1

RIZAL TECHNOLOGICAL UNIVESITY

College of Engineering and Industrial Technology
Unified Mechanical Engineering and Technology Society

DIESEL POWER PLANT

Aviles, Emon Go
Buccat, John Carlo
Cervantes, Christian
Espallardo, John Arvin
Guzman, Dann Eidref
Ilao, Jayson
Mayordo, Rocky
Morales, Thirdy
Somigao, Jan Rey
Tanjeco, Ryan

ADVISER:
ENGR. GERRY CABRERA
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INTRODUCTION

The energy crisis is a broad and complex topic. The energy crisis is a result of
many different strains on our natural resources, not just one. There is a strain on
fossil fuels such as oil, gas and coal due to overconsumption – which then in turn can
put a strain on our water and oxygen resources by causing pollution. In most parts
of the world, people do not realize the importance of conserving energy. It is only
limited to books, internet, newspaper ads, lip service and seminars. Unless we give
it a serious thought, things are not going to change anytime sooner. Simple things
like switching off fans and lights when not in use, using maximum daylight, walking
instead of driving for short distances, using CFL instead of traditional bulbs, proper
insulation for leakage of energy can go a long way in saving energy.
. The best possible solution is to reduce the world’s dependence on non-
renewable resources and to improve overall conservation efforts. Much of the
industrial age was created using fossil fuels, but there is also known technology that
uses other types of renewable energies – such as steam, solar and wind. The major
concern isn’t so much that we will run out of gas or oil, but that the use of coal is
going to continue to pollute the atmosphere and destroy other natural resources in
the process of mining the coal that it has to be replaced as an energy source. This
isn’t easy as many of the leading industries use coal, not gas or oil, as their primary
source of power for manufacturing.

Diesel Power Plant

Diesel Power Plants produce power from a diesel engine. Diesel electric
plants in the range of 2 to 50 MW capacities are used as central stations for small
electric supply networks and used as a standby to hydroelectric or thermal plants
where continuous power supply is needed. Diesel power plant is not economical
compared to other power plants.

ADVANTAGE OF DIESEL POWER PLANT

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1. Very simple design also simple installation and occupies less space.
2. Limited cooling requirement.
3. Diesel power plant are more efficient than steam power in the range of
150MW capacity.
4. Quickly started and put on load.
5. It can be respond to varying loads without any difficulty.
6. Smaller storage is needed for the fuel.
7. Layout of diesel power plant is quite simple.
8. There is no problem of ash handling.
9. Less supervision required.

DISADVANTAGE OF DIESEL POWER PLANT

1. High maintenance, lubrication cost and operating cost.

2. Fuel cost is more, since in india diesel is costly.
3. The plant cost per kW is comparatively more.
4. The life of diesel power plant is small due to high maintenance.
5. Noise is a serious problem in the diesel power plant.
6. Diesel power plant cannot be constructed for large scale.

The diesel power plants are cheaply used in the fields mentioned below.

1. Peak load plants

2. Mobile electric plants
3. Standby units
4. Emergency power plants
5. Starting stations of existing plants
6. Central power station and etc.

General Layout of Diesel Power Plants

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Figure shows the arrangement of the engine and its auxiliaries in a diesel power plant. The
major components of the plant.

LOCATION MAP 1
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Malasiqui, Pangasinan

TOTAL w-Hr Load Per Category

Residential 6,142,800 w-hr

Church 22,400 w-hr

Restaurants 549,336 w-hr

Bakery 23,230 w-hr

Oil Company 102,298 w-hr

Computer Shop 165,384 w-hr

 6

Hardware 6,840 w-hr

Grocery Store 1,030,416 w-hr

Mini Stop 211,008 w-hr

Total Populatiom: 2,000 Total: 8,253,712 w-hr

RESIDENTIAL
(CLASS A)

Energy
No. of Hrs Consume(Rating
Appliances Rating(w) Time(hr) use x Hrs use)(w-hr)
Airconditioning 12nn-5pm
944 14 26,432
Unit(10Hp)(2unit) 7pm-4pm
12am-
Refrigeration, 10 cu.ft. 170 12am 24 4,080
Computer Set 225 7pm-11pm 4 900
Ceiling Fan, 4-blades 160 12nn-7pm 7 1,120
5am-7am
T.V Set color 26" 180 5 900
4pm-7pm
Flat iron 1,000 4am-5pm 1 1,000
Washing Machine 585 4pm-6pm 2 1,170
5am-
Hair Dryer 320 5:30am 0.5 160
Water Heater 1,500 4am-5am 1 1,500
4am-7am
Incandescent Bulb(15) 20 4 1,200
5pm-7pm
5am-
Bread Toaster 600 5:10am 0.1 60
5pm-
Microwave Oven 1,200 5:40pm 0.6 720
Rice Cooker(1.8 liter) 650 5pm-6pm 1 650
4:30am-
Coffee Maker 600 5am 0.5 300
Component 380 3pm-5pm 2hrs 760
40,952(150) =
total: 6,142,800 w-hr
LOAD GRAPH (WATTAGE PER HOUR) CLASS A
 7

WATTAGE
4000
3500
3000
2500
2000
1500
WATTAGE
1000
500
0

CHURCH

Energy
Rating Consume(Rating
Appliances (w) Time(hr) No. of hrs. x Hrs use)(w-hr)
10 pcs. Ceiling fan (4 7am-9am
160
Blades) 5pm-7pm 4 6,400
7am-9am
15 pcs. Floor Lamp 30
5pm-7pm 4 1,800
7am-9am
5 pcs. Altar Lamp 10
5pm-7pm 4 200
20 pcs. Incandescent
20 5pm-5am
Lamp 12 4,800
7am-9am
Sound System 800
5pm-7pm 4 3,200
5 pcs. 42" Industrial 7am-9am
300
Fan 5pm-7pm 4 6,000
total: 22,400 w-hr

LOAD GRAPH (WATTAGE PER HOUR) CHURCH

 8

WATTAGE
6000

5000

4000

3000

2000 WATTAGE

1000

RESTAURANT
Energy
Consume(Rating
Appliances Rating (w) Time(hr) No. of hrs. x Hrs use)(w-hr)
2 units Air-
conditioning 10am-
System (2hp) 1,913 10pm 12 45,912
10am-
26" TV Set 180 10pm 12 2,160
Floor Polisher 200 7am-9am 2 400
10pm-
Vacuum Cleaner 400 11pm 1 400
20 pcs,
Incandescent 10am-
Lamp 20 10pm 12 4,800
10am-
Blender 300 10pm 12 3,600
10am-
Microwave Oven 1,200 10pm 12 14,400
Freezer (15 cu.- 12am-
ftfrost free) 266 12am 24 6,384
Refrigerator (12 12am-
cu.ft) 300 12am 24 7,200
10am-
Computer Set 225 10pm 12 2,200
Grilling Machine 180 10am- 12 2,160
 9

10pm
10am-
Vendo Machine 120 10pm 12 1,440
total: 23,230 w-hr

LOAD GRAPH (WATTAGE PER HOUR) RESTAURANT

WATTAGE
8000
7000
6000
5000
4000
3000
WATTAGE
2000
1000
0

BAKERY
Energy
Consume(Rating
Appliances Rating (w) Time(hr) No. of hrs. x Hrs use)(w-hr)
3 pcs. Ceiling Fan 3
blades 140 4am-6pm 14 7,200
5 pcs. Incandescent
Bulb 320 4am-6pm 14 2,700
Oven 1,450 4am-3pm 11 2,160
total: 23,230 w-hr

LOAD GRAPH (WATTAGE PER HOUR) BAKERY

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WATTAGE
2500

2000

1500

1000
WATTAGE
500

GAS STATION
Energy
Consume(Rating
Appliances Rating (w) Time(hr) No. of hrs. x Hrs use)(w-hr)
Air Conditioning 12am-
System (1.5 hp) 1,252 12am 24 30,048
20" TV Set 110 7am-10pm 15 1,650
30 pcs. Incandescent
Lamp 20 4pm-6am 12 7,200
Refrigerator (12 12am-
cu.ft) 300 12am 24 7,200
2 pcs. Exhaust Fan 200 7am-5pm 10 4,000
12am-
2 Computer Set 225 12am 24 10,800
2 Pumps 1,200 7am-4pm 9 21,600
2 Compressor 1,100 7am-4pm 9 19,800
total: 102,298 w-hr

LOAD GRAPH (WATTAGE PER HOUR) GAS STATION

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WATTAGE
9000
8000
7000
6000
5000
4000
3000 WATTAGE
2000
1000
0

COMPUTER SHOP
Energy
Consume(Rating
Appliances Rating (w) Time(hr) No. of hrs. x Hrs use)(w-hr)
15 Computer Set 225 8am-10pm 14 40,500
Printer 175 8am-10pm 14 2,100
Air Conditioning Unit
(1 hp.) 944 8am-10pm 14 11,328
5 Incandescent Bulb 20 8am-10pm 14 1,200
55,128(3) =
total: 165,384 w-hr

LOAD GRAPH (WATTAGE PER HOUR) COMPUTER SHOP

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WATTAGE
5000
4500
4000
3500
3000
2500
2000
WATTAGE
1500
1000
500
0

GROCERY STORE
Energy
Consume(Rating
Appliances Rating (w) Time(hr) No. of hrs. x Hrs use)(w-hr)
5 units Air
Conditioning Unit (3 10am- 150,240
hp.) 2,504 10pm 12
4 units Air
Conditioning Unit (4 10am-
hp.) 3,826 10pm 12 183,648
10am-
5 pcs Exhaust Fan 200 10pm 12 12,000
10am-
10 Computer Set 225 10pm 12 27,000
60 pcs. 10am-
Incandescent Bulb 40 10pm 12 28,800
10 pcs. Freezer (15 10am-
cu.ft.) 266 10pm 12 31,920
5 pcs. Chest 12am-
Freezer (12 cu.ft) 200 12am 24 24,000
8 pcs. Refrigerator 12am-
(12 cu.ft) 300 12am 24 57,600
515,208(2) =
total: 1,030,416 w-hr

LOAD GRAPH (WATTAGE PER HOUR) GROCERY STORE

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WATTAGE
50000
40000
30000
20000
10000 WATTAGE
0

HARDWARE
Energy
Consume(Rating
Appliances Rating (w) Time(hr) No. of hrs. x Hrs use)(w-hr)
3 pcs. Ceiling Fan
3 blades 140 8am-5pm 9 3,780
Exhaust Fan 200 8am-5pm 9 1,800
7 pcs. Incandescent
Bulb 20 8am-5pm 9 1,260
total: 6,840 w-hr

LOAD GRAPH (WATTAGE PER HOUR) HARDWARE

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WATTAGE
800
700
600
500
400
300
WATTAGE
200
100
0

MINISTOP
Energy
Consume(Rating
Appliances Rating (w) Time(hr) No. of hrs. x Hrs use)(w-hr)
Aircondtioning Unit 12am-
(3 hp.) 2,504 12am 24 30,048
7 pcs. Incandescent 12am-
Bulb 20 12am 24 3,360
12am-
2 pcs. Blender 700 12am 24 33,600
12am-
Ice Cream Maker 600 12am 24 14,400
12am-
2 pcs. Electric Oven 1,450 12am 24 69,600
2 pcs. Chest Freezer 12am-
(12 cu.ft.) 200 12am 24 9,600
7 pcs. Refrigerator 12am-
(12 cu.ft.) 300 12am 24 50,400
total: 211,008 w-hr

LOAD GRAPH (WATTAGE PER HOUR) MINISTOP

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WATTAGE
12000

10000

8000

6000

4000 WATTAGE

2000

TOTAL W-HR LOAD PER CATEGORY

w-hr
7,000,000
6,000,000
5,000,000
4,000,000
3,000,000
2,000,000 w-hr TOT
1,000,000 AL
0 W-
HR
LOA
D=
8,25
3,712 w-hr
 16

NOTE :
Use 4 engines (Diesel Engine):
Engine 1: 1250 kW Prime mover
Engine 2: 1250 kW Prime mover
Engine 3: 3300 kW Prime mover
Engine 4: 3300 kW Prime mover

Variable Load
Plant Capacity (PC) = 9,100 kW
Peak Load(PL) = 30% of PC
= (.30)(9100) = 2730 kW
Reserved Over Peak = PC – PL
= (9100-2730)kW
= 6370 Kw
Operation Engine No. Time Ratings (kW) Total kW Total
Ratings
(kW-hr)
12am-5am Engine 2 5 1250 1250 6250
5am-6am Engine 2+3 1 1250+3300 2500 4550
6am-11am Engine 3 5 3300 1250 16500
11am-12pm Engine 3+4 1 3300+3300 4550 6600
12pm-5pm Engine 4 5 3300 3300 16500
5pm-6pm Engine 4+1 1 3300+1250 4550 4550
6pm-11pm Engine 1 5 1250 1250 6250
11pm-12am Engine 1+2 1 1250+1250 2500 2500
Total: 63,700 kW-hr = AEP
 AEP = ACTUAL ENERGY PRODUCED Accumulated kw-hr in one day
 Operation engine from AEP in kW in 24hrs = 2,654.17 kW

63,700kW-hr/Day x 365days/ 1year = 23,250,500 kW-hr per Year

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23,250,500 kW-hr x 1year/ 8760hr = 2,654.17 kW =Average Load

Load Factor (LF) = Ave Load/ Peak Load = 2,654.17 kW/ 2730kW = 0.97

Capacity Factor (CF) = Ave Load/Plant Capacity = 2,654.17 kW/ 9,100 kW = 0.29

Annual Capacity Factor = 63,700kW-hr/9,100 kW = 7

Use Factor (UF) = AEP/PC x no. of hrs operation = 63,700kW / 9100(24)=0.29

Demand Factor (DF) = Ave demand load/Capacity Load = 1000kW/1500kW = 0.67

Plant Factor (PF) = Ave Load/PC = 2,654.17 kW/9,100 kW = 0.29

Utilization Factor (UF) = PL/PC = 2730 kW/ 9,100 kW = 0.3

Operation Factor (OF) = CF/UF = 0.29/0.3 = 0.97

Catalogue of Diesel Generating set (1250 kW prime power)

Technical Specifications for 6EY22ALW Diesel Generating Set
A. Model : 6EY22ALW
B. Type: 4 stroke, vertical, water cooled /water DC
C. No. of cylinders : 6
D. Cylinder bore: 220mm
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E. Piston stroke: 320mm

F. Rated Speed: 50Hz:1000 rpm, 60Hz:900 rpm
G. Rated output: Stand-by-power, prime mover 1370kW
H. Over all Dimensions (LxWxH) : 5647mm x 1782mm x 2675mm
I. Weight: 18100kg
J. Powe factor: 80%
K. Voltage : 200-6600V
L. Brake Horsepower : 1685 kw
M. Fuel Consumption : 295 L/Hr

Design of Diesel Generator Foundation

Generator Specifications
Number of cylinder : 6
Rated Speed : 1000rpm
Rated Output : 1250 kW
Over all Dimensions (LxWxH) :5647mm x 1782mm x 2675mm
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Weight : 18100 kg

I. For 1250 kW Prime Mover (2 units)

A)Solving for the weight of the foundation using the empirical formula from PSME
Code
WF = e x We √𝑵
Where:
WF = weight of the foundation, kg
We = weight of the engine, kg
N = engine speed, rpm
e = empirical coefficient
Solution:
For 6 Cylinder diesel generator; e=0.06

Wf= 0.06 (18100) (√1000)

WF= 34,342.33 kg

B)Solving for the volume of the foundation ,Vf

Vf= Wf/Pconcrete=34,342.33 kg/2,406kg/m3
Vf= 14.23 m3

C) Solving for the dimension of the foundation

Let;
wf= width of the foundation
wb= width of the bedplate
Lf = Length of the foundation
Lb= Length of the bedplate
Hf= height of the foundation

 Wf= wb+ 10% wb

Solve for wb
Wb= Wg+ 6in. = 1782mm + 6in (25.4mm/1in)
Wb= 1934.4mm
Wf= 1934.4mm + (.10)(1934.4)
Wf= 2127.84mm
 Lf = Lb+ 10% Lb
 20

Solve for Lb
Lb= Lg+ 6in = 5647mm + 6in (25.4mm/1in)
Lb= 5799.4mm
Lf = 5799.4mm + (.10)(5799.4)
Lf = 6379.34mm

 Vf= Lf + wf+ Hf

Hf= Vf/Lf x wf
= 14.23m3/6379.34mm x 2127.84mm (1000mm/1m)3
Hf= 1048.31mm

D) Concrete Mixture

Mixture Cements/sack Sand Stone Application Weight Safe

s Compressi
(sacks/m3) ve(t/m2)

1:2:4 7.8 0.44 0.88 RC floors and 2.66 382.10

beams columns

 No. of sacks of cement = Vf(7.8 sacks/m3)

= 14.23m3 (7.8 sacks/m3)
= 110.99 or 111 sacks

 Volume of Sand = 0.44 Vf

= 0.44 (14.23m3)
= 6.261m3

 Volume of Stone = 0.88 Vf

= 0.88 (14.23m3)
= 13.52m3

E) Reinforcement Bar

WRB = 1% WF
= (0.01)(34,342.33 kg)
WRB = 343.42kg

 No. of Reinforcement Bar; using 14mm diameter of reinforcement bar

WRB/PC = Psteelx VRB

= Psteelx pi D2/4 x Lf
=7,800kg/m3 (pi(14mm x 1m/1000mm)2 (4.5m)/4
 21

WRB/PC = 1.72kg/pc

No. of Reinforcement Bar = WRB/WRB/PC

= 343.42kg/1.72kg/pc
= 199.67 or 200pcs

E) Pressure exerted on the soil

PSI =Wg+ WF/wf+ Lf
= 18100kg + 34,342.33 kg/(1.96m)(4.5m)
PSI = 5945.84 kg/m2

G) Factor of Safety (N1)

Note: Soil bearing Capacity of break Masonry = 50 to 98 t/m2

N1 = Soil bearing Capacity/ Pressure Exerted on the soil

= 50,000kg/m2/5945.84kg/m2
N1 = 8.51 or 9

H) Common flexure formula (fb)

fb = mx/I
Check for turning:
Solving for Eccentrity from the mid-base (e)
Y1 = ½ h = ½ (2.68m) = 1.34m
Y2 = 1/3 h = 1/3 (2.68m) = 0.89m
A1 = Lh = (5.65m x 2.68m) = 15.142m2
A2 = ½ Lh = ½ (5.65m)(2.68m) = 7.57m2

∑ 𝐴 = A1 + A2
= (15.142 + 7.57)m2
∑ 𝐴 = 22.712m2

∑ 𝐴𝑋𝑌 = A1 Y1 + A2 Y2
= (15.142m2) (1.34m) + (7.57m2) (0.89m)
∑ 𝐴𝑋𝑌 = 27.03m3

e = ∑ 𝐴𝑋𝑌/∑ 𝐴 = 27.03m3/22.712m2
e = 1.2m

m = 18100kg/3 x 1.2m
m = 7240kg/m

x = L/2
= 5.65m/2
X = 2.83m

I = L3 x wf/12 = (5.65)3(1.78)/12 = 26.75m4

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fb = (7240kg/m)(2.83m)/26.75m4
fb = 765.95 kg/m2

I) Solving for the Bolts

 Diameter = 1/8 (bore)

= 1/8 (220mm)
= 27.5mm
 Length = 7/8 (stroke)
= 7/8 (320mm)
= 280mm
 Use From ASME code: L = 30 D
= 30 (27.5mm)
L = 825mm
(From table AT 7 DME by Faires)
Material: AISI 8640
Sy= 150KSI = 150,000 PSI
Cd = 0.5(150,000PSI)/ 7
Cd = 10,714.29lb/m2 x 101.325kPa/ 14.7lb/in2
Cd = 73,852.07kN/m2

Tbolts = Cd𝜋D3/16
Tbolts = (73,852.07kN/m2) (3.1416)(0.0275m3)(1000N/1kN)/16
Tbolts = 301.57 N-m

No. of Bolts = M/Tbolts

= (7240kg/m)(9.81N/kg)/301.57 N-m
No. of bolts = 235.52
= 236 Bolts

J) Brake Specific Fuel Consumption

BSFC = Fuel Consumption/Brake Horsepower

BSFC = 295L/hr/1658.33kW
BSFC = 0.18L/kW-hr

K) Solving for the Volume flow rate (Vf)

Vf= BSFC x Ave Load

Vf= 0.18L/kW-hr x2,056.25 kw
Vf= 370.125 L/hr
 23

Catalogue of Diesel Generating set (3300 kW prime power)

Technical Specifications for 8N330L-GW Diesel Generating Set
A. Model : 8N330L-GW
B. Type: 4 stroke, vertical/water Cooled
C. No. of cylinders : 18 x V
D. Cylinder bore: 330mm
E. Piston stroke: 380mm
F. Rated Speed: 750rpm:50Hz ,
720 rpm:60Hz
G. Rated output: Stand-by-power 3530kW,
prime mover 3300kW
H. Over all Dimensions (LxWxH) : 9550mm x 2480mm x 4000mm
I. Weight: 71,000kg
J. Brake horsepower: 4378kW
K. Fuel Consumption: 779L/hr
 24

Design of Diesel Generator Foundation

Generator Specifications
Number of cylinder : 8
Rated Speed : 750 rpm
Rated Output : 3300kW
Over all Dimensions (LxWxH) :9550mm x 2480mm x 4000mm
Weight :71,000kg

II. 3300kW Prime Mover (2 unit)

A)Solving for the weight of the foundation using the empirical formula from PSME
Code
WF = e x We √𝑵
Where:
WF = weight of the foundation, kg
We = weight of the engine, kg
N = engine speed, rpm
e = empirical coefficient
Solution:
For 8 Cylinder diesel generator; e=0.12

Wf= 0.12 (71000) (√750)

WF=233,329.81kg

B)Solving for the volume of the foundation ,Vf

Vf= Wf/Pconcrete= 233,329.81kg/2,406kg/m3
Vf= 96.98m3
 25

C) Solving for the dimension of the foundation

Let;
wf= width of the foundation
wb= width of the bedplate
Lf = Length of the foundation
Lb= Length of the bedplate
Hf= height of the foundation

 Wf= wb+ 10% wb

Solve for wb
Wb= Wg+ 6in. = 2480mm + 6in (25.4mm/1in)
Wb= 2632.4mm
Wf= 2632.4mm + (.10)(2632.4)
Wf= 2895.64mm

 Lf = Lb+ 10% Lb
Solve for Lb
Lb= Lg+ 6in = 9550mm + 6in (25.4mm/1in)
Lb= 9702.4mm
Lf = 9702.4mm + (.10)(9702.4)
Lf = 10,672.64 mm

 Vf= Lf + wf+ Hf

Hf= Vf/Lf x wf
= 96.98m3/10,672.64mm x 2895.64mm (1000mm/1m)3
Hf= 3138.1 mm

D) Concrete Mixture

Mixture Cements/sacks Sand Stone Application Weight Safe

(sacks/m3) Compres
sive(t/m2
)
1:2:4 7.8 0.44 0.88 RC floors and 2.66 382.10
beams columns

 No. of sacks of cement = Vf(7.8 sacks/m3)

= 90.98m3 (7.8 sacks/m3)
= 709.64 or 710 sacks

 Volume of Sand = 0.44 Vf

= 0.44 (90.98m3)
= 40.03 m3
 26

 Volume of Stone = 0.88 Vf

= 0.88 (90.98m3)
= 80.06 m3

E) Reinforcement Bar

WRB = 1% WF
= (0.01)(233,329.81 kg)
WRB = 2333.3 kg

 No. of Reinforcement Bar; using 14mm diameter of reinforcement bar

WRB/PC = Psteelx VRB

= Psteelx pi D2/4 x Lf
=7,800kg/m3 (pi(14mm x 1m/1000mm)2 (4.9m)/4
WRB/PC = 5.88kg/pc
No. of Reinforcement Bar = WRB/WRB/PC
= 1,094.58kg/5.88kg/pc
= 186.15 or 187pcs

E) Pressure exerted on the soil

PSI =Wg+ WF/wf+ Lf

= 71000 kg + 233,329.81 kg/(2.2m)(4.9m)
PSI = 28,231 kg/m2

G) Factor of Safety (N1)

Note: Soil bearing Capacity of break Masonry = 50 to 98 t/m2

N1 = Soil bearing Capacity/ Pressure Exerted on the soil

= 50,000kg/m2/ 28,231 kg/m2
N1 = 1.77 or 2

H) Common flexure formula (fb)

fb = mx/I

Check for turning:

Solving for Eccentrity from the mid-base (e)
Y1 = ½ h = ½ (4m) = 2 m
 27

Y2 = 1/3 h = 1/3 (4m) = 1.33m

A1 = Lh = (9.55m x 4m) = 38.2m2
A2 = ½ Lh = ½ (9.55m)(4m) = 19.1m2

∑ 𝐴 = A1 + A2
= (38.2 + 19.1)m2
∑ 𝐴 = 57.3 m2

∑ 𝐴𝑋𝑌 = A1 Y1 + A2 Y2
= (38.2m2) (2m) + (19.1m2) (1.33m)
∑ 𝐴𝑋𝑌 = 101.803m3

e = ∑ 𝐴𝑋𝑌/∑ 𝐴 = 101.803m3/57.3m2
e = 1.78m

m = 71000 kg/3 x 1.78m

m = 42,126.67kg/m

x = L/2
= 9.55m/2
X = 4.775m

I = L3 x wf/12 = (4.775)3(2.48)/12 = 22.5m4

fb = (42,126.67kg/m)(4.775m)/22.5m4
fb = 8940.22 kg/m2

I) Solving for the Bolts

 Diameter = 1/8 (bore)

= 1/8 (330mm)
= 41.25mm
 Length = 7/8 (stroke)
= 7/8 (380mm)
= 332.5mm

 Use From ASME code: L = 30 D

= 30 (41.25mm)
L = 1237.5 mm

(From table AT 7 DME by Faires)

Material: AISI 8640
Sy= 150KSI = 150,000 PSI
Cd = 0.5(150,000PSI)/ 7
Cd = 10,714.29lb/m2 x 101.325kPa/ 14.7lb/in2
Cd = 73,852.07kN/m2
 28

Tbolts = Cd𝜋D3/16
Tbolts = (73,852.07kN/m2) (3.1416)(0.04125m3)(1000N/1kN)/16
Tbolts = 1017.805 N-m

No. of Bolts = M/Tbolts

= (42,126.67 kg/m)(9.81N/kg)/1017.805N-m
No. of bolts = 406.03
= 406 Bolts

J) Brake Specific Fuel Consumption

BSFC = Fuel Consumption/Brake Horsepower

BSFC = 779L/hr/4378kW
BSFC = 0.18L/kW-hr

K) Solving for the Volume flow rate (Vf)

Vf= BSFC x Ave Load

Vf= 0.18 L/kW-hr x 2,056.25kW
Vf= 365.88 L/hr

III. Solving for the total Volume Flow Rate (Vf)

Vf= 3Vf1 + Vf2
= 3(370.125L/hr) + 365.88L/hr
Vf= 1476.26 L/hr (24hrs/1day) (30days/1month)
Vf = 1,062,903.6 L/month

* Assumed: Delivery will be made 16 times a month

Considering 100% contingency

VfT= Vf/16 per month

VfT= 1,062,903.6/16
VfT= 66431.475

IV.Solving for number of Storage Tank (per Gen. Set)

No. of the storage tank = VfT/VST

= 66431.475 L per month/113.4m3 per tank (1m/100cm)(100cm3/1L)
= 0.58 or 1 tank
 29

V. Day tank calculation

Above ground tank
Solving for the volume of day tank (VDT)
@ 100% Load (Prime Rating)
MSC = mass specific consumption
= 195g/kW-hr

Hours of operation : 24hrs

Brake power : 1203kW
For Mass of fuel (mf) :
mf=195g/kW-hr (1203) (1kg/1000g)
mf = 234.59kg/hr

 Using diesel # 2 16°API

141.5
SG = 131.5+16 = 0.959

 For density of Fuel:

SG = PH20/Pfuel
Pfuel= PH20/SG =1000kg/m3/0.959
Pfuel= 1042.753kg/m3

Vf= mf/Pfuel= 234.59kg/hr/1042.753kg/m3

Vf= 0.225m3/hr

VI. Solving for the diameter and length of the Day tank

VfT= 0.225m3/hr (24hrs)

VfT= 5.4 m3

VfT= 𝜋D2L/4 Note: L =2D

D = 1.51m

L = 2D
L = 2 (1.51m)
L = 3.02m

 From PSME Code:

tb= thickness at bottom = 3/16in
tf= thickness at floating roof = 1/8in
T = thickness of outside tank = (3/16in + 1/8in) = 5/16in
 30

 Design of fuel transfer Pump:

From the storage tank to day tank:
Qf= Vf =0.225m3/hr (100L/1m3) (1hr/60mins)
Qf= 3.75L/min

 For Pump Rating(Pp):

From PSME Code:
Pp= Qf x H x SG/ 6130.25 Note: SG of oil @ std temp. = 0.83
= 3.75x20x0.83/6130.25 Assumedheight = 20m
Pp = 10.15kW

VII. Materials of foundation

Reference: Hill Trading Merchandise Construction Supply
MATERIALS QUANTITY
Cement 182 sacks
Gravel 21.09m3
Sand 10.55 m3
Reinforcement bar 79pcs

Solving for the diameter and length of the storage tank

Let: VST = 30000 gal/tank = 113.4m3
Let: L = 2D

VST = 𝜋D2L/4 = 𝜋D2(2D)/4

D3 = 2(113.4m3)/ 𝜋
D = 14ft
L =2D
L = 2(14ft)
L= 28f

FOR COOLING TOWER

 31

DESIGN PREVIEW
 32

FOR COOLING TOWER

where:

Water entering Cooling tower = 65°C

Water leaving Cooling tower = 40°C
Air entering @ Cooling tower = 31C DB and 23C WB
Air leaving @ Cooling tower = 48C DB and 80% RH

@ Point 1 : Cooling H2O entering C.T.

@65°C (steam table)
h1 = h f
h1 = 272.06 KJ/kg

@Point 2 : Cooling H2O leaving C.T.

@40°C
h2 = h f
h2 = 167.57 KJ/kg

@Point 3 : Air entering @ C.T.

@31C DB and 23C WB
h3 = 74KJ/kg @ psychometric chart
W3 = 0.0165kgv/kgda

@Pont 4 : Air leaving C.T.

@48C and 80% RH

By Formula :

W4 = 0.622kgv/kgda x Pv/Pa
Pv= RH x Pd
Pa = Pb- Pv
Pd= sat temp @ 48C DB
@steam table; P 11.175 kPA
RH = Relative humidity
Pv= (0.80) (11.175)
Pv= 8.94 kPA

Pb = atm pressure = 101.325kPA

Pa = Pb- Pv= (101.325-8.94)kPA

Pa = 92.385 kPA

W4 = 0.622kg v/kg da x 8.94kPA /92.385 kPA

W4 = 0.0602 kg v/kg da
 33

h4 = 1013.4t4 + 18015.7 + 0.0602 (2585000J/kg)

h4 = 1013.4(48)+ 18015.7 + 0.0602(2585000J/kg)
h4 = 222.275 KJ/kg

Water Flowing in the Cooling tower

(from the heat balance of heat exchanger)

Qj= Qcw
(mj)(Cpj)(dTj) = (mcw)(Cpcw)(dTcw)
mj x dTj
mw1 = dTcw
Qj= (mj)(Cpj)(dTj)
Qh= 51716-8793.8 (0.959)2
Qh= 43628.51KJ/kg
Heat Supplied = (Nf)(Qh)
= (0.000124m3/s)(43628.51KJ/kg)
Heat Supplied = 5.41KJ/sec

Heat carried by jacket water = 30% (5.41)

Heat carried by jacket water = 1.62KJ/sec
Qj
mj = (Cpj)(ΔT)

1.62KJ/sec
mj= 4.187KJ
( )(65−40)c
kg c

mj= 0.0155 kg/s

dTj= 27.8c
dTcw= (65-40)c
dTcw= 25c
0.0155kg
( )(27.8c)
mw1 = s
25c
mw1 = 0.017kg/s

Mass Balance:
mw1 + maW3 = maW4 + mw2
mcw1−mcw2
ma= 𝑊4−𝑊3 (equation 1)

Heat Balance:
mw1 h1 + ma hg = ma h4 + m2 h3
 34

𝑚𝑤1 ℎ1−𝑚𝑤2 ℎ2
m a= (equation2)
ℎ4−ℎ3

Combining Equation 1 and 2:

0.017−𝑚𝑤2 4.52034−𝑚𝑤2 (167.57)
=
0.0375 130.222
130.222 (0.017 - mw2) = 0.0375 ((4.52034 – (167.57 mw2))
2.34-130.222mw2 = 0.1695 – 5.65725mw2
2.34−0.1695
mw2 =
130.222−5.65725

mw2 = 0.0165kg/s

From equation 2:
(0.017)(272.06)−(0.017)(167.57)
m a= (𝟐𝟐𝟐.𝟐𝟕𝟓−74)
ma= 0.012kg/s

Make –up Required:

mw5 = ma (W4 – W3)
= 0.012kg/s (0.0602- 0.0165)kgv/kgda
mw5 = 0.0005244kg/s

Cooling Tower Efficiency

𝑡1−𝑡2
eCT= 𝑡1−𝑡4

65−40
eCT= 65−25
eCT= 62.5%

Recommended Type : Force Draft

(From PPE by Morse)
Cooling Tower Pipe :
Aw = Qw
Qw= mw (Vf@ 34c)
Vf= 1.0056 L/kg or 0.0010056m3/kg)
Qw = (0.02kg/s) (0.0010056m3/kg)
Qw= 0.00002 m3/s or 0.02L/s

Velocity of H2O @ Hx= Velocity of H2O @ Cooling tower

8.82ft/s = 2.69m/s
0.00279𝑚3/𝑠
Aw = 2.69𝑚/𝑠
3.28𝑓𝑡 2 12𝑖𝑛 2
Aw = 0.0010372m2 ( 1𝑚
) ( 1𝑓𝑡 )
Aw = 1.61in2
 35

A = 𝜋/4 D2
D = 1.43 in
𝟏
Use : 1 𝟐inch pipe

Materials Specifications :
1
Size :1 2inch
Schedule : 80x
Inside dia : 1.50in
Outside dia :1.90in
Wall thickness : 0.20in
Weight of Pipe : 3.831lb/ft

Cooling Tower Pump Power (Pp) :

Pp= QwTDH
Assume : z= 2m = TDH

Pp= (0.00279m3/s) (9.81KN/m3)(2m)

1ℎ𝑝
Pp= 0.055kW (0.746𝑘𝑊)
Pp = 0.074hp
*Assume : Np = 75%
Pp
EPi= Np
0.074hp
EPi= 0.75
EPi= 0.099hp
Use : 0.10hp Rating

Fan Power of Cooling Tower

3.75ℎ𝑝
FP = 1000𝑔𝑝𝑚 x Qw
where:
Qw= (0.00279m3/s) (1000L/1m3)(1gal/3.785L)(60s/1min)
Qw= 44.23gal/min
3.75ℎ𝑝
FP = 1000𝑔𝑝𝑚 x 44.23gal/min
0.746𝑘𝑊
FP = 0.166hp x 1ℎ𝑝
FP = 0.124kW
Use : 0.20kW Motor

Fan Capacity :
Qa= maVa
where:
ma= mass of air = 1.87kg/s
 36

Va= specific volume of air @ 50°c

Pair = density of air @ 50°c = 1.165kg/m3
1
Qa= (1.87kg/s)(1.165𝑘𝑔/𝑚3)
60𝑠
Qa= 1.605m3/s (1𝑚𝑖𝑛)
Qa= 96.31m3/min

Cooling Tower Floor Area :

Let: concentration of H2O = 80L/min-m2
Let: ACT = Area of Cooling tower
Let: DCT = Diameter of Cooling Tower
𝑄𝑤 167.4𝐿/𝑚𝑖𝑛
ACT = H2O Concentration = 80L = 2.09m2
min 𝑚2

4(2.09𝑚2)
A = 𝜋/4DCT2 = DCT = √ = DCT = 1.63m
𝜋

FOR HEAT EXCHANGER

 37

DESIGN PREVIEW

FOR HEAT EXCHANGER

where:

tji = 64.6°c
tjo= 36.8°c
tcwi= 34°c
tcwj= 57°c
(From PPE by morse)
Qj= 249.16kW = 14166.67BTU/min
(From Catalogue)
 38

Solving for LMTD :

Δtmax= 64.6°c - 52.6°c = 12°c
Δtmin= 36.8°c - 31.2°c = 5.6°c
Δtmax−Δtmin
LMTD = ln(Δtmax/Δtmin)
12−5.6
LMTD = 12
ln( )
5.6
LMTD = 8.4°c
9
LMTD = 5 (8.4) + 32 = 47.16°F

𝑄𝑗
A= 𝑈(𝐿𝑀𝑇𝐷)

U = u x Ft x Fmx Fc x Fp

(from PPT by P.j. Potter)

Inlet temp of H2O = 51.2°c – 88.16°c

Material Specifications :
Tube : 8.82ft/s
Material : Aluminum brass
Vel. : 8.82ft/s
Ft : 1.09
Fp: 1.0 (turbine)
Fm : 0.96
FC : 0.85 (chlorinated)
C = 270
8.82𝑓𝑡
u : c √𝑣𝑒𝑙 = c √( )
𝑠
u : 801.86ft/s

U = 801.86 x 1.09 x 1 x 0.96 x 0.85

U = 713.21BTU/ft3-hr-°F
14166.67𝐵𝑇𝑈 60𝑚𝑚
( )
A= ℎ𝑟 1ℎ𝑟
(713.21)BTU/ft3−hr−°F
A = 25ft2

Total No. of Tubes = No. of tubes/Pass x No. of H2O pass

where :
𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝐻2𝑂 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑
No. of tube/pass = 𝑇𝑢𝑏𝑒/𝑝𝑎𝑠𝑠

Circulating H2O Required = MCW x V

mcw= mj= 7704kg/hr
 39

Vfc= Volume of circulating H2O

v = (64.6 + 36.8) °c
v = 50.17°c

Steam Table @ 50.17°c

By interpolation
51−50
v = 51−50.17
v = 1.0122L/kg

Vfc= (7704kg/hr)(1.0122L/kg)(1hr/60min)
Vfc= 129.97L/min
𝑉𝑓𝑐
No. of tubes/ Pass = 𝐻2𝑂 𝑄𝑢𝑎𝑛𝑡𝑖𝑡𝑦 𝑥 𝑣𝑔𝑝𝑚 @𝑓𝑡/𝑠𝑒𝑐

(from PPT by P.T. Potter)

Quantity of H2O = 1.042gpm/ft per sec.
129.97𝐿 1𝑔𝑎𝑙
( )( )
min 3.78𝑓𝑡
No. of tubes/pass = 1.042𝑔𝑝𝑚 8.82𝑓𝑡
𝑓𝑡 ( )
sec
𝑠

No. of tubes/pass = 3.04 ; Use: 4 tubes

25𝑓𝑡3 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡𝑢𝑏𝑒 31.84𝑓𝑡
Length of tube = 4?(1963) = 31.84𝑓𝑡 ; No. of H2O = 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑟𝑎𝑛𝑔𝑒 = = 3.184 ; 4m
10𝑓𝑡

Total No. of Tubes = No. of tubes/Pass x No. of H2O pass

Total No. of Tubes = 4 x 4
Total No. of Tubes = 16 tubes
 40

ISOMETRIC VIEW OF PLANT FLOOR PLAN

TOP VIEW
 41

FRONT VIEW

SIDE VIEW

Materials Foundation for Engine:

For 1250kW (2units) and 3300kW(2unit) and tank fuel storage

Sack of Cement 1642 sacks 264,362

Sand 92.582m3 10,878.39
Gravel Stone 187.16 m3 32,753
Reinforcement bar(14mm) 774 pcs 48,181.5
Bolts AISI 8640 1284pcs 23,038.81
Engine 1 and 2(1250kW) 2 units 10,720,000
Engine 3 and 4 (3300kW) 2 unit 20,697,600
 42

Total Php31,796,813.7

For Cooling Tower:

T-210 (1/4)hp -------------------------------------------- Php 76,524.00
Heat Exchanger------------------------------------------ Php 1,386,000.00
Fuel Pump------------------------------------------------- Php 106,522.00
Area propose for
Power plant (1000sq.m)-------------------------------Php 100,000.00

For 30% manpower

= 33,465,859.7 (.30)
= 10,039,757.91

Investment = 43,505,617.61

Diesel Consumption = 331, 947,936.00

Total Investment = Diesel Consumption + Investment

Total Investment = 331, 947,936.00 + 43,505,617.61
Total Investment = 375,453,553.6

Rate of Return

A. 1250 kW = Vf= 370,125 L/hr (2)

3300 kW = Vf= 365.88 L/hr (2)________
8760ℎ𝑟𝑠
1,472.01 L/hr ( 1𝑦𝑟 ) = 12,894,807.6 L/yr = Total Volume flowrate of
fuel
Fuel rate/price per year = 331,947,936.00

Annual Revenue = 331,947,936.00 (0.25)

= 82,986,984
= Fuel rate/price per yr + interest gained from fuel
= 331,947,936.00 + 82,986,984
Annual Revenue = 436,210,445.00
𝟑𝟕𝟓,𝟒𝟓𝟑,𝟓𝟓𝟑.𝟔−3,754,535.53
A. Depreciation = (1.25)5−1
0.25
Depreciation = 45,290,313.49

B. Operating on maintenance cost = 1,000,000.00

C. Taxes and insurance = (0.4) 375,453,553.6

Taxes and insurance = 150,181,421.4

Net Annual Profit =A-B-C-D

 43

= 436,210,445.00 – 45,290,313.49- 1,000,000.00 –

150,181,421.4
Net Annual Profit = 239,738,710.1
Net Annual 𝟐𝟑𝟗,𝟕𝟑𝟖,𝟕𝟏𝟎.𝟏
ROR = Investment x 100% = 𝟑𝟕𝟓,𝟒𝟓𝟑,𝟓𝟓𝟑.𝟔 𝑥 100%
ROR = 63.85%

Note:
Therefore if rate is 64.68% per year it is stimulated that within 1.5 years power plant will
attain breakeven point.

For Consumers :
116,181,720.00
Peso/Liter = 10,064,931.2 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑓𝑢𝑒𝑙 (𝑙𝑖𝑡𝑒𝑟𝑠)𝑝𝑒𝑟 𝑦𝑒𝑎𝑟
Price for customer pesos per liter of fuel = Php 39.42 per liter

𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑓𝑢𝑒𝑙 (𝑙𝑖𝑡𝑒𝑟)𝑝𝑒𝑟 𝑦𝑒𝑎𝑟 𝑥 𝑝𝑒𝑠𝑜 𝑝𝑒𝑟 𝑙𝑖𝑡𝑒𝑟

Price/kW-hr = 𝐴𝑐𝑡𝑢𝑎𝑙 𝐴𝑛𝑛𝑢𝑎𝑙 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑝𝑜𝑤𝑒𝑟
𝐿
12,894,807.6 𝑥 39.4 𝑝𝑒𝑟 𝑙𝑖𝑡𝑒𝑟
𝑦𝑟
Price/kW-hr = 9,990.050 𝑘𝑤−ℎ𝑟/𝑦𝑟

Price/kW-hr = Php 50.85/kw-hr