱850,000.00
Working Capital ₱10,500,000.00
Interest on Total Capital Investment @ 12%
₱1,250,600.00
TOTAL ₱13,100,300.00
Table 4.2 shows the operating cost of the project, the depreciation on every object used in
building and completing the industrial plant will be calculated. The working capital is the

88
salaries and wages of the employees working. 1% each month is the interest for the total capital
investment of the industrial plant.

Payback Period

Table 4.3 Turnover

Turnover per annum Quantity (T) Unit Price Total

₱127,928,072.2
Pencil Lead
1747.22 6 ₱127,928.072.26

In Table 4.3, the sales of the pencil lead will be ₱127,928.072.26 per year. This data will
be used in calculating the net profit of the company per annum. The net profit of the company
will reveal the remaining profit after all costs of production, administration and financing. This
will measure the overall results of the company, especially when combined with an
evaluation of how well it is using its working capital . 

Net Profit (per annum)

Net Profit=Turnover−Cost of Operation

₱127,928,072.26 - ₱13,100,300.00

₱114,827772.3

Net Profit Ratio

Net Profit
¿ x 100 %
Turnover

₱ 114,827,772.3
¿ x 100
₱ 127,928,072.26

¿ 89 %

The net profit ratio of the company is 89%. The rate of return is calculated by the net
profit over the total capital investment of the plant which is in the list of expenses.

Rate of Return

89
 Net Profit
¿ x 100 %
Total Capital Investment

¿ 23.29 %

In a year, the percentage of the rate of return in investing a plastic cup industrial plant
will be 23.29%. This percentage is way higher than the anticipated percentage in investing a
business which 1%.

REFERENCES

https://www.amazon.com/Portable-Hardness-Digital-Measuring-Durometer/dp/B07RYLGTSN

90
https://www.globalsources.com/si/AS/Naser-Machinery/6008847975086/pdtl/Industrial-Plastic-
Big-Capacity-Vertical-Stirring-Machine-mixer-screw-mixing-machine/1065478253.htm

https://www.ucandyna.com/en/product-151487/Rebound-Resilience-Elasticity-Tester-UA-
2207.htmlhttps://cnprinter.en.alibaba.com/product/60225880201-
801216679/New_Condition_and_Infrared_Ray_drying_machine_Type_Tunnel_Dryer_IR_.html

Horizontal hydraulic press machine http://www.lqjdjg.com/product-14/

https://www.alibaba.com/product-detail/Implex-Pencil-Lead-Cutting-
Attachment_50035395258.html

https://www.indiamart.com/proddetail/steel-belt-conveyor-15254498188.html

https://rhtc-workshoppress.com/products/four-column-presses/ppmv-220/

https://www.qrfs.com/blog/223-fire-sprinkler-system-pipe-material-nfpa-requirements-and-the-
pros-and-cons-of-steel/

APPENDIX

Hi-earns or OEM Diesel Generator 15kW Specification Sheet

91
 Figure 1. Generator Set Specifications

Ifanite 10kW Diesel Generator Specification Sheet

92
Figure 2

Generator Set Specifications

93
Daiden Diesel Generator 15kW Specification Sheet

Figure 3. Generator Set Specifications

94
Table 1. CLF with shading factor

Table 2. CLF with without shading factor

95
Table 3. CLTD sunlit walls

Table 4. CLTD external load factor

96
Table 5. CLTD correction for Latitude Month

97
Table 6. U-value insulation and wall

98
99