CHAPTER 1

PLANT LOAD CALCULATION

1. Load Assignment: 67,159 kW

1.1 Daily Load Demand:

TIME, hour LOAD TIME, hour LOAD

12:00 AM 20500 kW 1:00 PM 55759 kW

1:00 AM 20000 kW 2:00 PM 55500 kW

2:00 AM 15575 kW 3:00 PM 54000 kW

3:00 AM 17500 kW 4:00 PM 58900 kW

4:00 AM 20500 kW 5:00 PM 60000 kW

5:00 AM 25000 kW 6:00 PM 62578 kW

6:00 AM 25789 kW 7:00 PM 64700 kW

7:00 AM 35900 kW 8:00 PM 66,589 kW

8:00 AM 40574 kW 9:00 PM 40400 kW

9:00 AM 45789 kW 10:00 PM 35200 kW

10:00 AM 50500 kW 11:00 PM 26700 kW

11:00 AM 55000 kW
 12:00 PM 58900 kW

1.2 Generator Set to be used:

The Wärtsilä W16V46F Generator Set

19200 kW. 60 Hz, 600 rpm

Gen Set Capacity:

Engine 1 = 19200 kW

Engine 2 = 19200 kW

Engine 3 = 19200 kW

Engine 4 = 19200 kW

Design Load Curve

70000
66589
64700
62578
60000 58900 58900 60000
55000 55759 55500
54000 Engine 4
50000 50500
45789
Load, kW

40000 40574 Engine 3 40400

35900 35200
30000
26700
Engine 2 25000 25789 Engine 2
20000 20500 20000 20500
17500
15575

10000 Engine 1 Engine 1

0

Time
1.3 Schedule of Operation:

12:00 AM – 6:00 AM: Start Engine 1, 2 and 3

7:00 AM – 9:00 AM: Stop Engine 1and start engine 4,

while 2, 3 is running

10:00 AM – 5:00 PM: Stop Engine 2 while 1 is not

running, 3 and 4 is running.

06:00 – 08:00 PM: Start all engines.

09:00 – 10:00 PM: Stop engines 4 and 3,and start

engine 1 and 2.

11:00 PM: 1 engine running

12:00 AM: 1 engine running

1.4 Daily Energy Produced:

Daily Energy Produced= ∑ area under the curve

(20500+20000)
a1 = (1 hr)=20250kW-hr
2

(20000+15575)
a2 = (1 hr)=17787.5 kW-hr
2

(15575+17500)
a3 = (1 hr)=16537.5 kW-hr
2
 (17500+20500)
a4 = (1 hr)=38000 kW-hr
2

(20500+25000)
a5 = (1 hr)=22750 kW-hr
2

(25700+25789)
a6 = (1 hr)=25394.5 kW-hr
2

(25789+35900)
a7 = (1 hr)=30844.5 kW-hr
2

(35900+40574)
a8 = (1 hr)=38237 kW-hr
2

(40574+45789)
a9 = (1 hr)=43181.5 kW-hr
2

(45789+50500)
a10 = (1 hr)=48144.5 kW-hr
2

(50500+55000)
a11 = (1 hr)=52750 kW-hr
2

(55000+58900)
a12 = (1 hr)=56950 kW-hr
2

(58900+55759)
a13 = (1 hr)=57329.5 kW-hr
2

(55759+55500)
a14 = (1 hr)=55629.5 kW-hr
2

(55500+54000)
a15 = (1 hr)=54750 kW-hr
2

(54000+58900)
a16 = (1 hr)=56450 kW-hr
2

(58900+60000)
a17 = (1 hr)=59450 kW-hr
2
 (60000+62578)
a18 = (1 hr)=61289 kW-hr
2

(62578+64700)
a19 = (1 hr)=63639 kW-hr
2

(64700+66589)
a20 = (1 hr)=65644.5 kW-hr
2

(66589+40400)
a21 = (1 hr)=53494.5 kW-hr
2

(40400+35200)
a22 = (1 hr)=37800 kW-hr
2

(35200+26700)
a23 = (1 hr)=30950 kW-hr
2

(26700+20500)
a24 = (1 hr)=23600 kW-hr
2

Daily Energy Produced= ∑ area under the curve

Daily Energy Produced=1,030,853 kW-hr

1.5 Design and Operating Conditions:

Engine Manufacturer: W16V46F Generator Set

Engine Model: W16V46F

Generator Rating: 19,200 kW

Installed Capacity:

Installed Capacity=(GenSet Rating)(Number of Units)

 Installed Capacity=(19,200 kW/unit)(4 units)

Installed Capacity=76,800 kW

1.6 Reserve Over Peak Load:

Reserve Over Peak=Plant Capacity-Peak Load

Reserve Over Peak=75,000 kW-66,589 kW

Reserve Over Peak=10,211 kW

1.7 Average Load:

daily energy produced

Average Load=
no. of hours

1030853 kW
Average Load=
24 hrs

Average Load=42, 952.21 kW

1.8 Load Factor:

Average Load
Load Factor=
Peak Load

42952.21 kW
Load Factor= x 100
66589 kW

Load Factor=64.50 %

1.9 Plant Capacity Factor:

Average Load
Plant Capacity Factor= x 100
Plant Capacity

42952.21 kW
Plant Capacity Factor= x 100
75000 kW
 Plant Capacity Factor=57.26 %

1.10 Areas Under the Curve for Each Engine (for Daily

Energy Produced)

a. For Engines 1 and 2:

Area for Engines 1 and 2 = ∑ area under the curve

AREAS KW-HRS ENERGY

(5500 + 5000)kW
A1 = (1hr) 5,250 kW-hrs
2

(5000 + 575)kW
A2 = (1hr) 2787.5 kW-hrs
2

(575 + 2500)kW
A3 = (1hr) 1537.5 kW-hrs
2

(2500 + 5500)kW
A4 = (1hr) 4000 kW-hrs
2

(5500 + 10000)kW
A5 = (1hr) 7750 kW-hrs
2

(10000 + 10789)kW
A6 = (1hr) 10394.5 kW-hrs
2

(10789 + 9100)kW
A7 = (1hr) 844.5 kW-hrs
2

(5500 + 10000)kW
A8 = (1hr) 7750 kW-hrs
2

(10000 + 13900)kW
A9 = (1hr) 11950 kW-hrs
2

(13900 + 10759)kW
A10 = (1hr) 12329.5 kW-hrs
2
 (10759 + 10500)kW
A11 = (1hr) 10629.5 kW-hrs
2

(10500 + 9000)kW
A12 = (1hr) 9750 kW-hrs
2

9000 + 13900)kW
A13 = (1hr) 11450 kW-hrs
2

(13900 + 15000)kW
A14 = (1hr) 14450 kW-hrs
2

(15000 + 17578)kW
A15 = (1hr) 16289 kW-hrs
2

(17578 + 19700)kW
A16 = (1hr) 18639 kW-hrs
2

(19700 + 21589)kW
A17 = (1hr) 20644.5 kW-hrs
2

(21589 + 4600)kW
A18 = (1hr) 8494.5 kW-hrs
2

(-3300 + 5500)kW
A19 = (1hr) 1100 kW-hrs
2
 Area for Engines 1 and 2 =189490(2) kW-hr
Area for Engines 1 and 2 =378, 980 kW-hr

b. For Engine 3:

Area for Engine 3 = ∑ area under the curve

AREAS KW-HRS ENERGY

(-34211 + 35900)kW
A1 = (1 hr) 844.5 kW-hrs
2

(35900 + 40574)kW
A2 = (1hr) 3,8237 kW-hrs
2

(40574 + 30789)kW
A3 = (1hr) 35,681.5 kW-hrs
2

(30789 + 65500)kW
A4 = (1hr) 48,144.5 kW-hrs
2
 (65500 + 55000)kW
A5 = (1hr) 60,250 kW-hrs
2

(55000 + 58900)kW
A6 = (1hr) 56,950 kW-hrs
2

(58900 + 55759)kW
A7 = (1hr) 57,329.5 kW-hrs
2

(55759 + 55500)kW
A8 = (1hr) 55,629.5kW-hrs
2

(55500 + 54000)kW
A9 = (1hr) 54,750 kW-hrs
2

(54000 + 58900)kW
A10 = (1hr) 56,450 kW-hrs
2

(58900 + 60000)kW
A11 = (1hr) 59,450 kW-hrs
2

(60000 + 62578)kW
A12 = (1hr) 61,289 kW-hrs
2

(62578 + 64700)kW
A13 = (1hr) 63,639 kW-hrs
2

(64700 + 66589)kW
A14 = (1hr) 65,644.5 kW-hrs
2

(66589 + 40400)kW
A15 = (1hr) 53,494.5kW-hrs
2

(40400 + 35200)kW
A16 = (1hr) 37,800 kW-hrs
2

(35200 - 18200)kW
A17 = (1hr) 8450 kW-hrs
2
 Area for Engine 3 = 784, 033.5 kW-hr

c. For Engine 4:

Area for Engine 4 = ∑ area under the curve

AREAS KW-HRS ENERGY

(-64211 + 80900 )kW

A1 = (1 hr) 8344.5 kW-hrs
2

(80900 + 85574)kW
A2 = (1hr) 83237 kW-hrs
2

(85574 + 75789)kW
A3 = (1hr) 80681.5 kW-hrs
2

(75789 + 20500)kW
A4 = (1hr) 48144.5 kW-hrs
2

(20500 + 10000)kW
A5 = (1hr) 15250 kW-hrs
2

(10000 + 13900)kW
A6 = (1hr) 11950 kW-hrs
2

(13900 + 10759)kW
A7 = (1hr) 12329.5 kW-hrs
2

(10759 + 10500)kW
A8 = (1hr) 10629.5 kW-hrs
2
 (10500 + 9000)kW
A9 = (1hr) 9750 kW-hrs
2

(9000 + 13900)kW
A10 = (1hr) 11450 kW-hrs
2

(13900 + 15000)kW
A11 = (1hr) 14450 kW-hrs
2

(15000 + 137578)kW
A12 = (1hr) 76289 kW-hrs
2

(137578 + 139700)kW
A13 = (1hr) 138639 kW-hrs
2

(139700 + 141589)kW
A14 = (1hr) 140644.5 kW-hrs
2

(141589 + 85400)kW
A15 = (1hr) 113494.5kW-hrs
2

(85400 + 80200)kW
A16 = (1hr) 82800 kW-hrs
2

(80200 + 11700)kW
A17 = (1hr) 45950 kW-hrs
2
 Area for Engine 4 = 836, 533.5 kW-hr

Total Daily Energy Produced by Five Engines = 3, 176, 882 kW-h

1.11 Use Factor for Each Engine

a. For Engine 1:

Engine Daily Energy Produced

E1 Use Factor= x 100
(Engine Capacity)(no. of hrs operation)

189490 kW-hr
E1 Use Factor= x 100
(150000 kW)(19 hrs)

Engine 1 Use Factor=66%

b. For Engine 2:

Engine Daily Energy Produced

E2 Use Factor= x 100
(Engine Capacity)(no. of hrs operation)

189490 kW-hr
E2 Use Factor= x 100
(150000 kW)(19 hrs)

Engine 2 Use Factor= 66 %

c. For Engine 3:

Engine Daily Energy Produced

E3 Use Factor= x 100
(Engine Capacity)(no. of hrs operation)

78403.5 kW-hr
E3 Use Factor= x 100
(15000 kW)(17 hrs)

Engine 3 Use Factor=30.7%

 d. For Engine

Engine Daily Energy Produced

4:E4 Use Factor= (Engine x 100
Capacity)(no. of hrs operation)

83853.5 kW-hr
E4 Use Factor= x 100
(15000 kW)(17 hrs)

Engine 4 Use Factor=32.68 %

1.12 Plant Use Factor:

Total Daily Energy Produced by Engines

P Use Factor= x 100
(Plant Capacity)(no. of hrs operation)

3176882 / 5 kW-hr
P Use Factor= x 100
(75000)(24 hrs)

Plant Use Factor= 7.3 %

 SUMMARY OF PLANT LOAD CALCULATION

Daily Energy Produced 1,030,853 kW-hrs

Installed Capacity 75,000 kW

Reserve Over Peak Load 8,411 kW

Average Load 42, 952.21kW

Load Factor 64.50 %

Plant Capacity Factor 57.26%

Plant Use Factor 35.29%

Use Factor of Each Engine

Use Factor of Engine 1 66%

Use Factor of Engine 2 66 %

Use Factor of Engine 3 30.7 %

Use Factor of Engine 4 32.68 %

 CHAPTER II

DESIGN OF MACHINE FOUNDATION

1.1. Generating Set Specification:

Manufacturer: Wartsila 47F

Generator Set Model: W16V46F Generator Set

Length of Engine and Generator: 12871 mm

Height of Engine and Generator: 4234 mm

Width of Engine and Generator: 4678 mm

Weight of Engine and Generator: 233 ton= 233,000 kg

1.2. Weight of Foundation:

From PSME Code, 2003 ed., Chapter 2, Sec. 4.0, Article

4.1 b
 “Foundation mass should be from 3 to 5 times the weight of

the machinery it is supposed to support.”

For safety design, use the average which is 4 times.

WF=4WM

Where:

WM= Weight of the Machine or Generator Set

WF=4(233 tons)

WF=932 tons

1.3. Upper Width and Length of Foundation:

Allow a clearance from the edge of about one foot or

about 10% of the length of the bedplate.

For the Width of the Foundation, a:

a = 4678 mm + 2(0.10 x 4678) mm

a = 5613 mm.

For the Length of the Foundation, L : F

LF = 12871 mm+2(0.10 x 12871mm)

LF = 15444.2 mm.

1.4. Lower Width of the Foundation:

𝑠𝑏 𝑊𝑀 +𝑊𝐹
=
2 𝑏𝐿𝐹
 From https://theconstructor.org/geotechnical/safe-

bearing-capacity-values-different-soils/35734/

Safe Bearing Power of Soils, S : b

Since the proposed location of the designer is near the

sea coast for adequate supply of water for cooling system,

considering the soil quality of the location of the Power

Plant facility to be designed:

S = 245 tons/m (sandy gravel mixture, dry state)

b 2

𝟐 𝑾𝑴+ 𝑾𝑭
b= 𝑺𝒃 𝑳𝒇

Where:

Sb= Safe bearing power of soil

WM = Weight of the machine

WF = Weight of the foundation

LF = Length of the foundation

𝟐 (𝟐𝟑𝟑 𝒕𝒐𝒏𝒔+ 𝟗𝟑𝟐 𝒕𝒐𝒏𝒔)

b= 𝟐𝟒𝟓𝒕𝒐𝒏𝒔/𝒎𝟐(𝟏𝟓.𝟒𝟒 𝒎) b=615.95mm

Since the lower width “b” come out to be less than the

upper width “a”, it is customary to make “b” equal to “a”,

that is the foundation has rectangular cross-section.

Therefore,
b=616 mm.

1.5. Volume of Foundation:

𝑊𝐹
VF = 𝑃𝐹

Where:

WF = Weight of the foundation

PF = Density of the concrete, 2406 kg/m 3

932000kg
VF = 2406𝑘𝑔/𝑚3

VF = 387.37 m3

1.6. Height of the Foundation:

𝑉𝐹
h = 𝐿𝐹 𝑥 𝑎

Where:

VF = Volume of the foundation

LF = Length of the foundation

a = Width of the Foundation

387.37
h = h = 4.47m.
15.44,𝑥 5.613

1.7. Area of Foundation:

AF=LF x W

Where:

LF = Length of the foundation

 W = width of the foundation

AF=15.44 m. x 5.613 m.

AF=86.66m2

1.8. Net Weight Imposed by Machine and Foundation in Soil:

Wnet=WM+ WF

Wnet=233 tons+ 932 tons

Wnet=1165 tons

1.9. Stress Imposed by the Machine and Foundation in Soil:

𝑊𝑛𝑒𝑡
Si =
𝐴𝐹

1165 𝑡𝑜𝑛
Si =
86.66 𝑚2

Si =13.44 ton/m2

1.10. Foundation Factor of Safety:

𝑆𝑏
FS =
2𝑆𝑖

Where:

Sb = Safe soil bearing capacity

Si = Stress imposed by machine and foundation on

soil

245ton/𝑚2
FS = FS= 9.11
2(13.44 ton/𝑚2 )
Based on the computation, the foundation is safe since its factor

of safety exceeds the allowable factor of safety discussed in

PSME code, 2003 Edition, Chapter 2, Section 4.0, Article 4.1

which is 5.

2. FOUNDATION MATERIAL CALCULATION

2.1. Material Data:

2.2. Computed Dimensions of Foundation:

Foundation Geometric Figure = Rectangle

Length of Foundation = 15.44 m.

Width of Foundation = 5.613 m.

Height of Foundation = 4.47 m.

Volume of Foundation = 387.37 m. 3

Area of Foundation = 86.66m2

Determine the Amount of Cement, Sand and Stone in the Foundation:

From PSME Code, 2003 Edition, page 12, Section 4.2:

 The foundation should be concrete, of 1 part cement, 2

parts sand and 4 parts broken stone or gravel (maximum of 50 mm;

the entire foundation should be poured at one time, with no

interruption than are required for spading and ramming.

Table 4-1: DATA ON CONCRETE MIXES TO YIELD 1 CU. M. CONCRETE

(from Power Plant Engineering by Frederick T. Morse, p.90)

Mixtur Cement Sand Stone Applicati Weight Safe Densit

e , , , on , Comp. y,

Sacks m 3 m3 t/m3 Stress Kg/m 3

, t/m 2

1:2:4 7.8 0.44 0.88 Foundatio 2.66 328.10 2.406

ns

2.3. Number of Cement Sacks:

NSC=VF x 7.8 sacks/m3

Where:

VF = Volume of foundation = 159.6 m 3

NSC=387.37 x 7.8 sacks/m3

NSC=3021 sacks
Say use, NSC=3025 sacks/foundation

NSC=3021 sacks(4+1 reserve)

NSC=15105 sacks

2.4. Volume of Sand:

VS=VF x 0.44 m3 sand/m3 concrete

 VS=387.37 m3 x 0.44 m3 sand/m3 concrete

VS=170.44 m3

VS=170 m3/foundation

VS=170 m3(4+1 reserve)

VS=850 m3

2.5. Volume of Stone:

VST=VF x 0.88 m3 sand/m3 concrete

VST=387.37 m3 x 0.88 m3 sand/m3 concrete
VST=340.88 m3
VST=341 m3/foundation
VST=341 m3 (4+1 reserve)
VST=1705 m3

2.6. Quantity of Plywood to be used as Foundation Form

At Mirola Construction Supply, the standard dimension of

plywood available is 4’ x 8’. The actual price per piece is Php

590.00

1. For the Surface Area of the Machine Foundation where the

Plywood would serve as the Guide of Foundation:

SAmf=2b x h+2(h x LF)

SAmf=2(5.613 m x 4.47 m)+2(4.47 +15.44 m)

SAmf=90 m2=968.75ft2

b. For the Number of Plywood to be used as Foundation Guide:

 𝑆𝐴𝑚𝑓
NPW= 𝑓𝑡2
(4𝑥8)
𝑝𝑐

968.75𝑓𝑡 2
NPW= 𝑓𝑡2
(4𝑥8)
𝑝𝑐

NPW= 30 pc

c. For Cutting Loss: Additional 10% as allowance

NPW'= 30 pcs x 1.1

𝑝𝑐𝑠
NPW= 33 (4+1Reserve)
𝑓𝑜𝑢𝑛𝑑𝑎𝑡𝑖𝑜𝑛

𝑝𝑐𝑠
NPW= 33 (4+1Reserve)
𝑓𝑜𝑢𝑛𝑑𝑎𝑡𝑖𝑜𝑛

NPW = 165 pc

2.7. Quantity of Reinforced Lumbers

a. For Scaffoldings use: 2” × 3” × 12’

From Architectural and Construction Data by G. Salvan and

S. Thapa, p. 657

“To get the board feet of 2”3” of lumber, multiply the total

area of plywood in 60%”

Thus,

Total board feet of 2”×3” lumber=( 968.75ft.)(0.6)

Total board feet of 2”×3” lumber=581.25ft2

Therefore, the quantity of 2” ×3” × 12′ lumber, 𝑁𝐿𝑅𝑇 required:

581.25 ft2
NLRT =
6board feet/pcs

NLRT =96.875 pcs x (4+1 reserve)=388.5 ~ 389pcs

2.8. Quantity of Nails

a. For Plywood

𝑡𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑙𝑦𝑤𝑜𝑜𝑑

No. of kegs of 2"C.W. nails= 2303

Where:

1 keg = 45.5 kg. of nails

90𝑚2
No. of kegs of 2"C.W. nails= 2303

No. of kegs of 2"C.W. nails=0.0391 kegs

45.5 𝑘𝑔
Quantity of 2" Nails for Plywood=0.0391 kegs× 1𝑘𝑒𝑔

2" Nails for Plywood=1.78 kg. x (4+1 res)=8.85 kgs

b. For Lumber No. of kegs of 4"C.W. nails=Total

board foot of Lumber2800
Where: 1 keg = 45.5 kg. of nails

968.75𝑓𝑡 2
No. of kegs of 4"C.W. nails= 2800

No. of kegs of 4"C.W. nails=0.346 kegs

 45.5kgs
Quantity of 4" Nails for Lumber=0.346 kegs× 1kegs

4" Nails for Lumber=16kg. x (4+1 res)=80kgs.

b. For Lumber No. of kegs of 4"C.W. nails=Total board

foot of Lumber2800

Where: 1 keg = 45.5 kg. of nails

No. of kegs of 4"C.W. nails=968.75ft2/2800

No. of kegs of 4"C.W. nails=0.346 kegs

45.5kgs
Quantity of 4" Nails for Lumber=0.346 kegs× 1kegs

4" Nails for Lumber=16 kg. x (4+1 res)=80kgs.

2.9 Steel Bar Reinforcement:

a. Weight of the Steel Bar Reinforcements:

From PSME Code, 2003 Edition, p.11, Sec. 4.0, Art. F:

“Concrete foundations should have steel bar reinforcements

placed both vertically and horizontally, to avoid thermal

cracking. Weight of reinforcing steel should be from 0.5% to 1%

of the weight of the foundation.”

For safety design, use the average which is 0.75%.

WSBR = 0.75%WF
WSBR = 0.75%(233000 kg)
WSBR = 1747.5 kg
b. Volume of the Steel Bar Reinforcements:
 From Kent’s Mechanical Engineering Handbook, Power Volume,

Page 6-02, the density of structural steel is equal to 490

lb./ft .
3

VSBR = Weight of steel bar reinforcementDensity of steel

1747.5kg x 2.2ln/kg
VSBR = 490lb/𝑓𝑡 3

VSBR = 7.86 ft3 =0.73 m3

c. Volume of the Steel Bar Reinforcements per Piece:

Say use, Standard size of steel bar reinforcements with

standard diameter equal to 16 mm and length of 6 m.

πDb 2 Lb
VRPP =
4

Where:

Db = diameter of steel bar

Lb = length of steel bar

π(0.016m)2 (6m)
VRPP = =0.001206 m3 /pc
4

d. Total Number of Steel Bar Reinforcements:

Volume of steel bar reinforcements

TSBR =
volume of steel bar reinforcements per piece

0.73 m3
TSBR = 3
0.001206 m ⁄piece
 TSBR = 605.31

Say use, TSBR = 605 (4+1 reserve)

TSBR = 3025 pcs

2.10 Quantity of Tire Wire (G.I wire)

Assume that the weight of the GI wire to be used in the

foundation is approximately 2% of the weight of steel bars in

foundation. (Construction estimate)

a. Weight of GI Wire to be used in the Foundation, WGI:

WGI =2% WSBR

WGI =2%(1747.5 kg)

WGI =349.5 kg

For Cutting loss, add another 10% allowance:

WGI' =(349.5 kg x 4+1) x 1.1

WGI' =1538.5 kg

WGI' =1539 kgs

2.11. Anchor Bolts

a. Selection of Anchor Bolts:

From PSME Code, 2003 Edition, page 13, Section 4.2,

Article F:

“To prevent pulling out of the bolts when the nuts are

tightened, the length embedded in concrete shall be equal to or

more than thirty (30) times the bolt diameter. The upper ends

shall be surrounded by a 50 mm or 75 mm sheet metal pipe, 460

mm to 610 mm long to permit them to be bent slightly to fit the

holes of the plate.”

Dimensions:

D x L x C x T

For specification of anchor bolts:

From PSME Code 1984, Chapter 2, Statement 2.4.1.7

“Foundation bolts of specified size should be used and

surrounded by a pipe sleeve with an inside diameter of at

least three (3) times the diameter of the anchor bolt and a

length of at least 18 times the diameter of the bolt. No

foundation bolts shall be less than 12 mm diameter.”

b. Diameter of anchor bolts:

For the availability of size in the market say use and to fit

with the statement above,

3
DAB = inch = 19.05 mm
4

c. Length of anchor bolt imbedded in concrete:

Since the standard lengths of a 100 mm. anchor bolt that

suits the statement in the PSME Code, 2003 edition stating “the
length embedded in concrete shall be equal to or more than thirty

(30) times the bolt diameter”.

Therefore:

LIB =(30)(19.05 mm)

LIB =571.5 mm.=22.5 in.

For the availability in the market and considering the

Length of the bolt, from catalog of All America Threaded

Products:

Say Use, LIB =24 in.

Other dimensions of the selected anchor bolt:

SKU: 45200

Thread Length: 4 inches

Hook Length: 3 inches

d. Foundation Bolt Length, T:

The foundation bolt length should be at least 18 times the

diameter of the anchor bolt. The designer assumes 18 times the

diameter.

Therefore,

T = (18)(19.05 mm)

T = 342.9 mm = 13.5 in or 14 inch (for availability)

e. Quantity of Bolts, BQ:

Assuming that there are 2 bolts per meter of the bedplate.

 BQ = 2(W + L) x 2 pcs/m

Where:

W = width of bedplate

L = length of bedplate

BQ = 2(3.06 m + 10.075 m) x 2 pcs/m

BQ = 52.54 pcs/bedplate

BQ = 53 pcs(4+1 reserve)=265 pcs

2.12. Bill of Materials

QTY UNIT DESCRIPTION UNIT TOTAL COST

COST (PHP)
(PHP)
15105 Sack portland Cement (Home & 250.00 PHP
More Hardware and General 3,776,250
Merchandise)
850 𝑚3 Sand (Sunrise Sand, 550.00 PHP467,500
Gravel and Hollow Blocks)
1705 𝑚3 Stone (Sunrise Sand, 900.00 PHP.
Gravel and Hollow Blocks) 1,534,500
165 pcs Plywood (Mirola 590.00 PHP.
Construction Supply) 97,350
389 pcs Lumber 2”X3”X12” (Mirola 70.00 PHP.
Hardware) 27,230
9 kg Nails 2” Cement (Home & 70.00 PHP.
More Hardware and General 630
Merchandise)
80 kg Nails 4” Cement (Home & 80.00 PHP.
More Hardware and General 6,400
Merchandise)
 3025 pcs Steel Bar 16mm x 6m (Home 105.00 PHP.
& More Hardware and 317,625
General Merchandise)
1539 kg G.I Wire #16 (Home & More 52.00 PHP.
Hardware and General 80,028
Merchandise)
265 pcs Anchor Bolts (Unisorb) 976.00 PHP.
258,640
Total Material Cost PHP.
6,408,143
Labor Cost (30% Of Material Cost) PHP.
873,088.20
TOTAL COST PHP.
7,281,231.1

CHAPTER III

FUEL SYSTEM and its Auxiliaries

1. DESIGN OF FUEL OIL STORAGE TANK

1.1 DESIGN AND OPERATING CONDITION

From Wartsila 46F Product Guide (2020)

Diesel Fuel Designation

MDF (ISO-F-DMA)

Density @ 15 °C 890 kg/m3

Brake Power 26110 kWm

Specific Fuel Consumption @

182.5 g/kW-hr
100% Load
Temperature at which fuel
45 °C
is consumed

1.2 DESIGN CONSIDERATIONS:

1. The fuel storage tank is designed to supply fuel on the engine

good for (3) three months operation with one provided for each

engine.
 2. Due to unexpected problem on delivery or any unexpected delay,

the designer decided to add a 25% contingency. This would

guarantee about 22 days of reserve in case of failure on

delivery.

3. The designer decided to put a cylindrical diesel fuel oil storage

tank vertically seated above the ground considering the

advantage in terms of maintenance. The dimension is assumed to

be H = 2d.

4. Corrosion allowance is constructing the vessels with thicker

walls to allow for the thinning. The Peters, Timmerhaus, and

West suggest 0.25 to 0.38 mm annually. Use an average corrosion

allowance of 0.315 mm.

5. The type of steel to be used is Carbon Steel (A285, Gr. A) with

a tensile stress value of 310 MPa. To provide air space and other

auxiliaries to the storage tank the designer should add an

allowance of 0.75 meter to the computed height.

1.3 FUEL CONSUMPTION

mf
mb =
Brake Power

mf =(mb )(Brake Power)

182.5 g
mf =( ) (26110 kW)
kW-hr

mf =4.765,075 g/hr

mf =4,765.1 kg/hr

DENSITY OF FUEL

ρ@ 15.6
ρf =
1+0.0007(t-15.6)

ρ@ 15.6 =ρ15°C
[1+0.0007(t-15.6)]

ρ@ 15.6 =(890)
[1+0.0007(15-15.6)]
 ρ@ 15.6 =889.63 kg/m3

For the density of fuel at 45°C

ρ@ 15.6
ρf =
1+0.0007(t-15.6)

889.63
ρf =
1+0.0007(45-15.6)

ρf =871.69 kg/m3

1.5 VOLUME FLOW OF FUEL, Vfi

mf 4,765.1 kg/hr
VF = =
pf 871.69 kg/m3

VF =5.47 m3 /hr

For three months volume of fuel:

24 hr 30 days
VF =5.47 m3 /hr ( )( ) (3 months)
1 day 1 month

VF =3218.4 m3

1.6 VOLUME OF FUEL OIL STORAGE TANK, 𝑉𝐹𝑂𝑆𝑇

Since the contingencies are set to 25% of the fuel consumption

per month,

Therefore:

VFOST = Vf + 0.25Vf

VFOST = 1.25Vf

VFOST = 1.25(3218.4 m3 )

VFOST =4023 m3

1.7 DIMENSION OF FUEL OIL STORAGE TANK

1.7.1 Diameter of Fuel Oil Storage Tank, d

 The volume of the tank is equal to the volume of cylinder
π 2
VFOST = d H Since: H=2d
4

Thus,
π 2
VFOST = d x 2d
4

π 3
VFOST = d
2

3 (2)(V
FOST )
d =√
π

3 (2)(4023 m3 )
d =√
π

d = 13.68 m.

1.7.2 Height of Diesel Fuel Storage Tank, H

H = 2d + allowance

H = 2(13.68 m) + 0.75 m

H = 28.13 m

1.7.3 Thickness Diesel Fuel Storage Tank, t

From Plant Design and Economics for Chemical Engineers 5th ed.

By Peters, M.S. and K.D. Timmerhaus, Page 554

Pri
t=
SEJ -0.6P
Where:
P = maximum allowable internal pressure, kPa

ri = inside radius of the shell, before corrosion

allowance is added, mm
S = maximum allowable working stress, kPa

EJ = efficiency of joints
a. Internal Pressure, P

Pi =δf H

Where:

δf = specific weight of fuel

δf = SGf x δw

= 0.828 x 9.81 kN/m3 = 8.12 kN/m3

H = height of storage tank

H = 26.89 m.

Substituting:

P=(8.12 kN⁄m3 )(28.13 m)

P=228.42 kPa

Pi =Pg +Patm

Pi =(228.42 kPa)+(101.325 kPa)

Pi =329.75 kPa

b. Inside Radius, r

d
r =
2
13.68 m
r=
2

r= 6.84 m.

c. Welding Joint Efficiency, EJ

From PSME Code, page 147, the efficiency of doubled but weld

for fusion weld joints is 70%.

Single Lap Weld 40%

Double Lap Weld 60%
Single Butt Weld 50%
 Double Butt Weld 70%
Forged Weld 70%
Brazed Weld 80%

d. Maximum Allowable Working Stress

From Steel Plates Catalog by NIPPON Steel Corporation,

p.52

Carbon Steel for Boilers and Pressure Vessels

yield Strength ASTM Standard

165 N/mm2 A285 Gr. A

Therefore,

Pri
t=
SEJ -0.6P

(329.75 kPa)(6840 mm.)

t=
(310,000 kPa)(0.70)-0.6(228.42 kPa)

t=19.55mm.

Adding a corrosion allowance of 0.315 mm:

t = 19.55 mm. + 0.315 mm.

t = 19.866mm.

From Steel Plates Catalog by NIPPON Steel Corporation, p.18,

use available size of carbon steel plate closer to the value, which

is:

t = 24mm

1.8.1. Total Surface Area of the Storage Tank:

π 2
SAST = 2 d + πdh
4

Where:

d= Diameter of the Storage Tank

h = Height of the Storage Tank

 π
SAST =2( (13.68 m)2 + π(13.68 m)(28.13 ))
4

SAST = 1502.91 m2

1.8.2. Quantity of Steel Plate, QSPS:

SAST
QSPS =
Size of Steel Plate

From Steel Plates Catalog by NIPPON Steel Corporation, p.18,

use the widest and longest size available for carbon steel plate in

10 mm thickness:

Thickness: 10 mm.

Width x Height: 4200 mm x 25000 mm

1502.91 m2
QSPS =
(4.2 m x 25 m)

QSPS = 14.31 pcs x 4 tanks

QSPS = 57.24 or 57 Steel Plates for four (4) storage tanks

1.9 SPECIFICATION OF DIESEL FUEL OIL STORAGE TANK

DIESEL FUEL OIL STORAGE TANK

Shape of Tank Cylinder

Vertical above
Installation
ground

Number of Tanks 4

Holding Capacity
4023m3

Diameter 13,680mm

Height 28,130

Thickness 24mm
 Steel Plate
57 pcs (4.2m x 25m)
Quantity

Tank Material Carbon Steel (A285,

Gr. A)

2. DESIGN OF FUEL OIL DAY TANK

2.1 DESIGN AND OPERATING CONDITIONS:

From Previous Computations:

Volume Flow of Fuel, Vf 5.87 m3 /hr

Density of Fuel 889.63 kg/m3 (8.727 kN/m3 )

2.2 DESIGN CONSIDERATIONS:

1. The plant will have one day tank for each engine and this will

store diesel fuel oil for (8) eight hours of operation.

2. The designer choses a cylindrical diesel fuel oil day tank

vertically seated above the ground considering the advantage in

terms of maintenance. The dimension is assumed to be H = 2d.

3. Add a corrosion allowance of 0.315 mm for the thickness of the

tank. The type of steel to be used will be Carbon Steel (A285,

Gr. A) with a tensile stress value of 310 MPa.

 4. The designer decided to add an allowance of 0.25 m to the

calculated height of the tank to provide air space.

2.3 VOLUME OF DAY TANK, VFODT

VFODT = Vf (8 hrs)

VFODT =(5.47 m3 /hr)(8 hrs)

VFODT =43.76 m3

2.4 DIMENSIONS OF FUEL OIL DAY TANK

2.4.1 Diameter of Fuel Oil Day Tank, d

The volume of the tank is equal to the volume of cylinder

π 2
VFODT = d H Since: H=2d
4

Thus,
π 2
VFODT = d x 2d
4

π 3
VFODT = d
2

3 (2)(V
FODT )
d = √
π

3 (2)(43.76 m3 )
d = √
π

𝒅 = 𝟑. 𝟏 𝐦.

2.4.2 Height of Diesel Fuel Day Tank, H

 H = 2d + allowance

H = 2(3.1 m) + 0.25 m

H = 6.45 m

2.4.3 Thickness Diesel Fuel Day Tank, t

From Plant Design and Economics for Chemical Engineers 5th ed.

By Peters, M.S. and K.D. Timmerhaus, p. 554

Pri
t=
SEJ -0.6P
Where:
P = maximum allowable internal pressure, kPa

ri = inside radius of the shell, before corrosion

allowance is added, mm
S = maximum allowable working stress, kPa

EJ = efficiency of joints
a. Internal Pressure, P

P=δf H

Where:

δf = specific weight of fuel

δf = SGf x δw

= 0.828 x 9.81 kN/m3 = 8.12 kN/m3

H = height of storage tank

H = 6.45 m.

Substituting:

P=(8.12 kN⁄m3 )(6.45 m)

P=52.374 kPa

Pi =Pg +Patm
 Pi =(52.374 kPa)+(101.325 kPa)

Pi =153.699 kPa

b. Inside Radius, r

d 3.1 m
r = =
2 2

r= 1.55 m.

c. Welding Joint Efficiency, E J

From PSME Code, page 147, the efficiency of doubled but weld

for fusion weld joints is 70%.

Single Lap Weld 40%

Double Lap Weld 60%
Single Butt Weld 50%
Double Butt Weld 70%
Forged Weld 70%
Brazed Weld 80%
d. Maximum Allowable Working Stress

From Steel Plates Catalog by NIPPON Steel Carbon Steel for

Boilers and Pressure Vessels

yield Strength ASTM Standard

165 MPa A285 Gr. A

Therefore,

Pri
t=
SEJ -0.6P
(153.669 kPa)(1550 mm.)
t=
(165,000 kPa)(0.70)-0.6(52.439 kPa)

t=2.06 mm.
Adding a corrosion allowance of 0.315 mm:

t = 2.06 mm + 0.315 mm

t = 2.38 mm

From Nippon Steel Corporation use available size of carbon

steel plate closer to the value, which is:

 t = 6 mm

2.5.1 Total Surface Area of the Day Tank:

π 2
SADT = d + πdh
4
π
SADT = ( (3.1 m)2 + π(3.1 m)(6.45 m))
4

SADT = 77.91m2

2.5.2 Quantity of Steel Plate, QSPD:

SAST
QSPD =
Size of Steel Plate

From Steel Plates Catalog by NIPPON Steel Corporation, p.18,

use the size available for carbon steel plate in 6 mm thickness:

Thickness: 6 mm.

Width x Height: 1400 mm x 25000 mm

77.91 m2
QSPD =
(1.4 m x 25 m)

QSPD = 2.226 pc x 4 tanks

QSPD = 8.904 or 9 Steel Plates for four (4) day tanks

2.6 SPECIFICATION OF DIESEL FUEL OIL DAY TANK

FUEL OIL DAY TANK

Shape of Tank Cylinder

Vertical above
Installation
ground

Number of Tanks 4

Holding Capacity
46.96 m3

Diameter 3,100 mm
 Height 6,450 mm

Thickness 6 mm

Steel Plate
9 pcs (1.4m x 25m)
Quantity

Tank Material Carbon Steel (A285,

Gr. A)

3. DESIGN OF RETURN FUEL TANK

3.1 DESIGN AND OPERATING CONDITIONS:

From Wartsila 34DF Product Guide (2020):

Return Fuel Tank Capacity 100 Li(min.)

From Previous Computations:

Diameter of Day Tank 3.100 m

Height of Day Tank 6.450 m

Thickness of Day Tank 6 mm

3.2 DESIGN CONSIDERATIONS:

As to the dimensions of return fuel tank, the designer decided

to have a diameter and height of about one-fourth the diameter and

height of the diesel fuel day tank. And for the thickness, it is equal

to the thickness of diesel fuel day tank. The type of steel to be used

will be the same as the Day Tank: Carbon Steel (A285, Gr. A) with a

tensile stress value of 310 MPa.

3.3 DIMENSIONS OF RETURN FUEL TANK

3.3.1 Diameter of Return Fuel Tank, d

1
d = 4 (3.100 m)

d = 0.775 m

3.3.2 Height of Return Fuel Tank, H

1
H = 4 (6.450 m)

H = 1.6125 m

3.3.3 Thickness of Leak Fuel Tank, t

t = 6 mm

3.4 VOLUME OF RETURN FUEL TANK, VRFT

π 2
VRFT = d H
4
π
VRFT = (0.776)2 (1.6145)
4

VRFT = 0.761 m3 =764 Li>100 Li (from 46f Product Guide)

3.5.1 Total Surface Area of the Return Fuel Tank:

π 2
SADT = d + πdh
4
π
SADT = 2( (0.775 m)2 + π(0.775 m)(1.6145m)
4

SADT = 4.87 m2 3.5.2 Quantity of Steel Plate, QSPD:

SAST
QSPD =
Size of Steel Plate

From Steel Plates Catalog by NIPPON Steel Corporation, p.18,

use the size available for carbon steel plate in 6 mm thickness:

Thickness: 6 mm.

Width x Height: 1400 mm x 25000 mm

 4.87 m2
QSPD =
(1.4 m x 25 m)

QSPD = 0.14 pcs x 4 tanks

QSPD = 0.6 or 1 Steel Plate for four (4) return tanks

3.6 SPECIFICATION OF RETURN FUEL TANK

RETURN FUEL TANK

Shape of Tank Cylinder

Installation Vertical above ground

Number of Tanks 4

Holding Capacity 0.764 m3

Diameter 775 mm

Height 1612.5 mm

Thickness 6 mm

Steel Plate Quantity 1 pc (1.4m x 25m)

Tank Material Carbon Steel (SA-285, Gr.

D)

CHAPTER IV

SYSTEM BALANCE OF THE PLANT

1. MASS AND HEAT BALANCE

1.1 DESIGN AND OPERATING CONDITION:

From Wartsila 46F Product Guide (2020), Heat Balance at

100% Load:

Heat Loss to Jacket Water, HT Circuit 2432 kW

Heat Loss to Lube Oil 1952 kW

Heat Loss to Charge Air Cooler, HT Circuit 4144 kW

Heat Loss to Charge Air Cooler, LT Circuit 2016 kW

Radiation 560 kW

1.1 MASS FLOW RATE OF JACKET WATER (LT AND HT CIRCUIT)

From Wartsila Genset Catalogue:

qHT = 280 m3 /hr

 m3 1000 kg 1 hr
mwh = 280 x x
hr m3 3600 sec

mwh = 77.78 kg/sec

qLT = 280 m3 /hr

m3 1000 kg 1 hr
mwt = 280 x x
hr m3 3600 sec

mwh = 77.78 kg/sec

1.2 TOTAL FLOW RATE OF JACKET WATER

From Wartsila Genset Catalogue:

3.6 ∅
qtotal = qLT +
4.15 (Tout - Tin )

where: qtotal = LT pump capacity m3 /hr

∅ = heat dissipated to HT water, kW

Tout = HT water temp. after engine, 105°C

Tin = HT water temp. after cooler, 85°C

3.6(2432 kW)
qtotal =280+
4.15 (105°C-85°C)

qtotal =385.48 m3 /hr

1.3 TOTAL MASS FLOW RATE OF JACKET WATER

m3 1000 kg 1 hr
mtotal = 385.48 x 3
x
hr m 3600 sec
 mtotal = 107.1 kg/sec

1.4 TEMPERATURE ENTERING THE LT CHARGE AIR COOLER

From Wartsila Genset Catalogue:

QLT =2016 kW

Temp. before LT Cooler = 38°C

Heat Balance:

QLT =mw Cpw (38-t)

QLT
t = 38°C-
mw Cpw

kJ
2016 sec
t = 38°C- kg kJ
77.78 sec x 4.187
kg-°C

t = 31.81 °C

1.5 TEMPERATURE ENTERING THE LUBE OIL COOLER

From Wartsila Genset Catalogue:

QLOC =1952 kW

Heat Balance:

QLOC =mw Cpw (32.3-t)

QLT
t = 33.47°C-
mw Cpw
 kJ
1952 sec
t = 33.47°C- kg kJ
77.78 sec x 4.187
kg-°C

t = 27.48 °C

1.6 CENTRAL COOLER/JACKET WATER HEAT EXCHANGER CAPACITY

QCC =mtotal Cpw (85-28.65)

kg kJ
QCC =107.1 x 4.187 (85-28.65)°C
sec kg- °C

QCC =25,268.9 kW

CHAPTER V

COOLING SYSTEM

1. DESIGN OF LUBE OIL HEAT EXCHANGER

1.1 DESIGN AND OPERATING CONDITION:

From Wartsila 46DF Genset Catalogue:

 Heat Loss to Lube Oil 1952 kW

Lube Oil Inlet Diameter 202 mm

Temperature of Lube Oil

Entering the Heat Exchanger 75 °C

Leaving the Heat Exchanger 56 °C

Temperature of Cooling Water

Entering the Heat Exchanger 26.83 °C

Leaving the Heat Exchanger 32.3 °C

1.2 OVER ALL COEFFICIENT OF HEAT TRANSFER

Table 1. Approximate Values for Over All Coefficient of

Heat Transfer (including allowance for fouling)

Fluid UO, W/m2 K

Oil - Water 425

(From Kutz Mechanical Engineers Handbook, pg.304)

1.3 LOGARITHMIC MEAN TEMPERATURE DIFFERENCE

 θmax-θmin
LMTD = θmax
ln
θmin

(75-32.3)-(56-26.83)
LMTD = (75-32.3)
ln (56-26.83)

LMTD = 35.5 °C

1.4 SURFACE AREA OF HEAT TRANSFER

QL =(Ao )(Uo )(LMTD)

Q
Ao =
U(LMTD)

732000 W
Ao = W
425 x (35.5 +273)K
m2 K

Ao =5.582 m2

1.5 SELECTION OF HEAT EXCHANGER

 The lightweight and compact construction of plate type

heat exchanger reduces the required installation space and the

weight to 1/4 and 1/3 of a shell and tube type heat exchanger.

In addition, a plate type can be disassembled for cleaning

without isolating from main line, while the shell and tube

requires an additional space for removal of the tubes.

Therefore, the designers decided to use a plate type heat

exchanger rather than the shell and tube type.

From HISAKA PHE Catalogue:

Guide in Selecting the PHE Series

Hot Temp. In-Hot Temp. Out

NTU =
LMTD

LX Series are used in application where low NTU is

required, while SX Series are best suited for high NTU

application. NTU of 1.5 or less is generally referred to as

low NTU, and 3.0 and above is considered as high NTU.

 75-56
NTU =
5.598

𝐍𝐓𝐔 = 𝟑. 𝟑𝟗𝟒 (𝐒𝐗 𝐒𝐞𝐫𝐢𝐞𝐬)

Since the Lube Oil Inlet has a diameter of 202 mm, select

the Model SX-40 plate heat exchanger which is suitable for the

design.

1.5.1 NUMBER OF PLATES

Heating Surface Area

No. of Plates =
Heating Surface Area per plate

Where:

Heating Surface Area per plate for SX-40=(2.166 x 0.805) m2

Heating Surface Area per plate for SX-40=1.744 m2

5.598 m2
No. of Plates =
1.744 m2

No. of Plates=3.21 or 4 plates

1.5.2 PLATE HEAT EXCHANGER DIMENSION

NP Type Frame

Height = 2166 mm
 Width = 805 mm

Length = 913 – 3113 mm

Heat Transfer Area = 60 𝑚2 − 500 𝑚2

Connection Diameter = 200 mm

2. DESIGN OF CENTRAL COOLER

2.1 DESIGN AND OPERATING CONDITION:

From Previous Computation:

Temperature of Jacket Water

Entering the Heat Exchanger 75 °C

 Leaving the Heat Exchanger 26.83 °C

The economic cooling range of the cooling tower is 10 oF to

20 oF. Assuming cooling tower outlet of 26 oC. (From PPE by

Morse, p.183)

CTR = two – twi

Where:

CTR = Cooling tower range

two = Cooling tower water outlet

twi = Cooling tower inlet

Taking the average cooling tower range which is 10 °F (5.56

°C )

twi = two +CTR

twi = 26+5.56

twi = 31.56 ℃

Thus, the temperatures of Cooling Water are,

Entering the Heat Exchanger 26°C

Leaving the Heat Exchanger 31.56 °C

2.2 OVERALL COEFFICIENT OF HEAT TRANSFER

From Kutz Mechanical Engineers Handbook, p.304.

Approximate Values for Over All Coefficient of Heat Transfer

(including allowance for fouling)

 Fluid UO, W/m2 K

Water - Water 1,400

2.3 LOGARITHMIC MEAN TEMPERATURE DIFFERENCE

θmax-θmin
LMTD = θmax
ln θmin

(75-32..3)-(26.83-26)
LMTD =
(75-32.3)
ln (26.83-26)

LMTD = 10.625 °C

2.4 SURFACE AREA OF HEAT TRANSFER

QL =(Ao )(Uo )(LMTD)

Q
Ao =
U(LMTD)

8,593,260 W
Ao = W
1400 x (10.625 +273)K
m2 K
 Ao =21.64 m2

2.5 SELECTION OF HEAT EXCHANGER

The lightweight and compact construction of plate type

heat exchanger reduces the required installation space and the

weight to 1/4 and 1/3 of a shell and tube type heat exchanger.

In addition, a plate type can be disassembled for cleaning

without isolating from main line, while the shell and tube

requires an additional space for removal of the tubes.

Therefore, the designers decided to use a plate type heat

exchanger rather than the shell and tube type.

From HISAKA PHE Catalogue:

Since the Cooling Tower Outlet has a diameter of 200 mm

we select the Model SX – 40 plate heat exchanger which is

suitable for the design.

2.5.1 NUMBER OF PLATES

Heating Surface Area

No. of Plates =
Heating Surface Area per plate

Where:

Heating Surface Area per plate for SX-40=(2.166 x 0.805) m2

Heating Surface Area per plate for SX-40=1.744 m2

21.64 m2
No. of Plates =
1.744 m2

No. of Plates=12.41 or 13 plates

2.5.2 PLATE HEAT EXCHANGER DIMENSION

NP Type Frame

Height = 2166 mm

Width = 805 mm

Length = 913 – 3113 mm

Heat Transfer Area = 60 m2 - 500 m2

Connection Diameter = 200 mm

3. DESIGN OF EXPANSION TANK

3.1 DESIGN AND OPERATING CONDITION:

From Wartsila Catalogue:

Water Volume in the Engine 2.6 m3

Volume in Expansion Tank 10% of Water Volume

3.1.1 DESIGN CONSIDERATION

1. The designer decided to put a cylindrical expansion tank

vertically seated above the ground. The dimension is assumed

to be 𝐻 = 2𝑑

2. Corrosion allowance is constructing the vessels with thicker

walls to allow for the thinning. The Peters, Timmerhaus, and

West suggest 0.25 to 0.38mm annually. Use an average

corrosion allowance of 0.315 mm.

3. The type of steel to be used is Carbon Steel (A285, Gr. A)

with a tensile stress value of 310 MPa.

3.2 CAPACITY OF EXPANSION TANK, VET

VET = 0.10 x Water Volume in the Engine

VET = 0.10 x 2.6 m3

VET = 0.26 m3

3.3 DIMENSIONS OF EXPANSION TANK

3.3.1 Diameter of Expansion Tank, d

π 2
VET = d x H
4

π 2
VET = d x 2d
4

π 3
VET = d
2

3 (2)(V
ET )
d = √
π

3 (2)(0.26 m3 )
d = √
π

𝐝 = 𝟎. 𝟓𝟓 𝐦

3.3.2 Height of Expansion Tank, H

H=2d

H = 2(0.55 m)
 𝐇 = 𝟏. 𝟏 𝐦

3.3.3 Thickness of Expansion Tank, t

From Plant Design and Economics for Chemical Engineers

5th ed. By Peters, M.S. and K.D. Timmerhaus, P. 554

Pri
t=
SEJ -0.6P
Where:
P = maximum allowable internal pressure, kPa

ri = inside radius of the shell, before

corrosion allowance is added, mm
S = maximum allowable working stress, kPa

EJ = efficiency of joints
a. Internal Pressure, P

Pi =δ H
w

Where:

3
δf = specific weight of water = 9.81 kN/m

H = height of expansion tank

H = 0.72 m

Substituting:

P = (9.81 kN⁄m3 )(0.72 m)

P=10.971 kPa

Pi =Pg +Patm

Pi =(10.791 kPa )+(101.325 kPa)

Pi =112.116 kPa
b. Inside Radius, r

d
r =
2
0.55 m
r=
2

r= 0.28 m

c. Welding Joint Efficiency, E J

From PSME Code, p. 147

Single Lap Weld 40%

Double Lap Weld 60%
Single Butt Weld 50%
Double Butt Weld 70%
Forged Weld 70%
Brazed Weld 80%

d. Maximum Allowable Working Stress

From Steel Plates Catalog by NIPPON Steel

Corporation, p.52

Carbon Steel for Boilers and Pressure Vessels

yield Strength ASTM Standard

165 N/mm2 A285 Gr. A

Therefore,

Pri
t=
SEJ -0.6P

(112.116 kPa)(180 mm.)

t=
(165000 kPa)(0.70)-0.6(10.791 kPa)

t = 0.17 mm.

Adding a corrosion allowance of 0.315 mm:

t = 0.17 mm. + 0.315 mm.

t = 0.485 mm.
 From Steel Plates Catalog by NIPPON Steel Corporation,

p.18, use available size of carbon steel plate closer to the

value, which is:

t = 6 mm

3.3.4 Total Surface Area of the Expansion Tank

π 2
SAET = d + πdh
4
π
SAET = (0.55 m)2 + π(0.55 m)(0.72 m)
4

SAET = 1.72 m2

3.3.5 Quantity of Steel Plate

SAST
QSED =
Size of Steel Plate

From Steel Plates Catalog by NIPPON Steel Corporation,

p.18, use the size available for carbon steel plate in 6 mm

thickness:

Thickness: 6 mm.

Width x Height: 1000 mm x 25000 mm

1.72 m2
QSED =
(1 m x 25 m)

QSED = 0.0688 pcs x 4 tanks

QSED = 0.28 or 1 Steel Plate for four (4) expansion tanks

3.4 SPECIFICATION OF EXPANSION TANK

EXPANSION TANK

Shape of Tank Cylinder

 Vertical above
Installation
ground

Number of Tanks 4

Holding Capacity
0.26 m3

Diameter 550 mm

Height 1100 mm

Thickness 6 mm

Steel Plate
1 pc (1m x 25m)
Quantity

Tank Material Carbon Steel (A285,

Gr. A)

4. DESIGN OF COOLING TOWER

4.1 DESIGN AND OPERATING CONDITION:

From Previous Computation:

Heat Loss to Central Cooler 25,268 kW

4.2 DESIGN CONSIDERATION:

Since the inlet and outlet temperatures of the cooling

water are lacking, the designer decided to base the selection

of the cooling tower on the heat to be dissipated on the

central cooler.
4.3 COOLING TOWER CAPACITY

kJ 1 kcal 3600 sec

Q=8,897.2 x x
sec 4.187 kJ 1 hr

𝐐 = 𝟐𝟏,726,305 kcal/hr

4.4 SELECTION OF COOLING TOWER

From King Sun Industry KFT Cooling Tower Catalogue,

Counter Flow, Square, Modular Type

Select Model KFT – 2000(500-C4) which satisfies the

heating capacity needed. The inlet water temperature is 37°C,

outlet water temp is 32°C and ambient wet bulb temp of 27°C.
KFT – 2000 (4 Cells)

Specification of Pipe Connection:

Cell Model Name: 400

Inlet, De = 200 mm

Outlet, S = 200 mm

Automatic Make up, Ba = 40 mm

Quick Make up, Q = 40 mm

Overflow, O = 50 mm

Drain, Dr = 50 mm

5. DESIGN OF MAKEUP WATER TANK

5.1 DESIGN AND OPERATING CONDITION:

From King Sun Cooling Tower Catalogue:

Volume Flow Rate 26,000 Li/min

5.2 DESIGN CONSIDERATION:

The water volume in the makeup water tank is assumed to be

1/4 of the volume of the circulating water in the cooling tower,

which accounts to 25% loss on the circulating cooling water.

The designer decided to put a cylindrical expansion tank

vertically seated above the ground. The dimension is assumed to

be H = 2d. Corrosion allowance is constructing the vessels with

thicker walls to allow for the thinning. The Peters, Timmerhaus,

and West suggest 0.25 to 0.38mm annually. Use an average

corrosion allowance of 0.315 mm. The type of steel to be used

is Carbon Steel (A285, Gr. A) with a tensile stress value of 310

MPa.

5.3 CAPACITY OF MAKEUP WATER TANK

Li 1 m3 60 min
VMWT =26000 x x
min 1000 Li hr

VMWT = 1560 m3 x 0.25

VMWT = 390 m3

5.4 DIMENSIONS OF MAKEUP WATER TANK

5.4.1 Diameter of Makeup Water Tank, d

π 2
VMWT = d x H
4

π
VMWT = d2 x 2d
4

π 3
VMWT = d
2

3 (2)(VMWT )
d = √
π

3 (2)(390 m3 )
d= √ = 6.285 m
π

5.4.2 Height of Makeup Water Tank, H

H = 2d

H = 2(6.285 m)

𝐇 = 𝟏𝟐. 𝟓𝟕 𝐦
5.4.3 Thickness of Makeup Water Tank, t

From Plant Design and Economics for Chemical Engineers

5th ed. By Peters, M.S. and K.D. Timmerhaus, Page 554

Pri
t=
SEJ -0.6P
Where:
P = maximum allowable internal pressure, kPa

ri = inside radius of the shell, before

corrosion allowance is added, mm
S = maximum allowable working stress, kPa

EJ = efficiency of joints
a. Internal Pressure, P

Pi =δw H

Where:

3
δf = specific weight of water = 9.81 kN/m

H = height of expansion tank

H = 12.57 m

Substituting:

P = (9.81 kN⁄m3 )(12.57m)

P=123.312 kPa

Pi =Pg +Patm

Pi =(123.312 kPa )+(101.325 kPa)

Pi =224.637 kPa

b. Inside Radius, r
 d
r =
2
6.285 m
r=
2

r= 3.1425 m.

c. Welding Joint Efficiency, E J

From PSME Code, page 147, the efficiency of doubled but

weld for fusion weld joints is 70%.

Single Lap Weld 40%

Double Lap Weld 60%
Single Butt Weld 50%
Double Butt Weld 70%
Forged Weld 70%
Brazed Weld 80%

d. Maximum Allowable Working Stress

From Steel Plates Catalog by NIPPON Steel

Corporation, p.52

Carbon Steel for Boilers and Pressure Vessels

yield Strength ASTM Standard

165 N/mm2 A285 Gr. A

Therefore,

Pri
t=
SEJ -0.6P

(224.637 kPa)(3142.5 mm.)

t=
(165,000 kPa)(0.70)-0.6(123.312 kPa)

t = 6.12 mm.
 Adding a corrosion allowance of 0.315 mm:

t = 6.12 mm. + 0.315 mm.

t = 6.435 mm.

From Steel Plates Catalog by NIPPON Steel Corporation,

p.18, use available size of carbon steel plate closer to the

value, which is:

t = 6 mm

5.4.4 Total Surface Area of the Makeup Water Tank

π 2
SAMWT = d + πdh
4
π
SAMWT = (6.285 m)2 + π(6.285 m)(12.57 m)
4

SAMWT = 310.24 m2

5.4.5 Quantity of Steel Plate

SAST
QSMWD =
Size of Steel Plate

From Steel Plates Catalog by NIPPON Steel Corporation,

p.18, use the size available for carbon steel plate in 6 mm

thickness:

Thickness: 6 mm.

Width x Height: 3400 mm x 25000 mm

310.24 m2
QSMWD =
(3.4 m x 25 m)

QSMWD = 3.65 pcs xx 4 tanks

QSMWD = 14.6 or 15 Steel Plates for four (4) makeup water tanks

5.5 SPECIFICATION OF MAKEUP WATER TANK

MAKEUP WATER TANK

Shape of Tank Cylinder

 Vertical above
Installation
ground

Number of Tanks 4

Holding Capacity
390 m3

Diameter 6285 mm

Height 12570 mm

Thickness 6 mm

Steel Plate
15 pcs (3.4m x 25m)
Quantity

Tank Material Carbon Steel (A285,

Gr. A)

CHAPTER VI

LUBRICATING SYSTEM
6.1 DESIGN OF LUBE OIL STORAGE TANK

6.1.1 DESIGN AND OPERATING CONDITION:

From Wartsila 46F Product Guide (2020):

Lubricating oil viscosity

SAE 40
class

Brake Power 6000 kWm

Oil consumption at 100%

0.35 g/kW-hr
load

From www.engineersedge.com/fluid_flow/fluid_data.htm

Fluid Name Oil SAE 40

Viscosity 900 Centistokes

Density 0.9 kg/liter (900 kg/m3)

6.1.2 DESIGN CONSIDERATIONS:

4. The lube oil storage tank is designed to supply oil on all

engines good for three months operation.

5. To avoid shortage of lube oil due to unexpected problem on

delivery or any unexpected incident that would cause delay,

 the designers decided to add a 25% contingency. This would

ensure 22 days reserve in case of failure on delivery.

6. Corrosion allowance is constructing the vessels with thicker

walls to allow for the thinning. the Peters, Timmerhaus, and

West suggest 0.25 to 0.38mm annually or 3mm for 10 years. Use

an average corrosion allowance of 0.315 mm.

7. The type of steel to be used is Carbon Steel (A285, Gr. A)

with a tensile stress value of 310 MPa. To provide air space

and other auxiliaries to the storage tank, add an allowance

of 0.75 meter to the computed height.

6.1.3 LUBE OIL CONSUMPTION

mL =mLB × Pb

Where:

mL = Lube Oil Consumption

mLB = Specific Lube Oil Consumption

Pb = Brake Power

g 1 kg
mL =0.35 × × 6000 kW
kWh 1000 g

kg
mL =2.1
hr

6.1.4 VOLUME OF LUBE OIL, VL

mL
VL =
ρL

2.1 kg/hr
VL =
0.9 kg/li

VL =2.33 li/hr
 For 3 months volume of lube oil:

24 hr 30 days
VL = 2.33 li/hr ( )( ) (3 months)
1 day 1 month

1 m3
VL = 5032.8 li x ( )
1000 li

VL =5.0328 m3

6.1.5 VOLUME OF LUBE OIL STORAGE TANK, VLOST

Since the contingencies are set to 25% of the fuel

consumption per month,

Therefore:

VLOST = Vl + 0.25Vl

VLOST = 1.25Vf

VLOST = 1.25(5.0328 m3 )

VLOST =6.291 m3 x 4 engines=25.164 m3

6.1.6 DIMENSION OF LUBE OIL STORAGE TANK

6.1.6.1 Diameter of Lube Oil Storage Tank, d

The volume of the tank is equal to the volume of cylinder

π 2
VlOST = d H Since: H=2d
4

Thus,
π 2
VlOST = d x H
4

π 2
VlOST = d x 2d
4

π 2
VlOST = d
2
 3 (2)(VLOST )
d =√
π

3 (2)(25.164 m3 )
d = √
π

d = 2.521 m

6.1.6.2 Height of Lube Fuel Storage Tank, H

H = 2d + allowance

H = 2(2.521 m) + 0.75 m

𝐇 = 𝟓. 𝟕𝟗𝟐 𝐦

6.1.6.3 Thickness Lube Fuel Storage Tank, t

From Plant Design and Economics for Chemical Engineers

5th ed. By Peters, M.S. and K.D. Timmerhaus, Page 554

Pri
t=
SEJ -0.6P
Where:
P = maximum allowable internal pressure, kPa

ri = inside radius of the shell, before

corrosion allowance is added, mm
S = maximum allowable working stress, kPa

EJ = efficiency of joints
a. Internal Pressure, P

Pi =δL H

Where:
 δL = specific weight of lube oil

3
δL = SGL x δw = 0.9 x 9.81 kN/m = 8.829 kN/m3

H = height of storage tank

H = 5.792 m `

Substituting:

P = (8.829 kN⁄m3 )(5.792 m)

P=51.138 kPa

Pi =Pg +Patm

Pi =(51.138 kPa )+(101.325 kPa)

Pi =152.463 kPa

b. Inside Radius, ri

d 2.521 m
ri = =
2 2

ri =1.2605 m.

c. Welding Joint Efficiency, E J

From PSME Code, page 147

Single Lap Weld 40%

Double Lap Weld 60%
Single Butt Weld 50%
Double Butt Weld 70%
Forged Weld 70%
Brazed Weld 80%

d. Maximum Allowable Working Stress

From Steel Plates Catalog by NIPPON Steel

Corporation, p.52

Carbon Steel for Boilers and Pressure Vessels

yield Strength ASTM Standard

 165 MPa A285 Gr. A

Therefore,

Pri
t=
SEJ -0.6P
(207.73 kPa)(2825 mm.)
t=
(165,000 kPa)(0.70)-0.6(106.4 kPa)

t=5.08 mm.
Adding a corrosion allowance of 0.315 mm:

t = 5.08 mm + 0.315 mm

t = 5.399 mm

From Nippon Steel Corporation use available size of

carbon steel plate closer to the value, which is:

𝐭 = 𝟔 𝐦𝐦

6.1.6.4 Total Surface Area of the Lube Oil Storage Tank:

π 2
SADT = d + πdh
4
π
SADT = 2 (5.65 m)2 + π(5.65 m)(12.05 m)
4

SADT = 264.03 m2

6.1.6.5 Quantity of Steel Plate, QSPD:

SAST
QSPD =
Size of Steel Plate

From Steel Plates Catalog by NIPPON Steel Corporation,

p.18, use the size available for carbon steel plate in 6 mm

thickness:

Thickness: 6 mm.

Width x Height: 1300 mm x 25000 mm

 238.96 m2
QSPD =
(1.4 m x 25 m)

QSPD = 7.5 or 8 Steel Plates for one(1) lube oil storage tank

6.1.7 SPECIFICATION OF LUBE OIL STORAGE TANK

LUBE OIL STORAGE TANK

Shape of Tank Cylinder

Installation Vertical above ground

Number of Storage Tanks 1

Holding Capacity 25.164 m3

Diameter 2521 mm

Height 5792 mm

Thickness 6 mm

Steel Plate Quantity 8 pcs (1.4m x 25m)

Carbon Steel (A285, Gr.

Tank Material
A)
6.2 DESIGN OF SYSTEM OIL/SERVICE TANK

6.2.1 DESIGN AND OPERATING CONDITION

From Wartsila Genset Catalogue:

Designation SAE 40

Oil Volume in System Oil Tank 6 m3

From Previous Computation:

Density of Oil 8.829 kN/m3

6.2.2 DESIGN CONSIDERATION:

1. The plant will have one service tank for each engine and

this will store lube oil.

2. The designer choses a cylindrical service tank vertically

seated above the ground. The dimension is assumed to be H

= 2d.

3. Add a corrosion allowance of 0.315 mm for the thickness of

the tank. The type of steel to be used is Carbon Steel

(A285, Gr. A) with a tensile stress value of 310 MPa.

4. To provide air space and other auxiliaries of the system

oil tank we will add an allowance of 0.25 meter to the

computed height.

6.2.3 DIMENSION OF SYSTEM OIL TANK

6.2.3.1 Diameter of System Oil Tank, d

The volume of the tank is equal to the volume of cylinder

π 2
VlOST = d H Since: H=2d
4
π 2
VlOST = d x H
4

π 2
VlOST = d x 2d
4

π 2
VlOST = d
2

3 (2)(VLOST )
d =√
π

3 (2)(6 m3 )
d = √ =1.56 m
π

6.2.3.2 Height of System Oil Tank, H

H = 2d + allowance

H = 2(1.56 m) + 0.75 m

𝐇 = 𝟑. 𝟖𝟕 𝐦
6.2.3.3 Thickness of System Oil Tank, t

From Plant Design and Economics for Chemical Engineers

5th ed. By Peters, M.S. and K.D. Timmerhaus, Page 554

Pri
t=
SEJ -0.6P

Where:
P = maximum allowable internal pressure, kPa
 ri = inside radius of the shell, before
corrosion allowance is added, mm
S = maximum allowable working stress, kPa

EJ = efficiency of joints
a. Internal Pressure, P

Pi =δ H
L

Where:

δL = specific weight of lube oil

δL = SGL x δw

= 0.9 x 9.81 kN/m3 = 8.829 kN/m3

H = height of storage tank

H = 3.87 m
Substituting:
P = (8.829 kN⁄m3 )(3.87 m)

P=34.168 kPa

Pi =Pg +Patm

Pi =(34.168 kPa )+(101.325 kPa)

Pi =135.493 kPa

b. Inside Radius, 𝒓𝒊

d 1.56 m
ri = =
2 2

ri =0.78 m.

c. Welding Joint Efficiency, E J

From PSME Code, page 147

Single Lap Weld 40%

Double Lap Weld 60%
Single Butt Weld 50%
 Double Butt Weld 70%
Forged Weld 70%
Brazed Weld 80%

d. Maximum Allowable Working Stress

From Steel Plates Catalog by NIPPON Steel

Corporation, p.52

Carbon Steel for Boilers and Pressure Vessels

yield Strength ASTM Standard

165 MPa A285 Gr. A

Therefore,

Pri
t=
SEJ -0.6P
(155.1 kPa)(1340 mm.)
t=
(165,000 kPa)(0.70)-0.6(53.77 kPa)

t=1.8 mm.
Adding a corrosion allowance of 0.315 mm:

t = 1.8 mm + 0.315 mm

t = 2.115 mm

From Nippon Steel Corporation use available size of

carbon steel plate closer to the value, which is:

𝐭 = 𝟔 𝐦𝐦

6.2.3.4 Total Surface Area of the System Oil Tank:

π 2
SADT = d + πdh
4
π
SADT = 2( (2.67 m)2 + π(2.67 m)(6.09 m))
4

SADT = 62.28 m2

6.2.3.5 Quantity of Steel Plate, QSPD:

 SAST
QSPD =
Size of Steel Plate

From Steel Plates Catalog by NIPPON Steel Corporation,

p.18, use the size available for carbon steel plate in 6 mm

thickness:

Thickness: 6 mm.

Width x Height: 1400 mm x 25000 mm (for bulk order)

56.68 m2
QSPD =
(1.4 m x 25 m)

QSPD = 1.78 pcs x 4 tanks

QSPD = 7.12 pcs or 7 Steel Plates for four (4) system oil tank
6.2.4 SPECIFICATION OF SYSTEM OIL TANK

SYSTEM OIL TANK

Shape of Tank Cylinder

Installation Horizontal above ground

Number of Tanks 4

Holding Capacity 6 m3

Diameter 1560 mm

Height 3870 mm

Thickness 6 mm

Steel Plate Quantity 7 pcs (1.4m x 25m)

Carbon Steel (A285, Gr.

Tank Material
A)

CHAPTER V1I

PIPING SYSTEM

1. PIPE ESTIMATE FOR FUEL SYSTEM

1.1. PIPINGS FOR STORAGE TANK TO DAY TANK

1.1.1 DESIGN AND OPERATING CONDITIONS:

From Previous Computations:

Volume of Day Tank 46.96 m3

Assumed Filling Time 60 min

From Wartsila 46F Product Guide (2020)

 Piping Fuel Oil Piping

Pipe Material Black Steel (SCH 40)

Max. Velocity (Pump Discharge)1.0m/s(60m/min)

1.1.2 DESIGN CONSIDERATION:

Since the velocity of fuel at the suction side is lacking,

assume that the suction velocity and discharge velocity are

equal. Therefore, the pipe diameter at the pump suction side and

discharge side are also equal.

1.1.3 VOLUME FLOW RATE

V
Q =
tf

Where:

V = Volume of Day Tank

tf = Assumed Filling Time

46.96 m3
Q =
120 min

m3
Q = 0.3913
min

1.1.4 DIAMETER OF PIPE (SUCTION AND DISCHARGE LINE)

From General Flow Equation,

Q=AVmax

Where:
 πD2
A=
4

Vmax =60m/min

πD2
Q= ( ) Vmax
4

4Q
D2 =
πVmax

4Q
D=√
πVmax

4(0.3913 m3 /min)
D =√
π(60 m/min)

39.37 in
D = 0.0911 m ( )
1 m

D = 3.59 in

From ASME B36.10M-2015, use the nearest value, which is D

= 4 in (101.6mm).

Nominal Pipe Size 4 in. (DN100)

Schedule Number 40

Outside Diameter 114.3 mm.

Inside Diameter 102.26 mm.

Wall Thickness 6.02 mm.

Plain End Mass 16.08 kg/m

1.2. PIPINGS FOR DAY TANK TO RETURN FUEL TANK

1.2.1 DESIGN AND OPERATING CONDITIONS:

From Previous Computations:

Volume of Return Fuel Tank 0.764 m3

Assumed Filling Time 10 min

From Wartsila 46F Product Guide (2020)

Piping Fuel Oil Piping

Pipe Material Black Steel (SCH 40)

Max. Velocity (Pump Discharge)1.0 m/s(60 m/min)

1.2.2 DESIGN CONSIDERATION:

Since the velocity of fuel at the suction side is lacking,

assume that the suction velocity and discharge velocity are

equal. Therefore, the pipe diameter at the pump suction side and

discharge side are also equal.

1.2.3 VOLUME FLOW RATE

V
Q =
tf

Where:

V = Volume of Day Tank

tf = Assumed Filling Time

 0.764 m3
Q =
10 min

m3
Q = 0.0764
min

1.2.4 DIAMETER OF PIPE (SUCTION AND DISCHARGE LINE)

From General Flow Equation,

Q=AVmax

Where:

πD2
A=
4

Vmax =60m/min

πD2
Q= ( ) Vmax
4

4Q
D2 =
πVmax

4Q
D=√
πVmax

4(0.0764 m3 /min)
D =√
π(60 m/min)

D = 0.04027 m

D = 40.27 mm
 From ASME B36.10M-2015, use the nearest value: D = 1 1/2

in (40.94 mm).

Nominal Pipe Size 1 1/2 in. (DN40)

Schedule Number 40

Outside Diameter 48.3 mm.

Inside Diameter 40.94 mm.

Wall Thickness 3.68 mm.

Plain End Mass 4.05 kg/m

1.3. PIPINGS FOR RETURN FUEL TANK TO THE ENGINE

1.3.1 DESIGN AND OPERATING CONDITIONS:

From Wartsila Catalogue:

Leak Fuel Drain DN 32 (1 ¼ NPS)

From ASME B36.10M-2015, p. 3

Nominal Pipe Size 1.25 in. (DN32)

Schedule Number 40

Outside Diameter 42.2 mm.

Inside Diameter 35.08 mm.

 Wall Thickness 3.56 mm.

Plain End Mass 3.39 kg/m

1.4. PIPINGS FOR DAY TANK TO THE ENGINE

1.4.1 DESIGN AND OPERATING CONDITIONS:

From Wartsila Catalogue:

Fuel Inlet and Outlet DN 125 (5 NPS)

From ASME B36.10M-2015,

Nominal Pipe Size 5 in. (DN125)

Schedule Number 40

Outside Diameter 141.3 mm.

Inside Diameter 126.9 mm.

Wall Thickness 6.55 mm.

Plain End Mass 21.77 kg/m

2.PIPE ESTIMATE FOR LUBRICATION SYSTEM

2.1. PIPINGS FOR LUBE OIL STORAGE TANK TO SYSTEM OIL TANK

2.1.1 DESIGN AND OPERATING CONDITIONS:

From Previous Computations:

Volume of System Oil Tank 30 m3

Assumed Filling Time 10 min

From Wartsila Catalogue:

Piping Lubricating Oil

Pipe Material Black Steel

Max. Velocity(Pump Discharge) 1.5 m/s(90 m/min)

2.1.2 DESIGN CONSIDERATION:

Since the velocity of lube oil at the suction side is

lacking, we will assume that the suction velocity and discharge

velocity are equal. Therefore, the pipe diameter at the pump

suction side and discharge side are also equal.

2.1.3 VOLUME FLOW RATE

V
Q =
tf

Where: V = Volume of Lube Oil Tank

 tf = Assumed Filling Time

30 m3
Q =
10 min

m3
Q = 3
min

2.1.4 DIAMETER OF PIPE (SUCTION AND DISCHARGE LINE)

From General Flow Equation,

Q=AVmax

Where:

πD2
A=
4

Vmax =60 m/min

πD2
Q= ( ) Vmax
4

4Q
D2 =
πVmax

4(3 m3 /min)
D =√
π(60 m/min)

39.37 in
D = 0.2523 m ( )
1 m

D = 9.93 in

From ASME B36.10M-2015, use the nearest value, which is D

= 10 in (254 mm).

Nominal Pipe Size 10 in. (DN250)

 Schedule Number 40

Outside Diameter 273 mm.

Inside Diameter 250 mm.

Wall Thickness 5.16 mm.

Plain End Mass 22.61 kg/m

2.2. PIPINGS FOR SYSTEM OIL TANK TO ENGINE

2.2.1 DESIGN AND OPERATING CONDITIONS:

From Wartsila V46F Catalogue:

Lube Oil Inlet 2 x DN 800

Lube Oil Outlet DN 1500

From ASME B36.10M-2015, p. 6

Nominal Pipe Size 10 in. (DN125)

Schedule Number 40

Outside Diameter 273 mm.

Inside Diameter 250 mm.

Wall Thickness 5.16 mm.

From ASME B36.10M-2015, p. 6

Nominal Pipe Size 12 in. (DN200)

Schedule Number 40

Outside Diameter 323.8 mm.

 Inside Diameter 300 mm.

Wall Thickness 3.96 mm.

3. PIPE ESTIMATE FOR COOLING SYSTEM

3.1 MAKEUP WATER TANK TO COOLING TOWER

From King Sun Industry KFT Cooling Tower Catalogue,

D = 200 mm (DN200)

From ASME B36.10M-2015, p. 6

Nominal Pipe Size 8 in. (DN200)

Schedule Number 40

Outside Diameter 219.1 mm.

Inside Diameter 202.74 mm.

Wall Thickness 8.18 mm.

Plain End Mass 42.55 kg/m

3.2 COOLING TOWER TO JACKET WATER HEAT EXCHANGER

Connection Diameter = 200 mm (8 in)

From ASME B36.10M-2015, p. 6

Nominal Pipe Size 8 in. (DN200)

Schedule Number 40
 Outside Diameter 219.1 mm.

Inside Diameter 202.74 mm.

Wall Thickness 8.18 mm.

Plain End Mass 42.55 kg/m

3.3 JACKET WATER HEAT EXCHANGER TO LUBE OIL HEAT EXCHANGER

Connection Diameter = 200 mm (8 in)

From ASME B36.10M-2015, p. 6

Nominal Pipe Size 8 in. (DN200)

Schedule Number 40

Outside Diameter 219.1 mm.

Inside Diameter 202.74 mm.

Wall Thickness 8.18 mm.

Plain End Mass 42.55 kg/m

3.4 LUBE OIL HEAT EXCHANGER TO ENGINE

Connection Diameter = 100 mm (4 in)

From ASME B36.10M-2015, p. 5

Nominal Pipe Size 4 in. (DN100)

Schedule Number 40

Outside Diameter 114.3 mm.

 Inside Diameter 102.26 mm.

Wall Thickness 6.02 mm.

Plain End Mass 16.08 kg/m

3.5 ENGINE TO EXPANSION TANK

Connection Diameter = 100 mm (4 in)

From ASME B36.10M-2015, p. 5

Nominal Pipe Size 4 in. (DN100)

Schedule Number 40

Outside Diameter 114.3 mm.

Inside Diameter 102.26 mm.

Wall Thickness 6.02 mm.

Plain End Mass 16.08 kg/m

CHAPTER VIII

PUMPING SYSTEM

1. DESIGN OF FUEL OIL PUMP

1.1 DESIGN PARAMETERS

Density of fuel oil 890 kg/m3
Discharge flow rate of Fuel Oil 0.0978 m 3 /min
Viscosity of Fuel Oil 1780
centipoise
Pressure inside the storage tank (suction) 329.75 kPa
Pressure at the day tank (discharge) 155.1 kPa
Velocity at pump - outlet and inlet line 1 m/sec
Inside diameter of suction & discharge line 45.36 mm
 Length of suction pipe line, Lss 21 m
Length of discharge pipe line, Lsd 84.43
Number of standard elbows at inlet line 1
Number of standard elbows at outlet line 7
Number of gate valve at inlet line 2
Number of gate at outlet line 4
Number of standard tee at inlet line 1
Number of standard tee at outlet line 4
Number of check valve at outlet line 1
Static suction head 0 m
Static discharge head 7.34 m

1.2 PUMP POWER

Total Dynamic Head, TDH:

TDH = Hp + Z + Hf

1. Total pressure head, Hp:

Pd- Ps
Hp = ( )
γ

where:

Ps = Pressure inside the storage tank

Pd = Pressure in the day tank

γ = spec. wt. of water

Substituting,

329.75 kN/m2 - 155.1 kN/m2

Hp = ( )
890 3 x 9.81 m/s2
kg/m
1000
Hp =20 m.
2. Total static head, Z:

Z = Zd –ZS = 7.34 m – 0 m =7.34 m

3. Total friction head, Hf:

 Hf = Hfs + Hfd

a. For the suction side:

2fLv2
Hfs = <-Morse Equation
gd

For the friction factor, 𝒇:

From Power Plant Engineering by Morse, pg. 605

For turbulent liquid flow

z 0.424
f = 0.0035 + 0.0007562 ( )
dvs

where: z = viscosity of fuel

d = pipe inside diam.

v = velocity

s = fuel spec. gravity ,0.89

Substituting values:
0.424
1780
f = 0.0035 + 0.0007562 [ ] = 0.0312
(0.4094 m)(1 m/sec)(0.89)

For total length of pipe, L:

L = Ls + Le

where:

Ls = total length of straight pipe

Le = effective length of fittings

From 2017 ASHRAE Fundamentals (SI Edition), p.22.30

Effective Length of Fittings for DN40 pipe size

(1) Standard elbow 1.1 m

(1) Standard tee – through run 2.1 m

 (2) Gate Valve 0.2 m

Substituting: L = 5.03 m + [(2)(0.2) + (1)(2.1) +

(1)(1.1)] m = 8.63 m

Then:

2(0.0312)(8.63 m)(1 m/sec)2

Hfs = = 4.77 m.
(9.81 m/s2 )(0.10226m)

b. For the discharge side:

2fLv2
Hfd = <-Morse Equation
gd

Solving for total length of pipe, L:

L = Lsd + Le

where: Lsd = total length of straight pipe

Le = effective length of fittings

From 2017 ASHRAE Fundamentals (SI Edition), p.22.30,

Effective Length of fittings for DN40 pipe size

(7) Standard elbow 1.1 m

(4) Standard tee – through run 2.1 m

(1) Check Valve 1.6 m

(4) Gate Valve 0.2 m

Substituting:L = 84.43 m + [(7)(1.1) + (4)(2.1) + (4)(0.2) +

1.6] m = 102.5 m

Then:

2(0.0312)(102.5m)(1 m/sec)2
Hfd = =52.21 m.
(9.81 m/s2 )(0.10226m)
 Substituting the values,

Hf =4.77 m+52.21 m=20.975 m.

Therefore:

TDH = 19 m + 7.347 + 56.98 m = 83.327 m.

Hydraulic power of pump, Pp:

Pp = Qγ(TDH)

1 min
=0.0978 m3 /min ( ) (9.81kN/m3 )(83.327 m)
60 sec

Pp = 1.33 kW

Motor power for the pump, Pm:

1.36 kW
Pm = where: Ƞp = pump efficiency, assume: Ƞp = 80%
Ƞp

1.36
Pm = = 1.7 kW = 2.28 hp, Use standard motor, 3 hp
0.8

2. DESIGN OF LUBE OIL PUMP

2.1 DESIGN PARAMETERS

Pressure loss at lube oil heat exchanger 0.5 m

Volume flow rate of Lube Oil 3 m 3 /min

Lube Oil Viscosity 225 cP

Velocity at pump- suction line 1.5 m/sec

Velocity at pump discharge line 1.5 m/sec

Inside diameter of suction pipe line 126.9 mm

Inside diameter of discharge pipe line 126.9 mm

Length of suction pipe line, Lss 2.81 m

Length of discharge pipe line, Lsd 31.24 m

Number of elbows at suction line 1

Number of elbows at discharge line 7

 Number of gate valve on in/out lines 2

Number of check valve at discharge line 1

Static suction line 0 m

Static discharge line 2.1 m

2.2 PUMP POWER

Total Dynamic Head, TDH:

TDH = Hp + Z + Hf

1. Pressure head loss in Lube Oil Heat Exchanger, Hp:

Hp = ΔPs
where: ΔPs = pressure drop at Lube Oil Heat Exchanger
Hp =0.5 m.

2. Total static head, Z:

Z = Zd –ZS =2.1-0 m=2.1 m
3. Total friction head, Hf:

Hf = Hfs + Hfd

a. For the suction side:

2fLv2
Hfs = <-Morse Equation
gd

Solving for the friction factor, f:

For turbulent liquid flow

z 0.424
f = 0.0035 + 0.0007562 ( )
dvs

For viscous flow:

z
f = 0.000016026 (dvs)

where:

z =viscosity of lube oil

d =pipe inside diam.

 v =velocity

s =lube oil spec. gravity, 0.9

z
If (dvs) < 1163.5, it is turbulent flow, if not it is

viscous.

z 225
( )=[ ] = 1313.37  viscous
dvs (0.1269 m)(1.5 m/sec)( 0.9)

Substituting values:

225
f = 0.000016026 [ ] = 0.021
(0.1269 m)(1.5 m/sec)( 0.9)

For total length of pipe, L:

L = Ls + Le

where:

Ls = total length of straight pipe

Le = effective length of fittings

From 2017 ASHRAE Fundamentals (SI Edition), p.22.30

Effective Length of fittings for DN125 pipe size

(1) Standard 90° elbow 3.3 m

(1) Standard tee – through run 6.7 m

(2) Gate Valve 0.7 m

Substituting: L = 2.81 m + [(2)(0.7) + (1)(6.7) + (1)(3.3)] m =

14.21 m

Then:

2(0.021)(14.21 m)(1.5 m/sec)2

Hfs = = 1.079 m
(9.81 m/s2 )(0.1269m)

b. For the discharge side:

2fLv2
Hfd = <-Morse Equation
gd
For total length of pipe, L:

L = Lsd + Le

where: Lsd = total length of straight pipe

Le = effective length of fittings

From 2017 ASHRAE Fundamentals (SI Edition), p.22.30

Effective Length of fittings for DN125 pipe size

(7) Standard 90° elbow 3.3 m

(3) Standard tee – through run 6.7 m

(1) Close return bend (check valve) 1.6 m

(5) Gate Valve 0.7 m

Substituting:

L = 31.24 m + [(7)(3.3)+(3)(6.7)+(5)(0.7)+1.6] m = 73.54 m

Then:

2(0.021)(79.54 m)(1.5 m/sec)2

Hfd = = 6.038 m
(9.81 m/s2 )(0.1269m)

Substituting the values,

Hf =1.079 + 6.038=7.117 m

Therefore:

TDH = 0.5 m + 2.1m + 7.117 m = 9.717 m.

Hydraulic power of pump, Pp:

Pp = Qγ(TDH)

1 min
= 3 m3 /min ( ) (9.81kN/m3 )(9.717 m)
60 sec

Pp = 4.77 kW
 Motor power for the pump, Pm:

Ph
Pm = where: Ƞp = pump efficiency, assume: Ƞp = 80%
Ƞp

4.77
Pm = = 5.96 kW = 7.99 hp, Use standard motor size, 8 hp
0.8

3. DESIGN OF COOLING WATER PUMP

3.1 DESIGN PARAMETERS

Volume flow rate of circulating water 1.67 m3/min

Velocity of water at suction line 2.5 m/sec

Velocity of water at discharge line 2.5 m/sec

Inside diameter of inlet pipe 202.7 mm

Inside diameter of outlet pipe 202.7 mm

Length of suction pipe line 5.06 m

Length of discharge pipe line 24.94 m

Number of standard elbows at inlet pipe 4

Number of standard elbows at outlet 6

Number of gate valve at inlet pipe 1

Number of gate valve at outlet pipe 1

Number of standard tees at inlet pipe 1

Number of standard tees at outlet pipe 4

Pressure head at lube heat exchanger 4 m

Pressure head at j. water heat exchanger 3.6 m

Tower head 2.92 m

3.2 PUMP POWER

Total Dynamic Head, TDH:

 TDH = Hp + Z + Hf

1. Pressure head loss in Heat Exchanger, Hp:

Hp =∆Ptso +∆Ptsj

Where: ΔPtso = pressure head at tube side of

Lube Oil Heat Exchanger

ΔPtsj = pressure head at tube side of

Jacket Heat Exchanger

γ = spec. wt. of water

Substituting,

Hp =4 m + 3.6 m

Hp =7.6 m

2. Total static head, Z:

Z = Zd –ZS =2.92 - 0 m = 2.92 m

3. Total friction head, Hf:

Hf = Hfs + Hfd

a. For the suction side:

2fLv2
Hfs = <-Morse Equation
gd

For the friction factor, 𝒇:

From Power Plant Engineering by Morse, pg. 605

For turbulent liquid flow

z 0.424
f = 0.0035 + 0.0007562 ( )
dvs

For viscous flow:

z
f = 0.000016026 (dvs)
 where: z = viscosity of lube oil

d =pipe inside diam.

v =velocity

s =fuel spec. gravity

z
If (dvs) < 1163.5, it is turbulent flow, if not it is

viscous.

From Power Plant Engineering by Morse, pg. 606:

Table 14-8. VISCOSITIES-CENTIPOISES

Temperature, Water

°C

26.7 0.9

27.6 0.88

32.2 0.8

z 0.88
( )=[ ] = 1.74 turbulent
dvs (0.2027 m)(2.5 m/sec)( 1)

Substituting
0.424
0.88
f = 0.0035 + 0.0007562 [ ] = 0.004
(0.2027 m)(2.5 m/sec)( 1)

For total length of pipe, L:

L = Ls + Le

where:

Ls = total length of straight pipe

Le = effective length of fittings

 From Power Plant Engineering by Morse, p. 666

Effective Length of fittings for 8 in. pipe size

(1) Standard 90° elbow 5.2 m

(1) Standard tee – through run 11 m

(3) Gate Valve 1.1 m

Substituting:

L = 5.06 m + [5.2+11+(3)(1.1)] m = 24.56 m

Then:

2(0.004)(24.56 m)(2.5 m/sec)2

Hfs = = 0.338 m
(9.81 m/s2 )(0.37m)

b. For the discharge side:

2fLv2
Hfd = <-Morse Equation
gd

For total length of pipe, L:

L = Lsd + Le

where:

Lsd = total length of straight pipe

Le = effective length of fittings

From 2017 ASHRAE Fundamentals (SI Edition), p.22.30

Effective Length of fittings for DN200. pipe size

(6) Standard 90° elbow 5.2 m

(4) Standard tee – through run 11 m

(1) Gate Valve 1.1 m

Substituting:

L = 24.94 m + [(6)(5.2)+(4)(11)+(1)(1.1)] m = 101.24 m

 Then:

2(0.004)(101.24 m)(2.5 m/sec)2

Hfd = = 2.55m
(9.81 m/s2 )(0.2027m)

Substituting the values,

Hf =0.338 + 2.55 = 2.888 m.

Therefore:

TDH = 2.888 m + 2.92 + 7.6 m = 13.41 m.

Hydraulic power of pump, Pp:

Pp = Qγ(TDH)

m3 1 min 9.81kN
=1.67 ( ) ( ) (13.41 m)
min 60 sec m3

Pp = 3.66 kW

Motor power for the pump, Pm:

3.66 kW
Pm = where: Ƞp = pump efficiency, assume: Ƞp = 80%
Ƞp

3.66
Pm = = 4.58 kW= 6.1 hp
0.8

Use standard motor size from PPE by Morse, pg 677

which is 7 1/2 hp

4 DESIGN OF MAKE UP WATER PUMP

4.1 DESIGN PARAMETERS

Volume flow rate of water 26 m3/min

Velocity of water at inlet line 2.5 m/sec

 Velocity of water at outlet line 2.5 m/sec

Inside diameter of inlet pipe 38.1 mm

Inside diameter of outlet pipe 38.1 mm

Length of inlet pipe 4.7 m

Length of outlet pipe 16.98 m

Number of standard elbows at inlet line 1

Number of standard elbows at outlet line 2

Number of gate valve at inlet line 1

Number of gate valve at outlet line 3

Number of standard tee at inlet line 1

Number of standard tee at outlet line 5

Static suction head 0 m

Static discharge head 0.25 m

4.2 PUMP POWER

Total Dynamic Head, TDH:

TDH = Hp + Z + Hf

1. Total pressure head, Hp:

Pd- Ps
Hp = ( )
γ

where:

Pd = pressure at cooling tower = 247.18 kN/m2

Ps = pressure at make-up water tank =
224.637 kN/m2
γ = spec. wt. of water
Substituting:
 247.81-224.637 kN/m2
Hp = [ ] =2.36 m
9.81 kN/m3
2. Total static head, Z:

Z = Zd –ZS =0.25 - 0 m =0.25 m

3. Total friction head, Hf:

Hf = Hfs + Hfd

a. For the suction side:

2fLv2
Hfs = <-Morse Equation
gd

For the friction factor, 𝒇:

From Power Plant Engineering by Morse, pg. 605

For turbulent liquid flow:

z 0.424
f = 0.0035 + 0.0007562 ( )
dvs

For viscous flow:

z
f = 0.000016026 ( )
dvs

where: z = viscosity of lube oil

d = pipe inside diameter

v = velocity

s = spec. gravity, 1

z
If (dvs) < 1163.5, it is turbulent flow, if not it is

viscous.

Temperature of make-up water is 26°C

From Power Plant Engineering by Morse, pg. 606:

Table 14-8. VISCOSITIES-CENTIPOISES

 Temperature, Water

°C

21.1 1

26 0.9125

26.7 0.9

z 0.88
( )=[ ] = 1.74 turbulent
dvs (0.2027 m)(2.5 m/sec)( 1)

Substituting values:
0.424
0.9125
f = 0.0035 + 0.0007562 [ ] = 0.004
(0.2027 m)(2.5 m/sec)( 1)

For total length of pipe, L:

L = Ls + Le

where:

Ls = total length of straight pipe

Le = effective length of fittings

From 2017 ASHRAE Fundamentals (SI Edition), p.22.30,

Effective Length of fittings for DN40 pipe size

(1) Standard 90° elbow 1.1 m

(1) Standard tee – through run 2.1 m

(1) Gate Valve 0.2 m

Substituting:

L = 4.7 m + [(1)(1.1)+(1)(2.1)+(1)(0.2)] m = 8.1 m

 Then:

2(0.004)(8.1 m)(2.5 m/sec)2

Hfs = = 0.108 m
(9.81 m/s2 )(0.3810m)

b. For the discharge side:

2fLv2
Hfd = <-Morse Equation
gd

Solving for total length of pipe, L:

L = Lsd + Le

where:

Lsd = total length of straight pipe

Le = effective length of fittings

From 2017 ASHRAE Fundamentals (SI Edition), p.22.30,

Effective Length of fittings for DN40 pipe size

(2) Standard 90° elbow 1.1 m

(5) Standard tee – through run 2.1m

(3) Gate Valve 0.2 m

Substituting:

L = 16.98m + [(2)(1.1)+(5)(2.1)+(3)(0.2)] m = 30.28 m

Then:

2(0.004)(30.28 m)(2.5 m/sec)2

Hfd = = 0.405 m
(9.81 m/s2 )(0.3810m)

Substituting the values,

Hf = 0.108 + 0.405 = 0.513 m

Therefore:

TDH = 2.36 m + 0.513 m + 0.25 m = 3.123 m

Hydraulic power of pump, Pp:

 1 min
Pp = Qγ(TDH)=26 m3 /min (60 ) (9.81kN/m3)(3.123 m)
sec

Pp =13.28 Kw

Motor power for the pump, Pm:

Ph
Pm = where: Ƞp = pump efficiency, assume: Ƞp = 80%
Ƞp

13.28 kW
Pm = = 16.6 kW=22.26 hp
0.8

Use standard motor size from PPE by Morse, pg 677

which is 25 Hp

CHAPTER IX

EXHAUST GAS SYSTEM

ITEM NO. 1 DESIGN OF AIR FILTER

1.1 DESIGN AND OPERATING CONDTION

From Wartsila Genset Catalogue

Piston Displacement 96.4 L/cyl

Speed 600 rpm

No. of Cylinders 16 (V-Twin)

AIR FILTER AREA CALCULATION

VD x RPM
A=
20,839

where: A = effective filtering area

VD = cubic inch displacement

RPM = Speed, rpm

For the Volume Displacement:

VD = PD x no. of cylinders
 96.4 li 1 m3 (100)3 cm3 1 in3
VD= x 16 cyl x x x
cyl 1000 li 1 m3 (2.54)3 cm3

VD = 94,123.02 in3

Substituting:

94,123.02 in3 x 600 rpm

A=
20,839

(2.54)2 cm2 1 m2
A=2710.01 in2 x x
1 in2 (100)2 cm2

A=1.748 m2

2. DESIGN OF SMOKE STACK

2.1 DESIGN AND OPERATING CONDITION

Wartsila 46F Product Guide (2020)

Exhaust stack gas temperature, after turbo: 332° C

Exhaust gas flow rate: 34.56 kg/s

2.2 VOLUME FLOW RATE OF FLUE GAS, 𝑉ƒ𝑔

Mƒg
Vƒg =
ρg

Where:

Mƒg = mass flow rate of flue gas.

ρg = density of flue gas.

From Power Plant Engineering by Morse, figure 12-44, p. 495

The density of flue gas at the exhaust gas temperature, the value

is. 0.56 kg/m3

 kg⁄
(34.56 sec ))
Thus, Vƒg = kg
0.56 ⁄m3

Vƒg =61.71 m3 /sec

2.3 SMOKE STACK AREA, AS

Vƒg
As =
vƒg

Where:

Vƒg = volume flow rate of flue gas.

vƒg = flue gas velocity.

From Power Plant Engineering by Morse, p. 493,

The worst velocity condition of flue gas is ranges from 6.1 to

15.24 𝑚/𝑠𝑒𝑐.

Thus,

61.71 m3 /sec
As =
15.24 m/sec

As = 4.05 m2

2.4 SMOKE STACK INSIDE DIAMETER, 𝑫𝒊

πDi 2
As =
4

4(4.05 m2 )
Di =√
π
 39.37 in
Di =2.27 m ( )
1 m

Di =89.37 in.

2.5 HEIGHT OF SMOKE STACK, 𝑯𝒔

From Power Plant Engineering by Morse, page. 494

Di
Hs = x30 m
D30

Where:

vƒg 5
D30 = K(da -dg )- 0.0075dg √ ( )
Qƒg

But;

𝐷 = available draft per 30 m of chimney, cm

water.

𝐾 = 2.7 for brick chimney and 2.4 for steel

stacks.

kg
da =ρa = density of air, ⁄m3

kg
= 1.16 ⁄m3

(from PPE by Morse at 32°C ambient temperature)

kg
dg =ρg = density flue gas, ⁄m3
 vƒg = flue gas velocity in the chimney, m⁄sec

3
Qƒg = flue gas flow rate, m ⁄sec

Substituting the values:

13.085
D30 = 2.4(1.16-0.56)- 0.0075(0.56)√ ( )
20.14

D30 = 0.8642 m. or 86.42 cm. of water

Also, from Power Plant Engineering by Morse, p. 495,

Di=0.004 vfg 2 dg ,cm of water

Where:

vfg = flue gas velocity in the chimney

kg
dg = density flue gas, ⁄m3

Di = 0.004 ((13.08 m⁄sec )2 (0.56 kg⁄ 3 ))

m

𝐃𝐢 = 𝟎. 𝟑𝟖𝟑𝟐 𝐦. 𝐨𝐫 𝟑𝟖. 𝟑𝟐 𝐜𝐦. 𝐨𝐟 𝐰𝐚𝐭𝐞𝐫

Substituting:

0.3832 m of water
Hs = x 30 m
0.8642 m of water

Hs =13.3 m.

2.6 THICKNESS OF SMOKE STACK

 From PSME Code, 1984 Ed., p. 18, Table 2.4.2.1 (a)

Thickness of
Stack Diameter, in Weight of Stack
Materials

59 #10 BWG 104.90 kg/m

Note: #10 BWG = 0.1406in = 3.57mm

2.7 SPECIFICATION OF SMOKE STACK

TYPE Guyed stack

DIAMETER 2.287 m. (90 in.)

HEIGHT 12.74 m

THICKNESS 3.57 mm

MATERIALS Galvanized steel