Don Bosco Technical

College S.Y. 2020 – 2021

Faculty of Mechanical Engineering

DIESEL FUEL GAS – TURBINE POWER

PLANT

Medina, Cedric Isaiah A.

4 – ME

Submitted to:

Engr. Ernesto L. Ponce, PME, MBA, Peng.

1
 TABLE OF CONTENTS

Introduction 3

Related Literature 4

Statement of the Design Project 5

About the Design 5

Assumptions 6

Descriptions and Function of the Components in the Design 6

Pictures and Illustrations of the Components 7

Computations for the Design 8

Cost Estimation and Analysis 12

Selection of Location 13

Conclusion 13

Recommendation 14

Bibliography 15

Tables and Charts 15

References 17

Technical Drawings of the Designed Power Plant 18

2
INTRODUCTION

In 1791, John Barber (an Englishman) patented the first gas turbine engine. The design was intended to

propel a "horseless carriage". Barber's design took advantage of the thermodynamic cycle we know in the

modern gas turbine – there was a compressor, a combustion chamber and a turbine.

The first successful gas turbine, built in 1903 in Paris, consisted of a multistage three-cylinder reciprocating

compressor, a combustion chamber and an impulse turbine. It worked as follows: The air supplied by the

compressor was burned in the combustion chamber with liquid fuel. The resulting gases were cooled slightly by

the injection of water and then passed to a pulse turbine. This system, which had a thermal efficiency of about

3%, demonstrated the feasibility of a practical gas turbine engine for the first time.

A gas turbine is an internal combustion engine at the heart of a power plant that can convert natural gas or

other liquid fuels into mechanical energy. This energy then powers a generator that creates electrical energy

that is transported through power lines to homes and businesses.

In gas turbine power plants, we use high pressure and temperature air instead of high pressure and

temperature steam to drive the turbine. In gas turbine power plants, turbine shafts, generators and air

compressors are common. Some of the mechanical energy generated in the turbine is used to compress the air.

The gas turbine works on the principle of the Brayton’s cycle, in which compressed air is mixed with fuel

and burned under constant pressure. The resulting hot gas is allowed to expand through a turbine to perform

work. Gas turbines consist of three main components: compressor, combustion chamber and power turbine.

In the compressor section, air is drawn in and compressed to 30 times the ambient pressure and led to the

combustion section where fuel is introduced, ignited and burned.

3
RELATED LITERATURE

“Study of the performance of the gas turbine power plants from the simple to complex cycle: A technical

review” Ibrahim, T. (2019)

In this study, a comprehensive review of previous studies on GT power plants was conducted. In recent

decades, there have been several studies on GT performance modeling and simulation. This review focused on a

GT Single Cycle Power Plant (GTPP) with a 2-axis, regenerative, reheater, intercooler, complex cycle GT with

intercooler, regenerative and reheater effect. Other assessments focused on the influence of operating conditions

on the GTPP's performance with a greater emphasis on the GT's complex and simple cycles. Finally, the

technical assessment focused on improving the performance of the GTPP. However, information can be found

on the performance evaluation of GTPPs, in particular for the operation of GTPPs under complex environmental

conditions and configurations. This review has taken a systematic approach to ensure that this research can be

properly conducted to contribute to the existing information in this area.

“Gas Turbines” Breeze, P. (2016)

This article talks about Gas Turbines where the final part of the gas turbine called the turbine section. Here, the

energy from the fuel is converted into a form of mechanical energy, with the rotation of the turbine shaft

generating torque. All gas turbines, with the exception of some very small machines, use axial flow turbine

sections. As with the compressor, the axial flow turbine will consist of a number of stages, each stage consisting

of a set of fixed blades, generally referred to as nozzles, and a set of rotating blades attached to the turbine shaft..

4
STATEMENT OF THE DESIGN PROJECT

1. The main objective of this design project is to be able to produce a design of a Gas – Turbine that

will accept and be powered by Diesel Fuel.

2. The Design paper also aims to produce and present the different components, factors, aspects,

and parameters of the designed Diesel Fuel Gas Turbine Power Plant.

3. The Design Paper also aims to determine the efficiency, load factors and various power plant factors

of the designed Diesel Fuel Gas – Turbine Power Plant.

4. To be able to locate a suitable location that will contain a present energy source and has a

community that the Power Plant will provide power.

ABOUT THE DESIGN

The Design of Diesel Fuel Gas – Turbine Power Plant will be used as a peak load and will be running an

open – cycle gas turbine system. The design will be having the following components; Compressor, Combustion

Chamber, Gas Turbine, and a Heat Exchanger. The peak load of the power demand curve will have a capacity of

35% of the given load capacity of 100 MW which will have an output of 35MW.

5
ASSUMPTIONS

1. The Design Power Plant is assumed to have an ambient temperature of 27°C at a standard pressure

of 1atm.

2. It is assumed that this kinds of Power Plant must be located in less polluted areas, so the

assumed location must be put in less population like provinces.

DESCRIPTION AND FUNCTION OF THE COMPONENTS IN THE DESIGN

• Compressor – A compressor is a device that increases the pressure of a substance (usually a gas) by

reducing the volume of the substance. Compressors are used in many applications, most of which

involve increasing the pressure inside a gas storage container, such as: Compression of gases in

petroleum refineries and chemical plants. Since turbines have high flow rates a use of rotary

compressor is required.

• Combustion Chamber – The combustion chamber of a gas turbine is where the energy that drives the

whole system is added. The fuel air mixture ignites in the combustion zone, releasing energy as heat.

The temperature in the combustion zone flame can reach over 1900°C, far higher than most

materials can withstand.

• Gas Turbine – or also known as Power turbine is a combustion engine at the heart of a power plant, its

function it so convert natural gases or other liquids to mechanical energy.

• Fuel Heater – or heater will serve as the source of heat for the Diesel Fuel to be evaporated or reach

its gaseous form.

• Generator – In electricity generation, a generator is a device that converts motive power (mechanical

energy) into electrical power for use in an external circuit. This will serve as the producer of

electrical energy that will travel along the power lines to serve as electricity.

• Chimney – These chimneys are some times known as stacks. They are always vertical to ensure the

hot gases flow smoothly. In power plants, the draft, or a part of it, is gathered by the confinement of a

tall column of the hot gas in the chimney.

6
 • Foundation – It is a structural connection where design varies based on the characteristics of the

structure and the soil and rock beneath. It functions to support the weight of the machine, where it

distributes the machine’s weight and its own to the safe sub-soil area. It also helps in absorbing

the vibration produced by the machine and provide stability and proper alignment for the

machine.

PICTURES AND ILLUSTRATIONS OF THE COMPONENTS

1. Gas Turbine: SIEMENS Energy

Model: SGT-700 Industrial Gas-Turbine (Performance Data for Simple Cycle Power Generation)

Power Output 35.2 MW(e)

Fuel Natural Gas, Liquid Fuel, Dual Fuel

Frequency 50/60 Hz

Gross Efficiency 38%

Heat Rate 9, 466 kJ/kWh (8, 972 Btu/kWh)

Turbine Speed 6, 500 rpm

Pressure Ratio 18.7 : 1

Exhaust Mass Flow 98.7 kg/s (217.6 lb/s)

Exhaust Temperature 531 °C (988 °F)

NOx Emissions ≤ 15 ppmvd at 15% O2 on fuel gas (with DLE)

7
2. Fuel Heater: ENERGYEN

Specifications:

Dimensions: L7000 x W1500 x H5400 mm

Weight: 32 ton

COMPUTATIONS FOR THE DESIGN

Design Problem 1 (Foundation for the

Design) Objectives:

Compute for the Foundation for the Design of the Diesel Fuel Gas-Turbine.

Given:

Wm = 169, 193 kg = 169.193 tons

Vm = 18.8m x 4.6m x 4.0m

Illustration:

Assumption:

• 𝜌concrete = 2363 kg/m3

• Wf = 3 to 5 times Wm ; we assume to use Wf = 4Wm

• Safe bearing power for soil will be clay, compact, Sb = 50-78 tonnes/m2

• N = 5; Safe soil bearing capacity

8
Formulation:

Wf
V f=
p
L=Lb+2c

a=w+2 c

N (W m +W f )
b= Sb L

2Vf
h= (a +b) L

Solution:

W f =4 (169 , 193)=676 , 722 kg=676.722 tons

We therefore use plain concrete stone as building materials.

676 , 722
V = =286.38 m3
f
2363

We use Sb = 65 tonnes/m2

We use Lb = 20m; W = 6m; c = 0.21m

L=20+2(0.21)=20.42 m

a=6 +2(0.21)=6.42 m

5 (169.193+676.722)
b= 65(20.42) =3.19 m

Since b < a, let a = b

2 (286.38)
h= 2(6.42)(20.42) =2.20 m

9
Summary:

The dimensions are the following:

L = 20.42 m

a = b = 6.42 m

c = 0.21 m

h = 2.20 m

The Foundation that will be used in the design is plain concrete, stone and as for the bearing power of the soil

clay will be used. Compact with a load of 65 tonnes/m3.

Design Problem 2 (Chimney for the

Design) Objectives:

Compute for the Design of the Chimney for the Diesel Fuel Gas-Turbine Power Plant.

Given:

Pa = 101.325 Kpa mg = 98.7 kg/s = 355, 320 kg/hr

Ta = 300.15 K Tg = 804.15 K

Illustration:

10
Assumption:

• We assume to use Tapered Chimney, Using 𝜃 = 2°

• We use Va = 50% of Vt

• R = 0.287 kJ/kg*K

• We assume to use H = 14(Q)0.3

Formulation:

P
p= RT

Q= Emission rate x Sulphur content x 2

H =14 (Q)0.3

dpch=H (P a −P g )
dpch
V = √2 g ( )
t
hg

(m g T g R g )
Q g=
P

V a=0.5 V t
4 Qg

√
d= ( )
πV a

D=2 Htan (θ)+d

Solution:
101.325
Pa= =1.176 kg /m3
(0.287)(300.15)

101.325
Pa= =0.4390 kg /m3
(0.287)(804.15)

H =14 (355320 x 0.0015 x 2)0.3=113.36 m≈114 m

dpch=114 (1.176−0.4390)(0.00981)=0.82 kPa

11
 0.82
V =√2(9.81)( )=0.40 m/ s
t
101.325

Va=0.5 (0.40)=0.20 m/ s

[(98.7)(0.287)(804.15)] 3
Qg = 101.325 =224.81 m / s

(224.81)
d =√ 4 =37.83 m≈38
m π (0.20)

We assume to use 𝜃 = 2°

D=2(114 ) tan(2)+38=45.96 m≈46 m

Summary:

The dimensions are the

following: H = 114 m d

= 38 m

D = 46 m Tapered angle is 𝜃 = 2°

COST ESTIMATION AND ANALYSIS

Gas-Turbine (SGT-700 Industrial Gas-Turbine) – PHP

600,575,625.00 Fuel Heater (ENERGYEN) – PHP 355,918.50

Production of Chimney – PHP 850,000.00

Foundation of the Power Plant – PHP

625,000.00

Item Quantity Price range

Gas-Turbine with Built in Generator 1 PHP 600,575,625.00
Fuel Gas Heater 1 PHP 355,918.50
Chimney 1 PHP 850,000.00
Foundation of the Power Plant 1 PHP 625,000.00
TOTAL COST PHP 602,406,543.50

12
SELECTION OF LOCATION

(San Pedro, Batangas)

The chosen location for the Design of the Diesel Fuel Gas-Turbine Power Plant is on San Pedro, Batangas.

As you can see the area is near the site of a power gird making it easier distribute power coming from the Power

Plant. Since Diesel Fuel Gas-Turbine Power Plant require less polluted area the location of this design is

somehow separated from the Island of Batangas where it is somehow less populated area therefore less pollution.

CONCLUSION

The produced design of the Diesel Fuel Gas-Turbine Power Plant can provide a power output of 35MW and

will be located in San Pedro, Batangas, Philippines. The area where the Power Plant is suppose to be designed

will be on a clay soil, therefore its weight will be equally distributed over the safe sub-soil area. The overall cost

of the Diesel Fuel Gas-Turbine Power Plant is estimated to around PHP 602,406,543.50.

13
RECOMMENDATION

The Design of the Diesel Fuel Gas-Turbine is to run a typical open cycle gas turbine system. In addition of a

Heat Exchanger to the open cycle gas turbine system this will turn it into a regenerative cycle where the heat

exchanger can be able to increase the temperature of the compressed air that will be entering the gas turbine. The

output of this is that it would require less fuel by the combustion chamber to achieve the inlet temperature of the

turbine.

14
BIBLIOGRAPHY

1. “Study of the performance of the gas turbine power plants from the simple to complex cycle: A

technical review” Ibrahim, T. (2019)

2. “Gas Turbines” Breeze, P. (2016)

TABLES AND CHARTS

1. Power Demand Curve

2. Simple Cycle Power Generation Data Sheet

15
3. Physical Dimensions Data Sheet

4. Brochure of the Gas-Turbine

16
REFERENCES

1. https://assets.siemens-energy.com/siemens/assets/api/uuid:c8a248c8-3b31-41c7-b6a4-b5b93e1f7055/t10028-

00-7600-factsheet-sgt-700-us-highres.pdf

2. https://www.siemens-energy.com/global/en/offerings/power-generation/gas-turbines/sgt-700.html

3. http://energyen.co.kr/en/business/sub01.html?num1=1&num2=6&cate=1

4. https://assets.siemens-energy.com/siemens/assets/api/uuid:ad43d253-34ec-48aa-a3c2-e8af1b51a45f/siemens-

air-cooled-generators-sgen-100a-2p-brochure-en.pdf

1
TECHNICAL DRAWINGS OF THE DESIGN

DIESEL FUEL GAS TURBINE POWER

PLANT

1
 12 11 10 9 8 7 6 5 4 3 2 1

H H

G G

38.00

F F

E E
114.00

D D

2.00

46.00

C C

B B

UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND

DO NOT SCALE REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
DRAWING
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
Diesel Fuel Gas-
Turbine Power
CHK'D

APPV'D

A
MFG
Plant
Q.A MATERIAL:
A
DWG
A2
Chimney Design
WEIGHT: SCALE:1:1000 SHEET 1 OF 1
12 SOLIDWORKS E ducational Produ ct . For Instructiona l Use Only.
11 1 0 9 7 6 5 4 3 2 1
8
 12 11 10 9 8 7 6 5 4 3 2 1

H H

G G

FUEL HEATER

F GENERATOR F

CHIMNEY
E E
GAS-TURBINE

TRANSMISSION
D D

C C

ELECTRIC GRID

B B

UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND

DO NOT SCALE REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
DRAWING
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
Diesel Fuel Gas-
Turbine Power
CHK'D

A
APPV'D

MFG
Plant
Q.A MATERIAL: DWG NO.
A
Power Plant Layout Design A
 WEIGHT: SCALE:1:1 SHEET 1 OF 1

SOLIDWORKS E ducational Produ ct . For Instructiona l Use Only.

12 11 1 0 9 7 6 5 4 3 2 1
8
 Don Bosco Technical College

S.Y. 2020 – 2021

Faculty of Mechanical Engineering

COAL FUEL STEAM POWER PLANT

Medina, Cedric Isaiah A.

4 – ME

Submitted to:

Engr. Ernesto L. Ponce, PME, MBA, Peng.

1
 TABLE OF CONTENTS

Introduction 3

Related Literature 3

Statement of the Design Project 4

About the Design 4

Assumptions 4

Description and Function of the Components in the Design 5

Pictures and Illustration of the Components 6

Computations for the Design 9

Cost Estimation and Analysis 14

Selection of Location 15

Conclusion 15

Recommendation 16

Bibliography 16

Tables and Charts 16

References 18

2
INTRODUCTION

A steam power plant consists of a boiler, a steam turbine, a generator, and other auxiliary units. Boilers

generate steam at high pressure and high temperature. Steam turbines convert the thermal energy of steam into

mechanical energy. The generator then converts mechanical energy into electrical energy. Coal-fired power

plants generate electricity by burning coal in a boiler to generate steam. The steam generated under enormous

pressure flows into the turbine that drives the generator to generate electricity. The steam is then cooled,

condensed and returned to the water, then returned to the kettle and the process restarted from the beginning.

RELATED LITERATURE

Performance Analysis of a Steam Power Plant: A Case Study (Al-Taha, 2018). In this paper, the rated

performance of a heating station is examined mechanically by determining the performance parameters of the

power generation unit that receives the computational model by performing the thermal balance of each key

component. A comparison is made between the particle results obtained from the station and the theoretical

results calculated from the thermodynamics of the first law. We considered the various workloads at full load

(40%, 70%, 100%) to determine the optimal working conditions, and also showed the impact of some working

and environmental conditions on device performance.

Steam Power Plants (Khalil, 2008). Efficient use of fossil energy in low-pollution power generation at

traditional thermal power plants is a topic of international interest. Energy availability and sustainability

scenarios are gaining interest and demand in many countries around the world as the aims to improve living

standards, increase productivity and maintain a clean environment. This is the field you are in. Efficient energy

consumption helps improve productivity, product quality, cost and quality of life, but the use of energy has a

negative impact on our environment.

3
STATEMENT OF THE DESIGN PROJECT

1. Determine where the Coal Fuel Steam Power Plant would be assigned to in the 24-Hours Load Curve.

2. The peak capacity assigned for the Coal Fuel Steam Power Plant is 100MW.

3. To determine the location where a Coal Fuel Steam Power Plant should be placed and installed that

is suitable and has a present energy source.

4. The Design Paper also aims to determine the efficiency, load factors and various power plant factors of

the designed Coal Fuel Steam Power Plant.

ABOUT THE DESIGN

The Design of the Coal Fuel Steam Power Plant will be used as a base load power plant and the design

will consist of a normal components for a steam power plant; Boiler, Steam Turbine, Generator, Condenser.

The power demand for the Coal Fuel Steam Power Plant will be 30% of the given and assigned peak capacity

which is 100 MW, and will have a result output of 30 MW.

ASSUMPTIONS

1. The design of the Coal Fuel Steam Power Plant is assumed to have an ambient temperature of 25°C at a

standard pressure of 1 atm.

4
2. It is assumed that this kinds of Power Plants must be located in areas with large amount of water, so that it

can be used to circulate around the system of the power plant.

DESCRIPTION AND FUNCTION OF THE COMPONENTS IN THE DESIGN

1. Chimney

These chimneys are some times known as stacks. They are always vertical to ensure the hot gases flow

smoothly. In power plants, the draft, or a part of it, is gathered by the confinement of a tall column of the hot gas

in the chimney.

2. Foundation

It is a structural connection where design varies based on the characteristics of the structure and the soil and rock

beneath. It functions to support the weight of the machine, where it distributes the machine’s weight and its own

to the safe sub-soil area. It also helps in absorbing the vibration produced by the machine and provide stability

and proper alignment for the machine.

3. Steam Turbine Generator

Is a machine that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating

output shaft. In simple terms, a steam turbine works by using a heat source (gas, coal, nuclear, solar) to heat

water to extremely high temperatures until it is converted into steam.

4. Cooling Tower

Are essentially large boxes designed to maximize evaporation of water. To do this, they contain material,

typically PVC plastic sheets, that create large surface areas for water evaporation to occur. This material is

what fills the inside of the cooling tower and is called "Cooling Tower Fill".

5. Condenser

Device for reducing a gas or vapor to a liquid. Condensers are employed in power plants to condense exhaust

steam from turbines and in refrigeration plants to condense refrigerant vapors, such as ammonia and fluorinated

hydrocarbons.

5
6. Generator

In electricity generation, a generator is a device that converts motive power (mechanical energy) into electrical

power for use in an external circuit. This will serve as the producer of electrical energy that will travel along the

power lines to serve as electricity.

PICTURES AND ILLUSTRATION OF THE COMPONENTS

1. Steam Turbine and Generator

ELLIOT GROUP: Steam Turbine and Generator Set

Multi-valve, Multi-stage (MVMS) Steam Turbine and Generator Set Specifications:

Power Output Range 25.5 MW – 60 MW

Exhaust Pressure Vac to 600 psig (41.4 barg)
Inlet Pressure 2000 psig (140.8 kg/cm2)
Inlet Temperature 1005°F (541°C)

6
2. Boiler

SHL Coal Fired Steam Boiler: SHL10-2.5/400

SHL 10-2.5/400 Coal Fueled Steam Boiler Specifications:

Rated Working Pressure 2.5 Mpa

Rated Steam Temperature 400 °C
Boiler Design Efficiency Greater than or equal to 82%

3. Condenser

Zoomlian Condenser

Zoomlian Condenser Specifications:

Maximum Working Pressure 1.0 Mpa

Liquid Flow Rate 10 m/s

7
4. Condensate Pump

Electric Motor Agricultural Irrigation Water Pump

Electric Motor Agricultural Irrigation Water Pump Specifications:

Capacity 745 m3/hr

Head 108 m
Speed 1450 rpm
Motor Power 500 kW

5. Cooling Tower

Circular Hybrid Cooling Tower

SPX Cooling Technologies Circular Hybrid Cooling Tower Specifications:

Water Flow 189.27-31545.10 kg/s

8
COMPUTATIONS FOR THE DESIGN

Design Problem 1 (Foundation for the

Design) Objectives:

Compute for the foundation of the design for the Coal Fuel Steam Power Plant.

Given:

Wm = 135,000 kg = 135 ton

Vm = 15m x 5m x 3m

Illustration:

Assumption:

1. 𝜌concrete = 2363 kg/m3

2. Wf = 3 to 5 times Wm ; we assume to use Wf = 4Wm

3. Safe bearing power for soil will be clay, compact, Sb = 50-78 tonnes/m2

4. N = 5; factor of safety for safe soil bearing capacity

Formulation:

Wf
V f=
p
L=Lb+2c

a=w+2 c

N (W m +W f )
b= Sb L

9
 2Vf
h= (a +b) L

Computations:

W f =4 (135,000)=540,000 kg=540 tons

We therefore use plain concrete stone as building materials.

540,000
V = =228.52 m3
f
2363

We use Sb = 65 tonnes/m2

We use Lb = 20m; W = 6m; c = 0.21m

L=20+2(0.21)=20.42 m

a=6 +2(0.21)=6.42 m

5 (135 +540)
b= 65(20.42) =2.54 m

Since b < a, let a = b

2(228.52)
h= 2(6.42)(20.42) =1.74 m

Summary:

The dimensions are the following:

L = 20.42 m

a = b = 6.42 m

c = 0.21 m

h = 1.74 m

The foundation to be used will be composed of plain concrete, stone and safe bearings power for the soil will

be clay, with a compact load of 64 tonnes/m2.

1
Design Problem 2 (Chimney for the

Design) Objectives:

Compute for the Design of the Chimney for the Coal Fuel Steam Power Plant.

Given:

Pa = 101.325 Kpa mg = 225.15 kg/s

Ta = 300.15 Kpa Tg = 623 K

Illustration:

Assumptions:

1. Tapered chimney, use θ = 2°

2. R = 0.287 kJ/kg·K

3. Va = 30% to 50% of Vt ; use Va = 40% of Vt

Formulations:

P V hw
ρ= RT hw 2g( ¿)
H =ρ + ρ

√
a g
¿
t =
hg

mg T g
Q=
V =0.4 V D=2 Htan (θ)+d
Rg g

√
P
a t
4
d= a

Qg π
π c
12
V =

1
H(
D2+d 2+
Dd)

1
Computations:
101.325
Pa= =1.176 kg /m3
(0.287)(300.15)

101.325 kg
pg = =0.5667 3
(0.287) (623) m

H =14 (810540 x 0.0015 x 2)0.3=72.76 m≈73 m

dpch=73(1.176−0.5667)(0.00981)=0.44 kPa
0.44
V =√2(9.81)( )=0.06 m/s
t
101.325

Va=0.5 (0.06)=0.03 m/ s

[(225.15)(0.287)(623)] 3
Qg = 101.325 =397.31 m / s

(397.31)
d =√ 4 =45.32 m≈46 m
π (0.03)

We assume to use 𝜃 = 2°

D=2(73) tan(2)+46=51.10 m≈52 m

Summary:

The dimensions are the

following: H = 73 m d

= 46 m

D = 52 m Tapered Angle is 𝜃 = 2°

1
Design Problem 3 (Foundation for the

Chimney) Objectives:

Design a foundation for the chimney of the Coal Fuel Steam Power Plant

Given:

H = 73 m d = 46 m

D = 52 m Wc = 152,000 tons = 152,000,000 kg

Illustration:

Assumptions:

• We assume that the safe bearing power for soil is clay compact. Sb = 50-78 tonnes/m2

• Use concrete stone as the material of the chimney ρconcrete = 2403 kg/m3

• We assume h = 4% of HC

Formulation:

1 h
B= 10 ( H )+ D V C= W C =( )(V C) W f =4 W c
¿ concrete
3 ρ

Computations:
π
A = (56 )2=2463.01 m2
1
4
π
A = (50)2=1963.50 m2
2
4
π
a = (52)2=2123.73 m2
1
4
π
a= ( 46 )2=1661.90 m2
2
4

1
 73
V = [ (2463.01+1963.50)+ √(2463.01) (1963.50)−(2123.73+1661.90)− √(2123.73) (1661.90) ]=23392
C
m3 3

W =(2403 )(23392)=56.2 × 106 kg=56,200 tons

C

W =4 (56.2 ×106 )=225 ×106 kg=225,000 tons

f

Top base=73+0.3=73.03 m

1
B= 10 (73)+52=59.3 m h=0.04 (73)=2.92 m

Summary:

• The Chimney design foundation has a weight of 225,000 tons.

• The top base of the foundation has a cross section of 73.03 m.

• The Bottom base of the foundation has a cross section of 59.3 m.

• The depth of the foundation of the chimney will be 2.92m

COST ESTIMATION AND ANALYSIS

Components for the Coal Fuel Steam Power Plant Design to bought:

Steam Turbine and Generator (Elliot Group) Php 425,000,000.00/unit

Boiler (SHL10-2.5/400 ) Approx. Php 1,625,959.00
Condenser (Zoomlian) Php 50,000.00

Condensate Pump Approx Php 142,000.00

Cooling Tower Php 10,030,100.00
Cost of foundation:

Php 733.60
(1669.5 f t2)=₱ 1,224,745.20 per
foundation f t2

Capital Cost and Operating Costs

Usual Charge on Running Natural Gas Power Plants: At minimum $670/kW = At minimum Php 33,897.56/kW

Running Charge = Php 33,897.56/ kW ×(240 ×103 kW )= Php 8,135,414,400.00

1
SELECTION OF LOCATION

(San Pedro, Batangas)

The chosen location of the Coal Fuel Steam Power Plant will be on San Pedro, Batangas. The are is near

a site of a power grid making it easier to distribute power coming from the Power Plant itself. The area is also

close to large amount of water because making it accessible for the Power Plant to use water to produce steam.

CONCLUSION

The produced design of the Coal Fuel Steam Power Plant can provide a power output of 30MW and will

be located in San Pedro, Batangas, Philippines. The area where the Power Plant is suppose to be designed will

be on a clay soil, therefore its weight will be equally distributed over the safe sub-soil area. The overall costing

of the Coal Fuel Steam Power Plant components is estimated around Php 436,848,059.00, and for the operating

cost it is Php 45,709.51/kW.

1
RECOMMENDATION

The Design of the Coal Fuel Steam Power Plant made had a built in generator set from the Steam

Turbine itself. For future designers who are to conduct a Coal Fuel Steam Power Plant Design choosing a more

quality steam turbine and also a more quality generator can make the design more efficient, but will also cost

more.

1
BIBLIOGRAPHY

1. “Steam Power Plants” Khalil, E. (2008)

2. “Performance Analysis of a Steam Power Plant: A Case Study” Al-Taha, W. (2018)

TABLES AND CHART

1. Power Demand Curve

2. Boiler Specification Sheet

1
2. Brochure of the Steam Turbine-Generator

REFERENCES

• https://www.witpress.com/Secure/elibrary/papers/9781845640620/9781845640620004FU1.pdf

• https://www.researchgate.net/publication/

328742025_Performance_Analysis_of_a_Steam_Power_Plant_A_Case_Study

• https://www.elliott-turbo.com/Files/Admin/Literature/Updated%20Cover%20092019/elliott-turbine-

generator-sets.pdf

1
• http://www.hnht-boiler.com/Coalfiredboiler/29.html#two

• https://atachpump.en.made-in-china.com/product/EjDxrUIVYNhH/China-Electric-Motor-Agriculture-

Irrigation-Water-Pump-350s125b-14sh-6b.html

• https://spxcooling.com/cooling-towers/marley-round-hybrid-plume-abatement/

2
 Don Bosco Technical

College S.Y. 2021-2022

Faculty of Mechanical Engineering

TIDAL MILL ARRAY POWER PLANT DESIGN

Submitted by:

Medina, Cedric Isaiah A.

Submitted to:

Engr. Ernesto L. Ponce, PME, MBA, PEng.

Date Accomplished:

December 21, 2021

 TABLE OF CONTENTS

INTRODUCTION

RELATED LITERATURE

STATEMENT OF THE DESIGN

ABOUT THE DESIGN

DESCRIPTION O F THE COMPONENTS OF THE

DESIGN COMPONENTS TO BE BOUGHT

COMPUTATIONS OF THE DESIGN

COST ESTIMATION ANALYSIS

SELECTION OF LOCATION

CONCLUSION

RECOMMENDATION

BIBLIOGRAPHY

BROCHURE

APPENDIX
INTRODUCTION

Tidal power, also known as tidal energy, is generated by transforming the energy of the tides

into usable types of energy, primarily electricity, through a variety of methods. Tidal energy has the

potential to provide electricity in the future, despite its lack of widespread application. The wind and

the sun are less reliable than the tides. Tidal energy has traditionally had a high cost and restricted

availability of sites with sufficiently high tidal ranges or flow velocities, limiting its total availability

among renewable energy sources. However, many recent technological advancements and

improvements, both in design and turbine technology suggest that total tidal power availability may be

much higher than previously assumed, and that economic and environmental costs may be brought

down to competitive levels. Tidal energy is used by converting energy from the tides into usable

forms of energy, primarily electricity. Tidal energy is currently one of the most common types of

marine renewable energy, and it uses a number of approaches. Energy is predictable because to its

origins in tide-producing processes. Wind and wave energy, as well as, to some extent, solar, are more

stochastic renewable energy sources than other renewable energy sources.

2
RELATED LITERATURE

According to Kuang, C. (May 2012) Tidal energy is a kind of new energy which is both

renewable and pollution-free so that the tidal power generation is increasingly popular in the world.

This paper is with respect to the current situation and prospects of development to the tidal power

generation at home and abroad, from which it is realized that countries around the world set out the

exploitation and utilization of tidal power generation as early as last century by carrying out a great

quantity of research and practice, and building numerous tidal power generation stations. As we all

know, water turbine generating units are absolutely necessary for tidal power generation. So this paper

also refers to the water turbine generating units used in some tidal power generation stations and briefly

presents their characteristics as well.

According to Lee, N. (2011) Blade selection for tidal turbine arrays for optimum performance.

The 30th International Conference on Ocean, Offshore, and Arctic Engineering (OMAE2011) was

held in Rotterdam, The Netherlands, from June 19 to 24, 2011. According to the American Society of

Mechanical Engineers (ASME), free stream devices are arranged in arrays to enhance tidal energy

capture at a given site. The downstream evolution of a spinning tidal energy conversion device's wake

effects the device's performance, the bypass flow to either side, and the performance of any

downstream devices in an array. As a result, designing a turbine that can operate efficiently and

effectively in these conditions is critical. It has been demonstrated that the use of passively adaptable

composite blades for horizontal axis tidal turbines improves performance in fluctuating inputs. In order

to improve performance throughout the tidal cycle, active adaptation and/or bi-directional hydrofoil

sections could be used.

3
STATEMENT OF THE DESIGN PROJECT

1. Determine where the Tidal Mill Array Power Plant would be assigned to in the 24-Hours Load Curve.

2. The peak capacity assigned for the Tidal Mill Array Power Plant is 100MW.

3. To determine the location where a Tidal Mill Array Power Plant should be placed and installed that is suitable

and has a present energy source.

4. The Design Paper also aims to determine the efficiency, load factors and various power plant factors of

the designed Tidal Mill Array Power Plant.

ABOUT THE DESIGN

The design of the Tidal Mill Array Power Plant will be used as mid load power plant and the design will

consist of Turbine, Generator and Tidal Mill. The power demand curve for the tidal mill array power plant is

35% and the assigned peak capacity which is 100 MW, and will have a result output of 35 MW.

ASSUMPTIONS

1. The design of the Coal Fuel Steam Power Plant is assumed to have an ambient temperature of 25°C at a

standard pressure of 1 atm.

4
2. It is assumed that this kinds of power plant must be placed in an area where there is a huge amount of

water and also has a strong current.

3. The assumed location must be the following:

• Velocity flow of 2.5 m/s

• Varying Depth of 30-100 m

DESCRIPTION OF THE COMPONENTS IN THE DESIGN

1. Tidal Turbine

Tidal power or tidal energy is harnessed by converting energy from tides into useful forms of power,

mainly electricity using various methods. Although not yet widely used, tidal energy has the potential

for future electricity generation. Tides are more predictable than the wind and the sun.

COMPONENTS TO BE BOUGHT

1. Turbine

Marine Current Turbines: SeaGen-S

5
Specifications: (Tidal – Turbine built it in generator)

Rated Power 1-2 MW

Rotor Speed 4-11.5 rpm
Rotor Diameter 20 m
Rotor Swept Area 628 m2 for 2 rotors
Power Regulation Active blade pitch regulation

Specifications: (Generator)

Type Asynchronous
Nominal Power Rated to provide 1,000kW into grid export cable
Voltage 690 V
Cooling System Direct to passing sea water

COMPUTATIONS FOR THE DESIGN

Design Problem 1 (Power Output of the

Turbine) Objectives:

Determine the Power Output of the Turbine.

Given:

V = 2.5 m/s Area of rotor = 628 m2

Blade Diameter, d = 20 m

Illustration:

6
Assumptions:

• Cp = 0.70

• P = 1020 kg/m3

Formulations:

P=Cp ( 1
2
pA V 3 )
Computations:
1 2 m 3

P=0.70 ( 2 (1020)(628 m )(2.5 s ) )=219992325 W

Final Answer:

219992325W = 2.2MW

Design Problem 2 (Foundationg to be used)

Objectives:

Determine the Foundation to be used for the Design.

Given:

Cylindrical Turbine system

Horizontal Installation Depth: 40 m

Illustration:

7
Assumptions:

The assumed installation is 40 to 80 meters.

Formulations and Computations:

According to the brochure of the turbine used it is installed in a water depths of 40 – 100 meters and is

possible to be positioned by gravity base into the seabed of the ocean.

Final Answer:

The type of Foundation to be used is Gravity Based.

Design Problem 3 (Layout of the

Turbine) Objectives:

Determine the number of units to be used to reach the required power output which is 35 MW.

Given:

L = 15 m

W = 25 m

Illustration:

Assumptions:

The Tidal Mill Array Turbine design was chosen to be used as Mid load with 35% power

capacity.

8
Formulation and Computations:

Array Size = Demand Load / Computed Power Output

2MW per unit needed Load is 35 MW

35/2 = 17.5 = 18 Units

Final Answers:

18 units will be used for the power plant design.

COST ESTIMATION ANALYSIS

Components for the Tidal Mill Array Power Plant Design

Tidal Turbine (each) Php 1,550,000.00

18 Units to be used Php 27,900,000.00
Total Php 27,900,000.00

Economic Power

Power Distributor = Meralco

Power Output of the Gas Power Plant = 35 MW

9
SELECTION OF LOCATION

(Northern Samar, Near Bernardino Strait)

The selected area for the Power Plant design is in Northern Samar near the Bernardino Strait.

This is a good location for the design because it has a huge amount of water, and also the current is

strong making it more efficient for the Tidal turbines to move and generate more efficient power

and electricity.

CONCLUSION

The produced design of the Tidal Mill Array Power Plant can provide a power output of 35MW

and will be located in Northern Samar, Near the Bernardino Strait. The foundation type that will be

used for the design will be gravity based. The overall costing of the design would cost for an average

of Php 27,900,000.00.

1
RECOMMENDATION

The Design of the Tidal Mill Array Power plant has a built in design of a generator for the Turbine

itself. For future designers who are to conduct a Coal Fuel Steam Power Plant Design choosing a more quality

steam turbine and also a more quality generator can make the design more efficient, but will also cost more.

1
BIBLIOGRAPHY

1.) https://en.wikipedia.org/wiki/Tidal_power

2.) https://www.scientific.net/AMR.512-515.900

3.) https://www.irjet.net/archives/V4/i4/IRJET-V4I449.pdf?

fbclid=IwAR0mjET8P0RPoyfLV1cLQXdLRi9n8og4EceadVEfLDRUCbOThRy75qEli2w

1
SeaGen-S
2MW
Proven and commercially viable
tidal energy generation
The SeaGen
Advantage
The generation of electricity from tidal flows requires robust,
proven, available, and cost effective technology. SeaGen-S
2MW is the most advanced, field proven tidal generation system
available. As the pioneer and first mover in tidal the energy
sector, MCT have developed and patented key features, that
deliver commercially viable electricity generation.

These system features have been field-proven since installation

in 2008, of the commercial scale, SeaGen - S
1.2 MW grid connected system. By 2012, SeaGen - S had
delivered ten times the amount of electricity to the grid than all
other tidal devices combined.

Following MCT’s acquisition by Siemens, SeaGen-S 2MW is

being developed and tested to the highest production standards,
benefitting from Siemens world class, delivery of renewable
energy technology to global utilities.
SeaGen-S 2MW is designed around the principles of; Cost-
Effectiveness, Availability, Proven Engineering and
Environmental Responsibility.

Cost-Effectiveness
Each SeaGen-S 2MW device consists of twin 1MW
powertrains, delivering 2MW of grid conditioned electricity to
the substation. This configuration reduces the cost per MW by
minimising cabling and associated distribution infrastructure.
The pitch-controlled blades and high efficiency powertrains,
extract the maximum energy from the available tidal resource.

Availability
Building upon 1000’s of generating hours from SeaGen
–S 1.2MW, SeaGen-S 2MW has matured its engineering for
greater reliability. With its unique raising mechanism allowing
low cost and rapid access to the powertrains, and power
conditioning and control systems in its tower, SeaGen-S
provides unparalleled maintainability and unbeatable
availability.

Proven Engineering
With 3GWh generated by 2012 and the system continuing in
24-7 operation, SeaGen-S has proven its’ engineering way
beyond any competing device. Not only is the concept fully
demonstrated, but the detailed engineering design including
longer-term fatigue characteristics are now proven.

Environmental
In addition to producing zero-carbon electricity, MCT is
committed to ensuring minimal impact on the environment
from installation and operation in sensitive coastal waters. An
independent environmental monitoring programme was
commissioned to study the installation and first three years of
operation of SeaGen 1.2 MW. In 2012 the studies concluded
that, with the mitigation in place, there had been “no significant
environmental impact”.
Technical
Description
SeaGen-S 2MW
The SeaGen-S 2MW tidal generation system evolves the highly
successful 1.2MW SeaGen S device that has been operational in
Strangford Lough since 2008. With the insight and experience
gained from this project, MCT has been able to optimise the
system design to deliver 2MW with greater availability and at
lower cost.
Rotor
The SeaGen S tidal turbine incorporates twin horizontal axis
rotors. The rotors utilise an active blade pitching system which
limit structural forces during high flow conditions. This allows
the use of blades that are highly efficient over the full range of
tidal velocities, from initial cut-in through to rated flow. Energy
capture is further enhanced by variable speed operation which
allows the turbine to operate at its optimum tip speed ratio (all
the way up to up to rated power) and also minimises the
dynamic loads on the transmission system. In summary, the
variable speed and active pitch features allow efficient energy
capture over the full range of tidal velocities and minimise
structural loading, weight and cost.
Blades
The highly efficient rotor blades are constructed from
composite materials and are the most advanced and tested
blade technology used in tidal generation. The 2MW design
blades are being verified by static and dynamic testing,
building upon 25,000+ blade operating hours gained during the
1.2MW SeaGen and SeaFlow projects .
Rotor hub
The rotor hub houses the blade pitch actuators, slew bearings
and automatic greasing system in a compact and easily
maintainable configuration.
Blade pitch system
The blade pitch arrangement is used to optimize and regulate
power output throughout the operating range. The blades can
be feathered to minimize hydrodynamic loads during extreme
wave or tidal conditions.
Main shaft and bearing
The main shaft is forged in alloy steel and is hollow for the
transfer of power and signals to the blade pitching system via
slip rings.
Gearbox
The efficient and lightweight planetary gearbox allows a very
compact and light power train to be realised. This simplifies
maintenance operations and support logistics as well as
reducing overall structural weight and cost.
The intermediary and high speed stages are normal helical
stages arranged with an offset of the high-speed shaft, allowing
the passage of power and control cables to the pitch systems.
The gearbox is equipped with large capacity filtering systems
that ensure optimum operating conditions and up to 12 months
of operation between filter changes. The gearbox is fully
sealed and is cooled by the tidal flow.
Generator
The generator is a fully-enclosed asynchronous machine with
squirrel-cage rotor, which does not require slip rings and is
very robust. In addition to variable speed operation, the use of
frequency converters enables the generator to achieve high
part-load efficiency, allowing the turbine to achieve high
system efficiency across the range of tidal flow velocities. The
generator is cooled naturally by the water flow.
Mechanical brake
The system incorporates a hydraulically realised brake which
serves as a parking brake for crossbeam lifting and maintenance
operations, and is also used to ensure safe shut-down under
some theoretical fault conditions.
Controller
The turbine utilises a standard wind turbine control system
provided by a leading supplier. The controller is compatible
with turbine safety requirements, is self-
diagnosing and includes a keyboard and display for easy status
readout and adjustment of settings. The system allows; remote
interrogation, the reset of turbine alarms and provides
comprehensive data logging functionality.
Power conversion
The power conversion system allows the rotor to operate at
optimal speed over the range of tidal velocities
(from initial cut-in to rated power) whilst supplying grid
compatible electrical power at a frequency and voltage to
match the local distribution network. The power conversion
system is a modular arrangement for easy maintenance.
The frequency converter output is interfaced to the grid via
an onboard transformer, protection switch and
standard grid protection relay. Each SeaGen device is a self-
contained power station, requiring minimal onshore
infrastructure and permitting multiple machines to use a
common subsea cable.
Grid compliance
The SeaGen system complies with current grid code
requirements and due to the use of modern frequency
converters, can be adapted to meet emerging standards and
network requirements associated with tidal arrays.
Operation
The tidal turbine operates automatically, self-starting when the
tide reaches an average speed of about 1 m/s. During operation
below rated power, the pitch angle and rotor speed are
adjusted to maximize the hydrodynamic efficiency. Rated
power is reached at a tidal speed
of about 2.5 m/s. At higher tidal speeds the output is regulated
at rated power and rated rotational speed.
Remote control
The tidal turbine is equipped with a web based SCADA
system. This system offers; remote control, a variety of status
views and useful reports from a standard internet web browser.
The status views present; electrical, mechanical,
meteorological and tidal data, as well as operation, fault and
grid status.
Turbine Condition Monitoring
In addition to the Web SCADA system, the turbine is equipped
with a web-based Turbine Condition Monitoring (TCM)
system. The TCM system carries out precise, continuous, real
time, condition diagnostics on main turbine components. The
TCM system has various alarm levels, from informative through
alerting level to turbine shutdown.
Support Structure
The twin 1MW tidal turbine drive trains are mounted at each
end of a crossbeam which in turn is supported by a surface
piercing tubular steel tower. The cross beam can be raised, as
required above the sea surface to maintain the drive trains,
avoiding the cost and delay associated with expensive marine
vessels. MCT can provide support to array developers to design
foundations to meet local site conditions.
Specifications
Rotor
Diameter 20 m
Swept area 628 m2 for 2 rotors
Rotor speed 4 –11.5 rpm
Power regulation Active blade pitch regulation
Tower
incorporating power conditioning
Transmission System
and control systems
Gearbox type Planetary
Gearbox cooling Direct to passing sea water

Mechanical brake
Type Hydraulically released

Generator
Type Asynchronous Crossbeam
Nominal power rated to provide 1,000kW into grid can be raised for access to
export cable the power trains
Voltage 690 V
Cooling system direct to passing sea water

Monitoring system
SCADA system Web based Remote
control Full turbine control

Tower
Type Cylindrical tubular steel
Hub height Tailored for water depth/navigation
constraint issues

Operational data
Cut-in tidal speed 1 m/s Rotors
Rated power at 2.5 m/s 20m diameter

Weights Powertrain
Drive trains 60 tons 1 MW
Tower Site-specific

Power Curve for SeaGen -S 2MW

2500

2000

1500
Power

1000
Foundation
export cable for grid-ready electricity
500

0
0 0.5 1 1.5 2 2.5 3 3.5 4
Velocity m/s
 Contact
E: info@marineturbines.com www.marineturbines.com

All rights reserved. Trademarks mentioned in this document are the property of Marine Current Turbines Ltd, its affiliates, or their respective owners. Subject to change without prior notice. The information in this document contains general desc
 2 1

B B

18 UNITS OF TIDAL TURBINE

A UNLESS OTHERWISE SPECIFIED: NAME DATE

A
DIMENSIONS ARE IN INCHES DRAWN
TOLERANCES:
FRACTIONAL CHECKED TITLE:
ANGULAR: MACH
TWO PLACE DECIMAL
BEND
ENG APPR.
TIDAL POWER PLANT
LAYOUT
THREE PLACE DECIMAL MFG APPR.
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC Q.A.
TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
MATERIAL SIZE DWG. NO. REV
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A
WHOLE WITHOUT THE WRITTEN
PERMISSION OF
NEXT ASSY USED ON
FINISH
A 1
<INSERT COMPANY NAME HERE> IS
PROHIBITED.
APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 1
SOLIDWORKS Educational Product. For 2 Instructional Use Only. 1