Power Plant Design Analysis Design

1 Power Plant Design for Sagay, Camiguin ACKNOWLEDGEMENT
First of all, we would like to say thank you for giving us the strength and health to
do this project work until it done not forgotten to my our family for providing everything
such as money to buy anything that are related to this work and their advised, which is
the most needed for this project. Internet, books, computers and all that as my source to
complete this project they also supported us and encouraged us to complete this task
so that we will not procrastinate in doing it. Then we would like to thank our professor
for guiding us and our friends throughout this project. We had some difficulties in doing
this task, but he taught us patiently until we knew what to do, he tried and tried to teach
us until we understand what we supposed to do with the project work. Last but not the
least, our friends who were doing this project with us and sharing our ideas they were
helpful that when we combined and discussed together we had this task done.
Power Plant Design / MEP544D2
2 Power Plant Design for Sagay, Camiguin
INTRODUCTION
In a diesel power station, diesel engine is used as the prime mover. The diesel burns
inside the engine and the products of this combustion act as the working fluid to
produce mechanical energy. The diesel engine drives alternator which converts
mechanical energy into electrical energy. As the generation cost is considerable due to
high price of diesel, therefore, such power stations are only used to produce small
power.
Although steam power stations and hydro-electric plants are invariably used to generate
bulk power at cheaper costs, yet diesel power stations are finding favour at places
where demand of power is less, sufficient quantity of coal and water is not available and
the transportation facilities are inadequate. This plants are also standby sets for
continuity of supply to important points such as hospitals, radio stations, cinema houses
and telephone exchanges. Power Plant Design / MEP544D2
The diesel engine is recognized as the most promising powertrain in the foreseeable
future due to its superior thermal efficiency and reliability. The diesel engine has been widely used in commercial vehicles, industrial applications and todays passenger cars
and light-duty trucks.
A diesel engine is a type of compression-ignition engine using diesel fuel. Diesel
engines can be classified into various categories. Understanding the differences and the
unique characteristics of each category of diesel engines is important for diesel engine
system design.
HISTORY
The first man, who had invented the engine with ignition from compression, was E. Steward. He was interested in engines, what can work without spark plugs. In Stewards
engine the air was compressed and compressed air was blown into the combustion
4 Power Plant Design for Sagay, Camiguin chamber. Unfortunately, Steward had not come into mind to test the efficiency of that
type of engines.
Developing the concept of economy-type heat-engine, Rudolph Diesel in 1890
invented the engine much more efficient due to high compression ratio. In his book he suggested to use the powdered coal, but it was difficult in real life the coal dust has an
abrasive properties and it should be found the way to put it somehow in combustion
chamber. So it was suggested to use the tailing that remains after oil refining in such
engines. So in 1897 Diesel had patented the engine design, later named Diesel engine.
Rudolf Diesel was born in Paris in 1858. His parents were Bavarian immigrants. Rudolf
Diesel was educated at Munich Polytechnic. After graduation he was employed as a
refrigerator engineer. However, he true love lay in engine design. Rudolf Diesel
designed many heat engines, including a solar-powered air engine. In 1893, he
published a paper describing an engine with combustion within a cylinder, the internal
5 Power Plant Design for Sagay, Camiguin combustion engine. In 1894, he filed for a patent for his new invention, dubbed the
diesel engine. Rudolf Diesel was almost killed by his engine when it exploded. However,
his engine was the first that proved that fuel could be ignited without a spark. He
operated his first successful engine in 1897.
POWER PLANT DESIGN FOR SAGAY

Diesel Power Plant for Sagay, Camiguin produces power in the range of 6.4 MW.
And they are used standby sets for continuity of supply such as hospitals, cinema
theatres and industries.
ADVANTAGES OF A DIESEL ENGINE

More efficient and economical to use. Fuel vapor is not explosive. Exhaust gases are less poisonous less carbon monoxide. Greater lugging power and torque. Power Plant Design / MEP544D2
6 Power Plant Design for Sagay, Camiguin Engines are durable and if properly cared for will maintain their economy. Fuel is less volatile no vapor lock problems Can use a variety of fuels and mixtures.
DISADVANTAGES OF DIESEL ENGINE

The fuel in diesel engine is ignited by the heat of the compressed air. HPFP of diesel engine is extremely unreliable unit. The exhaust filter is warming up in the flow of exhaust gas. it is expensive Noise and vibration till the latest times could not be separated from the words Diesel engine.
ADVANTAGES OF DIESEL POWER PLANT

The design and layout of the plant are quite simple. It occupies less space as the number and size of the auxiliaries is small. It can be located at any place. It can be started quickly and it can pickup load in a short time. There are no standby losses.
DISADVANTAGES OF DIESEL POWER PLANT

The plant has high running charges as the fuel (diesel) used is costly. The plant doesnt work satisfactorily under overload conditions for a longer
period. The plant can only generate small power. The cost of lubrication is generally high. The maintenances charges are generally high.
WHY WE CHOOSE DIESEL POWER PLANT
Purpose
Diesel power plants produce energy though the combustion of chemical fuel, in
most cases diesel derived from petroleum, into mechanical energy. This energy
is then used to power an alternator which in turn generates electricity. Diesel is
preferred to other fuel types as these engines have a higher thermal efficiency
than other commercial generators of equivalent size.
Process
Most modern generators harness mechanical energy through the process of
electromagnetic induction. In this system, the mechanical energy produced by
the diesel engine moves an electrical conductor, such as a magnetically charged
wire, in a magnetic field. The movement of the conductor creates a difference in
voltage between the two ends of the charged wire, creating a flow of electric
charges and thereby generating electricity.
LAYOUT OF DEISEL POWER PLANT
ESSENTIAL ELEMENTS OF DIESEL POWER PLANT
I.
DIESEL ENGINE
Diesel engine is a compressor ignition (CI) engine. The two stroke cycle engine is more favored for diesel power plants. The air required for the diesel engine is drawn through the air filter form the
atmosphere and compressed inside the cylinder. The fuel (diesel) from the diesel engine is drawn though a filter from the all-day
tank and injected into the cylinder through fuel injector. Because of the high temperature and pressure of the compressed air, the fuel
burns and the burn gases expand to do work on the moving part inside the
cylinder called piston. This movement of the piston rotates a flywheel and the engine is directly couple
to electric generator. The gases after expansion inside the cylinder are exhaust into the atmosphere
and passes through a silencer in order to reduce the noise.
II.
STARTING SYSTEM
The starting motor will crank the engine. The starting motor will spin the engine at a high enough rpm to allow the engines compression to ignite the fuel and start
the engine running. The engine will then accelerate to idle speed. When the starter motor is
overdriven by the running motor it will disengage the flywheel.
III.
FUEL SUPPLY SYSTEM
It consists of storage tank, strainers, fuel transfer pump and all day fuel tank. The
fuel oil is supplied at the plant site by rail or road. The oil is stored in the storage
tank. From the storage tank, oil is pumped to smaller all day tank at daily or short
intervals. From this tank, fuel oil is passed through strainers to remove
suspended impurities. The clean oil is injected into the engine by fuel injection
pump.
IV.
AIR INTAKE SYSTEM
This system supplies necessary air to the engine for fuel combustion. It consists
of pipes for the supply of fresh air to the engine manifold. Filters are provided to
remove dust particles from air which may act as abrasive in the engine cylinder.
V.
EXHAUST SYSTEM
This system leads the engine exhaust gas outside the building and discharges it
into atmosphere. A silencer is usually incorporated in the system to reduce the
noise level.
VI.
COOLING SYSTEM
The temperature of the burning fuel inside the engine cylinder is in the order of 15000 0C to 20000 0C. In order to lower this temperature water is circulated
around the engine.
13 Power Plant Design for Sagay, Camiguin The water envelopes (water jacket) the engine. The heat from the cylinder,
piston, combustion chamber etc., is carried by the circulating water. The hot water leaving the jacket is passed through the heat exchanger. The heat from the heat exchanger is carried away by the raw water circulated
through the heat exchanger and is cooled in the cooling tower.
VII.
LUBRICATING SYSTEM
The system minimises the wear of rubbing surfaces of the engine. It comprises of
lubricating oil tank, pump, filter and oil cooler. The lubrication oil is drawn from
the lubricating oil tank by the pump and is passed through filter to remove
impurities.
14 Power Plant Design for Sagay, Camiguin LOCATION MAP
LOCATION
Sagay, Camiguin
Sagay is a Philippine municipality. It is located in the province Camiguin in Region
X Northern Mindanao which is a part of the Mindanao group of islands. The municipality
Sagay is seated about 16 km south of province capital Mambajao and about 732 km
south-south-east of Philippine main capital Manila. The geographic coordinates of
Sagay are 9 6' 21'' N, 124 43' 29'' E.
Administratively the Municipality of Sagay is subdivided into 9 barangays. One forms
the center of the city wheras the other 8 are in the outlying areas. Some of them are
even several kilometers away from the center of the Municipality.
According to the 2007 census, Sagay has a population of 11,198 residents and is part
of the big group of 1073 cities and municipalities in the Philippines which have more
than 10.000 residents but did not reach 50.000 population yet. Based on the number of
its inhabitants Sagay is number 1483 of the most populous cities of the Philippines and
16 Power Plant Design for Sagay, Camiguin at 424 in Mindanao group of islands and at 4 of the most populous cities of province
Camiguin. With an area of 44.13 km Sagay occupies a relatively small urban area.
Accordingly, there is a high population density. In Sagay, by average, 253.75 people
live in one square kilometer. With this value, Sagay is only number 105 in Mindanao
and is nationally ranked 728th of the most densely populated cities in the Philippines.
According to the Philippine income classification for provinces, cities and municipalities
Sagay is a 5th class municipality. The urbanization status of Sagay is classified as
partly urban.
Among the bigger cities and municipalities in the neighborhood of Sagay there
areCagayan De Oro City (Misamis Oriental) 69 km south, Gingoog City (Misamis
Oriental) 55 km south-east, Manolo Fortich (Bukidnon) 83 km south, City Of
Cabadbaran (Agusan Del Norte) 88 km east, Butuan City (Agusan Del Norte) 90 km
east, Balingasag (Misamis Oriental) 40 km south, Tagoloan (Misamis Oriental) 63 km
17 Power Plant Design for Sagay, Camiguin south, Buenavista (Agusan Del Norte) 76 km east, Talakag (Bukidnon) 98 km south as
well as 50 km south of Sagay the municipality Jasaan (Misamis Oriental).
Municipalities
Total Population
Percentage Male Female
Camiguin
74,232
100
37,847
36,385
Catarman
15,368
20.7
7,864 7,522
Guinsiliban
5,092
6.9
2,620 2,472
Mahinog
12,592
17.0
6,368 6,224
Mambajao (Capital) 30,806
41.5
15,657
15,149
Sagay
10,356
14.0
5,338 5,018
Guinsiliban is 6.9% of total population of Camiguin therefore we can assume that out of
14,735 Occupied Housing Unit there are 1002 single houses which represents the
majority of the building structure on Guinsiliban and a household population of 1023.
18 Power Plant Design for Sagay, Camiguin Demographic Data:
Total No. of Population: 5,092
Household Population: 1023
Structures:
Group A
Group B
Single House: 1002
Multi- Unit Residential: 3
Duplex: 6
Commercial/Industrial/Agricultural: 1
19 Power Plant Design for Sagay, Camiguin GROUP A
GROUP B
20 Power Plant Design for Sagay, Camiguin Total Power Consumption Table
Time 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Total Load (w-hr / 24hrs.)
GROUP A 1632960 1632960 1632960 2237760 2136960 2136960 1532160 2056320 2056320 2378880 1854720 1854720 1854720 1310400 1310400 1310400 1532160 2136960 4354560 4677120 2459520 2459520 1632960 1632960 49815360 w-hr
No. of Consumer 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016 2016
Power Consumption 810 810 810 1110 1060 1060 760 1020 1020 1180 920 920 920 650 650 650 760 1060 2160 2320 1220 1220 810 810
GROUP B 16000 24000 24000 16000 24000 91200 94000 102000 110000 32000 28000 61200 48000 16000 24000 29200 29200 37200 53200 37200 53200 37200 64000 32000 1082800 w-hr
No. of Consumer 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
Power Consumption 2000 3000 3000 2000 3000 11400 11750 12750 13750 4000 3500 7650 6000 2000 3000 3650 3650 4650 6650 4650 6650 4650 8000 4000
Total Load (whr) 1648960 1648960 1648960 2253760 2160960 2228160 1626160 2158320 2166320 2419880 1882720 1915920 1902720 1326400 1334400 1339600 1561360 2174160 4407760 4714320 2512720 2496720 1696960 1664960
Total Load (w-hr / 24hrs.)
50898160 w-hr
21 Power Plant Design for Sagay, Camiguin Design Overview
Peak Load = 2357.16 kW, 2.35mW
Plant Capacity: 3200 kW, 3.2mW
No. of Engines: 5
Engine Capacity
Number of Hours of Operation/day
Unit 1 --- 800 kW
18hours/day
Unit 2 --- 800 kW
18hours/day
Unit 3 --- 800 kW
18hours/day
Unit 4 --- 800 kW
18hours/day
Unit 5 --- 800 kW
Reserve
Schedule of Engine Operation
Time of Operation
Engine Operating
Time Interval
12AM-6AM
Unit 1,2 and 3
6 hours Power Plant Design / MEP544D2
22 Power Plant Design for Sagay, Camiguin 6AM-12NN Unit 2,3 and 4 6 hours
12NN-6PM
Unit 1,4 and 2
6 hours
6PM-12AM
Unit 3,4 and 1
6 hours
Each Unit has a 6 straight hours break
DESIGN FOR MACHINE FOUNDATION
For 800 kW Generator Set (Per Unit 1,2,3,4 and 5)
Mixture for Concrete Foundation: Power Plant Design / MEP544D2
23 Power Plant Design for Sagay, Camiguin Use 1:3:5 concrete mixture ratio (from PPE by F.T. Morse, Table 4-1 p.90)
Soil Bearing Pressure:
Use 50-98 tones / m2 for common brick masonry
(from PPE by F.T. Morse, Table 4-4 p. 105)
Soil Bearing Pressure (Sb) =
= 50,000 kg/m2
Weight of Foundation
Wf = e x W e x
Where:
Wf = weight of the foundation, kgs
We = weight of the engine, kgs
N = engine speed, RPM
Use e = 0.11 (from PSME code, Table 2.4.2.3 (4), p.11)
24 Power Plant Design for Sagay, Camiguin Wf = 0.11 x 7897 kg x = 36, 859.21 kg
Volume of Foundation
Vf =
Where:
Vf = Volume of foundation [m3]
c = density of concrete = 2406 kg/m3
Vf =
= 15.32 m3
Depth of Foundation
h=
Where:
25 Power Plant Design for Sagay, Camiguin Hf = depth of foundation [m]
Lf = length of foundation [m]
Wf = width of the foundation [m]
Length of the Foundation
Lf = Lb + 10% Lb
Where:
Lb = length of bedplate [m]
Le = length of engine [m]
Lb = Lb + 6 in x
= 4,267 mm + 6 in x
5,047.4 mm
Lf = 4,419.4 mm + (0.10)(4,419.4 mm) = 4,861.34 mm
Lf = 4,861.34 mm x
= 4.86 = 5 m
Width of the Foundation
Wf = W b + 10%W b
Where:
Wb = Width of bedplate
We = width of the engine [m]
Wb = W b + 6 in x
= 2, 083 mm + 6 in x
= 2, 235.4 mm
Wb = 2,235.4 mm + (0.10)(2,235.4 mm) = 2,458.94 mm
Wf = 2,458.94 mm x
= 2.46 m = 2.5 m
h=
= 1.22 = 1.25 m
Soil Stress
27 Power Plant Design for Sagay, Camiguin Soil Stress =
Soil Stress =
= 3,580.50 kg/m2
Foundation Materials:
Concrete Mixture Ratio = 1 : 3 : 5
X + 3x + 5x = 15.32 m3
9x = 15.32 m3
X = 15.32 m3 / 9
X = 1.70 m3
Absolute Volume Material = Specific Weight of Material / (Bulk S.G.)(Sp. Weight of
Water)
For Cement:
28 Power Plant Design for Sagay, Camiguin 1 x 6.2 x 1.70 m3 = 10.54 m3
Absolute Volume Material =
= 0.48 ft3/bag x
= 0.014 m3/bag
No. of bags =
= 753 bags
3 x 0.52 x 1.70 m3 = 2.65 m3
= 2 ft3/bag x
= 0.057 m3/bag
For Gravel:
5 x 0.86 x 1.70m3 = 7.31m3
= 2.89 ft3/bag x
= 0.082 m3/bag
No. of Bags =
89 bags
For Reinforcing Bar:
Using 14 mm diam. Rebars
29 Power Plant Design for Sagay, Camiguin WRB = 1%Wf = (0.01)(36.859.21 kg) = 368.59 kg
Weight of Rebar/pc = density of steel x VRB
Weight of Rebar/pc 7800 kg/m3 x (/4)(14 mm/1000m)2 (6.1m) 29.3 kg
No. of Reinforcing Bars =
12.58 = 13 pcs
Flexure formula
Fb =
Eccentricity from mid-base
Y1 = 1/2h = (1.25m) = 0.625m
Y2 = 1/3h = 1/3 (1.25m) = 0.42m
A1 = Lf = h = (5m) (1.25m) = 6.25m2
A2 = Lf x b
Where:
30 Power Plant Design for Sagay, Camiguin B= = = 0.36m
If b < W f, then W f = b; used b = W f = 2.5 m
A2 = Lf x b = (5m)(2.5m) = 6.25m2
A = A1 + A2 = (6.25 + 6.25) m2 = 12.5m2
AY = A1Y1 = A2Y2 = [(6.25) (0.625) + (6.25) (0.42)] m3 = 6.53 m3
C=
= 0.52 m
For Bolts:
Diameter = 1/8 x (bore) = 1/8 x (150mm) = 18.75 mm
Length = 7/8 x (stroke) = 7/8 x (160mm) = 140 mm
Use L = 30D (from ASME code)
31 Power Plant Design for Sagay, Camiguin L = 30 (18.75 mm) = 562.5 mm
No. of bolts =
Where:
Tbolts =
From Table AT 7 DME by V.M. Faires
Material: AISI 8630 (for connecting rods, bolts, shapes)
Sy = 100ksi = 100,000psi; Fy = 7 (max. for Shock)
Sy =
= 7,142.86 psi x
= 49,234.69 kpa
Tbolts =
= 20.28 N.m
No. of Bolts =
= 662.13 = 663 bolts
Design for Fuel Tank Power Plant Design / MEP544D2
32 Power Plant Design for Sagay, Camiguin For 800 kW Generator Set (Per Unit 1, 2, 3, 4, and 5)
Type of oil: Diesel Fuel Oil
Specific Gravity = 0.917 @ 600F
(From Power Plant Theory and design by P.J. Potter, Table 5-4, and p.186)
SGf =
= SGf x
= 0.917 x
= 917 kg/m3
Generator Output (EP) =
Where:
BP =
g = 97.8% (For 1800 rpm & 494.73 kW Ave. Load)
(From Power Plant Theory and Design by P.J. Potter, figure 9-27, p.445)
BP =
= 818 kW
Specific Fuel Consumption
= 0.25 kg / kW hr
Plant Operation = 24 hrs/day
Engine Operation Hrs/Day = 18 hrs/day
Expected Fuel Delivery Schedule = Every 15 days
% Rated Capacity
x 100% =
x 100% = 75%
From PPE by F.T. Morse, Fig. 6-15, p.164
Max. Fuel Consumption = 0.25 kg/kW-hr
34 Power Plant Design for Sagay, Camiguin Min. Fuel Consumption = 0.21 kg/kW-hr
Volume of Day Tank
VDT =
Where:
mF = daily fuel consumption [kg/day],
= density of fuel = 917 kg/m3
mF = max. fuel consumption x BP x engine operating hrs/day
= (0.25 kg/kW-hr) (181kW) (18hrs/day)
= 3681 kg/day
VDT =
4.01 m3/day
Dimension of Day Tank
VDT =
DDT2 H
DDT -
(From the above equation) -
= 1.37m
35 Power Plant Design for Sagay, Camiguin Assume:
HDT = 2DDT = 2(1.37m) = 2.74m
Thickness of fuel Tank
TDT =
Where:
PT = Pressure inside tank = HDT x YFuel
YFuel = 8.996 kN/m3
PT = 2.74m x 8.996 kN/m3 = 24.65 kN/m3 or kPa
Sy = Tensile Yield = 35,000 psi (from DME by V.M. Faires, Table AT 4, p. 568)
F.S.y = Design factor of Safety
F.S.y = 3(for stainless steel from DME by V.M. Faires Table 1.1, p.20)
N = 75%
36 Power Plant Design for Sagay, Camiguin TDT = = 0.3 mm; use 1 mm thickness
Storage Tank for 30 days operation
VST = VDT = x 30 days/month = 4.01 m3/day x 30 days/month = 120.3 m3/month
Dimension of storage tank
VST =
DST2 H
DST =
(From the above equation) -
= 4.25m
Assume:
HST = 2DST = 2(4.25 m) = 8.5m
Material for fuel tank: AISI No. 321 (Stainless steel)
Thickness of fuel storage tank
TST = Power Plant Design / MEP544D2
37 Power Plant Design for Sagay, Camiguin Where:
PT = pressure inside tank = HST x YFuel
YFuel = 8.996 kN/m3
PT = 8.5m x 8.996 kN/m3 = 76.46 kN/m2 or kpa
SY = Tensile Yield = 48,000 psi (from DME by V.M. Faires, Table AT 7, p.576)
F.S.y = 2(for stainless steel from DME by V.M. Faires Table 1.1, p.20)
n = 75%
TST =
= 1.31 mm
Transfer Pump from Fuel Storage Pump to Day tank
Assumption:
Desired operating time for fuel pump = 1 hr/day
P = 72%
38 Power Plant Design for Sagay, Camiguin Power input for unit 1, 2, 3, 4, and 5
EPi =
Where:
EPi = electrical power input [kW] or [hp]
Yfuel = 8.996 kN/m3
THD = total dynamic head [m]
TDH = Z2 Z1 +
TDH = (2.74)-(-8.5)m = 11.24 m
Q = volume flow rate [m3/s]
Q --
Where:
VDT = volume of fuel at day tank [m3/s]
39 Power Plant Design for Sagay, Camiguin t = time of pump operation [sec]
Q --
0.00111 m3/s
EPi =
= 0.16 kW x
= 0.21 hp
1 hp is used for unit 1 transfer pump
VARIABLE LOAD CALCULATIONS
Plant Capacity = Peak Load + Peak Load (20)
= 2357.16kW + 471.432 kW = 2828.592 kW
(we use 3200kW from catalog 800kW x 4 genset)
Reserve over peak = plant capacity peak load
= (3200kW 2357.16kW) = 842.84kW
Average Load =
= 1060.378333kW
40 Power Plant Design for Sagay, Camiguin Capacity Factory = 33.14%
Annual capacity factor =
= 33.14%
Load Factor -
44.99%
Demand Factor
73.66%
Plant Factor =
= 33.14%
ENGINE APPLICATION DATA
Engine Specifications
Manufacturer
Mitsubishi Power Plant Design / MEP544D2
41 Power Plant Design for Sagay, Camiguin Engine Model # S12A2 Y2PTAW-2
Engine Type
4 Cycle, 12 Cylinder
Induction System
Turbochanged, Inter Cooler
Displacement, L (in3)
33.9 (2071)
EPA Emission Level
Tier 2
HP at Rated Speed BHP (KW)
1207 (900)
Rated RPM
1800
Bore and Stroke in (mm)
5.19 x 6.30 (150 x 160)
Compressor Ratio
15.3:1
Air Filter Type
Dry
Govermor Type/Model
Proact2
Govermor Manufacturer
Woodward
Freq Reg NL to FL
Isochronous Power Plant Design / MEP544D2
42 Power Plant Design for Sagay, Camiguin Freq Reg Steady State +/- 0.25%
Engine Lubrication System
Oil Pan Capacity gal (L)
26.4 (100.0)
Oil Pan w/ Filter
31.7 (120.0)
Oil Filter Quantity
Oil Cooler
Water Cooled
Recommended Oil
15W 40
Oil Press Psi (kPa)
57 (393)
Engine Cooling System
Genset Max Ambient Temperature
113 (45)
Engine Coolant Cap qt (L)
105.7 (100.0) Power Plant Design / MEP544D2
43 Power Plant Design for Sagay, Camiguin Engine + Radiant System Cap qt (L) 402.0 (380.4)
Water Pump Type
Centrifugal
Coolant Flow gpm (Lpm)
291 (1101.4)
Charge Cooler Flow gpm (Lpm)
124 (469.3)
Heat Rejected to Cooling Water
@ Rated kW: BTU/min (kW)
20418 (358.9)
Heat Rejected to Charge Cooler
16043 (282.0)
Heat Rejected to Ambient Air
4375 (76.9)
Max. Restriction of Cooling Air in
H20 (kPa)
0.5 (0.124)
Engine Exhaust System
Exhaust Manifold Type
Dry
Exhaust flow @ Rated kW cfm (c-mm)
8192 (232)
Exhaust Temp. (Dry manifold) 0F (0C)
953 (497)
Max. Back Pressure InH20 (kPa)
23.6 (5.9)
Exhaust Outlet Diameter in (mm)
8.35 (212)
Exhaust Outlet Type
JIS200A (approx. 8)
Engine Electrical System
Changing Alternator Volts dc
24
Changing Alternator Amps
25
Grounding Polarity
Negative Power Plant Design / MEP544D2
45 Power Plant Design for Sagay, Camiguin Started Motor Volts dc 24
Battery Recommendations
Battery Volts dc
24
Min Cold Cranking Amps
1100
Quantity Required
Ventilation Requirements
Cooling Airflow scfm (cmm)
40042 (1134)
Combustion Airflow cfm (cmm)
3107 (88)
Heat Rejected to Ambient
From Engine BTU/min (kW)
4375 (77)
From Alternator BTU/min (kW)
2275 (40)
Recommended Free Area Intake Power Plant Design / MEP544D2
46 Power Plant Design for Sagay, Camiguin Louver Size ft2 (m2) 87.0 (8.09)
Engine Fuel System
Recommended Fuel
# 2 Diesel
Fuel Line at Engine
Supply Line Min ID in (mm)
0.75 (19)
Return Line Min ID in (mm)
0.75 (19)
Fuel Pump type
Engine Driven
Fuel Pump Max Lift ft (m)
3 (1)
Fuel Flow to Pump gpm (Lph)
148 (560.2)
Fuel Filter
Secondary Filter
2 m
Secondary Water Separator
Not Included Power Plant Design / MEP544D2
47 Power Plant Design for Sagay, Camiguin Primary Filter Optional
Primary Water Separator
Optional
Fuel Consumption Standby Rating
100% Load gph (Lph)
65.2 (246.5)
75% Load gph (Lph)
46.8 (177.1)
50% Load gph (Lph)
32.2 (121.9)
25% Load gph (Lph)
19.3 (73.1)
Fuel Consumption Prime Rating Power Plant Design / MEP544D2
48 Power Plant Design for Sagay, Camiguin 100% Load gph (Lph) 59.3 (224.5)
75% Load gph (Lph)
42.6 (161.2)
50% Load gph (Lph)
29.3 (110.9)
25% Load gph (Lph)
17.6 (66.6)
Engine Output Deratings Standby
Rated Temp
400C
Rated Altitude
1500 m
Max Altitude
5000 m
Temperature Derate
-5% / 100C
Altitude Derate
-1% / 100 m
Alternator Specifications
Alternator Type
4-Pole Rotating Field
Exciter Type
Brushless
Excitation
PMG
Insulation
per NEMA MG1
Material
Class H
Standby Temp Rise
150 0C
Prime Temp Rise
125 0C
Lead Connection
12 Lead, Reconnect able
Stator Pitch
2/3 Power Plant Design / MEP544D2
50 Power Plant Design for Sagay, Camiguin Amortisseur Winding Full
Bearing
Single Double Shielded
Drive Coupling
Flexible Disk
Unbalance Load
20% of Standby Rating
Automatic Voltage Regulator
PMG
Std MX321
Voltage Regulation
No Load to Full Load
PMG Regulator
+/- 0.5%
Load Acceptance
100% of Rating
Subtransient Reactance
480V, Per Unit
18%
TIF (1960 Weighting)
<50
Line Harmonics
30% Max. Voltage Dip Power Plant Design / MEP544D2
51 Power Plant Design for Sagay, Camiguin Alt @ 480V SkVA HC1634G 311 2350
Alt @ 480V SkVA
HC1634H 311 2680
Genset Controller Specifications
Baldor Intelligent NT Features
Large back-lit graphical LCD display
64 x 128 pixel resolution
Sealed Membrane Panel to IP65
Push Buttons for Simple Control
Start, Stop, Fault Reset, Horn Reset, Mode
Page, and Enter Keys
Display Metering and Protection Power Plant Design / MEP544D2
52 Power Plant Design for Sagay, Camiguin Oil Pressure Warning / Shutdown
High / Low Coolant Temperature Warning
High Coolant Temperature Shutdown
Low Coolant Level Shutdown
Low Fuel Level Warning / Shut Warning
Over Speed Protection
Battery Voltage Under / Over Warning
Running Hour Meter
Generator Under / Over Volts Warn / Shutdown
Generator Under / Over Freq Warn / Shutdown
Generator over Current Shutdown
Generator Output Metering for V1, V3, I1 I3,
Hz, kW, kWh, kVAr, kWAh Power Plant Design / MEP544D2
53 Power Plant Design for Sagay, Camiguin User Configurable Inputs and Output
Up to 500 Event Based History Records
Integrated PLC Programming Functions
Interface to Remote Display or
Remote Annunciator
Controller Capable of Both Single or Multiple
Gensets Operating in standby or
Parallel Modes
Addition Standard Genset Features
Structural Steel Sub-Base Sub-Base Lifting Eyes Unit Mounted Radiator
54 Power Plant Design for Sagay, Camiguin Engine Mounted Fan Fan Guard Battery Changing Alternator Battery Rack and Cables Unit Mounted Control Panel Spin-On Filters for Oil and Fuel Enamel Set-Operator / Maintenance Manual Factory Tested Prior to Shipment Limited Warranty
Optional Agency Approvals
UL2200 (Review Option Availability)
NFPA110 (Request Remote Annuciator)
Weight and Dimensions (Open Unit)
Weight Wet lb(Kg)
17410 (7897)
Overall Dimension
Length x Width x Height
Inches
168 x 82 x 93
mm
4267 x 2083 x 2362
Note: Drawing is provided for reference only. Use engineering outline for installation
planning.
Materials
Quantity
Cement
3675
Gravel Equipment Quantity
435
Anchor Bolts 1/8 x 7/8
3315
800 kW Diesel Genset 5 (IDLC 800-2M)
Renforcing Bars 14mm
65
Fuel Transfer Pump 1hp
Cooling Tower Pump 10 0.11hp
Cooling Water Fan 0.27hp
10
57 Power Plant Design for Sagay, Camiguin PERSPECTIVE VIEW x 20 ft
Aluminum Brass Tude 120 3/4 in
ECONOMICS
Design of fuel storage tank assumes that diesel to be used is 30API with a temperature
of 26.67C. Power Plant Design / MEP544D2
SG =
SG@ 15.6 0C =
= 0.8761
SG@ 26.6 0C
= [(0.8761) (1- 0.00072) (26.67-15.6)]
SG @ 26.6 = 0.86911
= (0.86911) (62.4) lb/ft3
= 54.23 lb/ft3
HHV = 41, 130 + 139.6 (300API)
Qh = HHV = 45318 kJ/kg = 47.65 kw hr/gal
QL = LHV =27.39 kw hr/gal
Ave. =
= 10.13
Daily fuel consumption =
= 6071.07 gal/day
Storage tank for 1 month
= Daily Consumption x 30 Days/month
= 6071.07 x Days/month
= 182132.28 gal/month
Monthly fuel delivery
Fuel delivery in liter
1 gal = 3.7854 liter
Capacity of trailer truck = 72, 000 liters
62 Power Plant Design for Sagay, Camiguin One month = = 10 tank per month
ECONOMIC STUDIES
Capacity Factor = 52.08
Ave. Load of Power Plant = 125000 kw hr
Monthly fuel consumption = 182132.28 gal/month
Semi fuel consumption =
= 91066.14
Assuming the diesel fuel is supplied by the government at a whole sale price @ .75
per/gal cost of fuel per year
= 182132.28 gal/month x 20 month x .75
= Php 1639190.52
POWER PLANT ECONOMICS
63 Power Plant Design for Sagay, Camiguin Power Plant Cost:
Cost per Kw installed
Php = 500.00
Cost per unit
2000 Kw x 500.00
Php = 1,000,000
Total Cost per unit installed
5 x 500,000
Php = 2,500,000
Building
Php = 400,000
Real State
Php = 180,000
Equipment
Php = 150,000
Engineering Fees
Php = 70,000
Total Plant Cost Php = 3,300,000
Cost of Transmission Lines: Power Plant Design / MEP544D2
64 Power Plant Design for Sagay, Camiguin Primary line Php = 140,000
Secondary line
Php = 800,000
The annual costs of Operation are as follows:
Francise and Publicity
Php = 2.4 customer
Assuming 25, 000 customer
Php = 60,000
Supervision and management
Php = 30,000
Maintenance and repair
Php = 10, 000
Oil waste and supply
Php = 20,000
Fuel used
Php = 2617.48
Maintenance in secondary lines
Php = 70,000
Labor: Power Plant Design / MEP544D2
65 Power Plant Design for Sagay, Camiguin For Generation Php = 80,000
For Distribution Primary
Php = 20,000
For Distribution secondary line
Php = 20,000
For accounting
Php = 60,000
Interest Rate = 6% Taxes. 5% insurance
Life = 50 years
Primary distribution = 20 years
Secondary distribution = 20 years
Salvage Value:
Power Plant = 10% of the first cost
Primary line = 20% of the first cost
Secondary = 20% of the first cost Power Plant Design / MEP544D2
Fixed element annual cost:
Capital cost - cost of the PLANT - Cost of the Primary line
2,470,000 70,000
2,540,00
Primary Salvage Value:
20% of the primary line
.20 x 70,000
Php 14, 000
From Equation (3-1) p. 71, PPE by F.T. Morse
Straight line annual depreciation reserve
67 Power Plant Design for Sagay, Camiguin Where:
P The principal sum
S The final salvage value
N Terms in years
Plant annual Depreciation Reserve:
Primary Line annual appreciation reserve
= Php 5,600
Interest taxes and insurance of the capital cost:
= (0.06 + 0.05) x 3,300,000 = 363,000
Plant maintenance and repair
Php = 10,000
68 Power Plant Design for Sagay, Camiguin Supervision and management Php = 30,000
Plant Depreciation
Php = 88,800
Primary line depreciation
Php = 5,600
Total = Php 677,920
Energy Element:
Oil waste supply
Php = 20,000
Labor for generation
Php = 80,000
Maintenance on primary lines
Php = 10,000
Labor on distribution
Php = 20,000
Fuel consumption
Php = 2617488
Total = Php 2,746,954
Customer Element: Power Plant Design / MEP544D2
69 Power Plant Design for Sagay, Camiguin Secondary line Salvage value:
= 20% of secondary line first cost
= .20 x 800,000 = Php 160,000
Secondary line annual depreciation reserve:
= 32,000
Interest, Taxes and Insurance of Secondary Line
= (0.06 + 0.05) + 800,000 =
Php = 88,000
Publicity and franchine
Php = 70,000
Labor for accounting
Php = 60,000
Secondary line depreciation
Php = 18,000
70 Power Plant Design for Sagay, Camiguin Total = Php 236,000
A) Cost per kW installed
= Php 848 kW
B) Cost per kW hr produced:
= 0.09 cents kW hr produced
C) Cost per kW hr delivered:
Allow 20% Elec. Transmission loss
= 0.05 cents kW-hr
71 Power Plant Design for Sagay, Camiguin Investors Profit:
Assume annual profit of capitalization over and store interest to be 8.0%
Capitalization = cost of the plant, primary and secondary distribution system
= 3,300,000 + 140,000 + 800,000
= 4,240,000 x .08 = Php 339,200
Straight Line Meter Rate:
Assuming the various element lost
Fixed element
Php = 677920
Energy
Php = 2,746,954
Customer element
Php = 236,000 Power Plant Design / MEP544D2
72 Power Plant Design for Sagay, Camiguin Profit Php = 339,200
Total = Php 4,000,074
Rate =
= 0.09 cents kW/hr
Three Charge Rate
For this, let the profit element be placed with fixed element and customer
element in proportion to the capital (element) investment for customer element.
= 3,300,000 + 140,000
= 3,440,000
Demand charge = fixed element + portion of profit
339200 = 952,816.68
Assume over all diversity factor
4.5
73 Power Plant Design for Sagay, Camiguin Peak power plant demand 5,000 kw
Customer peak demand
5,000 x .45 + 22, 500 kW
Unit demand change
= 27.68 kW hr
Maximum demand per month =
= 2.308 per month
Energy element was:
= 2747954 for 24750 kW hr / year
Hence the unit energy charge = customer element + remainder of profit
= 236,000 +
x 33920
74 Power Plant Design for Sagay, Camiguin = Php 244223.03
Dividing equally between 25,000 customers
The result is
= 9.76
= Php .814 / month
COMPUTATION FOR TRANSFORMERS
Establishment
Transformer # 1 30
Quantities
Capacity
Total Watts
Residential A
756 Houses
2477 Watts
1,872,612 w
Transformer # 31 40
Quantities
Capacity
Total Watts
Residential B
252 Houses
2478 Watts
624456 w
For Transformer # 1 40, Residential A and B to be Total of 2,497,068 Watts -
hours
Establishment
Transformer # 41 - 45
Quantities
Capacity
Total Watts
Commercial A
135,350 Watts
270,000 w
Transformer # 46 - 50
Quantities
Capacity
Total Watts
Commercial B
135,350 Watts
270,000 w
For Transformer # 41 50, Commercial A and B to be Total of 541,400 Watts -
hours
FEEDERS LOAD BETWEEN TRANSFORMERS
Feeder #1 (Transformer 1 -10)
Max. Feeder Load =
Max. Feeder Load = 1249387.692 Watts = 1249.388 kW
Feeder #2 (Transformer 11 - 20)
Max. Feeder Load =
77 Power Plant Design for Sagay, Camiguin Max. Feeder Load = 1249387.692 Watts = 1249.388 kW
Max. Feeder Load =
Max. Feeder Load =
78 Power Plant Design for Sagay, Camiguin Max. Feeder Load =
Max. Feeder Load =
SUBSTATION LOAD BETWEEN FEEDERS
Substation #1
Max. Feeder Load =
79 Power Plant Design for Sagay, Camiguin Max. Feeder Load = 3123469.23 Watts = 3123.469 kW
Substation #2
Max. Feeder Load =
POWER PLANT LOAD BETWEEN SUBSTATIONS
Max. Feeder Load =

Power Plant Design Analysis Design

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Power Plant Design Analysis Design

Uploaded by

Copyright:

Available Formats

1 Power Plant Design for Sagay, Camiguin ACKNOWLEDGEMENT

Power Plant Design / MEP544D2

2 Power Plant Design for Sagay, Camiguin

and telephone exchanges. Power Plant Design / MEP544D2

3 Power Plant Design for Sagay, Camiguin

and light-duty trucks.

A diesel engine is a type of compression-ignition engine using diesel fuel. Diesel

Power Plant Design / MEP544D2

Developing the concept of economy-type heat-engine, Rudolph Diesel in 1890

Diesel was educated at Munich Polytechnic. After graduation he was employed as a

designed many heat engines, including a solar-powered air engine. In 1893, he

Power Plant Design / MEP544D2

operated his first successful engine in 1897.

POWER PLANT DESIGN FOR SAGAY

theatres and industries.

ADVANTAGES OF A DIESEL ENGINE

DISADVANTAGES OF DIESEL ENGINE

Power Plant Design / MEP544D2

7 Power Plant Design for Sagay, Camiguin

ADVANTAGES OF DIESEL POWER PLANT

DISADVANTAGES OF DIESEL POWER PLANT

Power Plant Design / MEP544D2

8 Power Plant Design for Sagay, Camiguin

WHY WE CHOOSE DIESEL POWER PLANT

is then used to power an alternator which in turn generates electricity. Diesel is

than other commercial generators of equivalent size.

Most modern generators harness mechanical energy through the process of

electromagnetic induction. In this system, the mechanical energy produced by

the diesel engine moves an electrical conductor, such as a magnetically charged

wire, in a magnetic field. The movement of the conductor creates a difference in

charges and thereby generating electricity.

Power Plant Design / MEP544D2

9 Power Plant Design for Sagay, Camiguin

LAYOUT OF DEISEL POWER PLANT

Power Plant Design / MEP544D2

10 Power Plant Design for Sagay, Camiguin

ESSENTIAL ELEMENTS OF DIESEL POWER PLANT

and passes through a silencer in order to reduce the noise.

Power Plant Design / MEP544D2

11 Power Plant Design for Sagay, Camiguin

overdriven by the running motor it will disengage the flywheel.

FUEL SUPPLY SYSTEM

Power Plant Design / MEP544D2

12 Power Plant Design for Sagay, Camiguin

AIR INTAKE SYSTEM

into atmosphere. A silencer is usually incorporated in the system to reduce the

around the engine.

Power Plant Design / MEP544D2

through the heat exchanger and is cooled in the cooling tower.

Power Plant Design / MEP544D2

14 Power Plant Design for Sagay, Camiguin LOCATION MAP

Power Plant Design / MEP544D2

15 Power Plant Design for Sagay, Camiguin

Sagay is a Philippine municipality. It is located in the province Camiguin in Region

south-south-east of Philippine main capital Manila. The geographic coordinates of

Sagay are 9 6' 21'' N, 124 43' 29'' E.

Administratively the Municipality of Sagay is subdivided into 9 barangays. One forms

even several kilometers away from the center of the Municipality.

Power Plant Design / MEP544D2

Accordingly, there is a high population density. In Sagay, by average, 253.75 people

Sagay is a 5th class municipality. The urbanization status of Sagay is classified as

areCagayan De Oro City (Misamis Oriental) 69 km south, Gingoog City (Misamis

Oriental) 55 km south-east, Manolo Fortich (Bukidnon) 83 km south, City Of