power plant design part iii

RIZAL TECHNOLOGICAL UNIVERSITY

College of Engineering and Industrial Technology

Location

Guinsiliban, Camiguin

Camiguin, the smallest province in Northern Mindanao (Region X), had a total population of 74,232 persons based on the results of the 2000 Census of Population and Housing. It was the second to the smallest in the Philippines in terms of population. It registered an annual growth rate of 1.88 percent from 1995 to 2000, higher than the 1.08 percent growth rate during the 1990 to 1995 period. If the current rate continues, the population of Camiguin was expected to double in 37 years.

The number of households rose to 14,826, higher by 1,352 households from the 1995 figure. The average household size was 5.0 persons (same as the national average), which was lower than the 1995 average of 5.04 persons.

Of the five municipalities in Camiguin, its capital Mambajao, which comprised 42 percent of the total provincial population, was the largest in terms of population size. Catarman, Mahinog, and Sagay followed with 21 percent, 17 percent and 14 percent, respectively. Of the total population, Guinsiliban had the least share (seven percent).

Camiguin had the least population in Northern Mindanao (Region X), contributing only 2.70 percent to the 2.7 million population of the region. At the national level, Camiguin shared 0.10 percent to the total Philippine population of 76.5 million as recorded in the Census 2000.

Of the total household population five years old and over, about two out of five persons had attended or completed elementary education. Thirty one percent had either attended or finished high school while 12 percent had attended college. Only four percent were academic degree holders. More than half of those who had attended or finished elementary education (53.1 percent) and post secondary (54.7 percent) were males. On the other hand, those who had attended or finished college, academic degree holders and post baccalaureate were predominantly females.

About 45 percent of the total population in Camiguin classified themselves as Cebuano. Kamigin/Kinamiging followed with 36 percent and the Boholanos, with 11 percent. The remaining three percent were either Binisaya or belonged to other ethnic groups.

There were 15,449 housing units in Camiguin, of which 14,735 were occupied. This registered an increase of 23.3 percentage points from 1990, a ratio of 1.01 household per occupied housing unit, and 5.03 persons per occupied housing unit. Almost all (98.6 percent) occupied housing units were single houses, an increase of 22 percentage points from the 1990 figure.



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 structures on Guinsiliban and a household population of 1023.

Demographic Data:

Total No. of Population: 5,092

Household Population: 1023

Structures:

(Group A)

Single House: 1002

Duplex: 6

(Group B)

Multi-Unit Residential: 3

Commercial/Industrial/Agricultural: 1



Graphical Representation of Load



Load Table (GROUP A)

Load Table (GROUP B)



Total Power Consumption Table

25449.08kW-hr/day

Design Overview

Peak Load = 2357.16 kW, 2.35716mW

Plant Capacity: 3200 kW, 3.2mW

No. of Engines: 5



Engine Capacity Number of Hours of Operation/day

Unit 1 – 800 kW 18 hours/day




Unit 5 – 800 kW Reserve

Schedule of Engine Operation

Time of Operation

Engine Operating

Time Interval

12AM - 6AM UNIT 1,2 & 3 6 hours6AM -12NN UNIT 2,3 & 4 6 hours12NN - 6PM UNIT 4,1 & 2 6 hours6PM - 12AM UNIT 3,4 & 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:

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 compact clay (from PPE by F.T. Morse, Table 4-4 p.105)

Soil Bearing Pressure (Sb)

Weight of foundation

Where:

Wf = weight of the foundation, kgs

We = weight of the engine, kgs

e = empirical coefficient

n = engine speed, RPM

Use e = 0.11 (from PSME code, Table 2.4.2.3 (4), p.11)

Volume of foundation

Where:

Vf = volume of foundation [m3]

ρc = density of concrete = 2406 kg/m3



Depth of Foundation

Where:

hf = depth of foundation [m]

Lf = length of foundation [m]

wf = width of the foundation [m]

Length of the foundation:

Where:

Lb = length of bedplate [m]

Le = length of engine [m]

Width of the foundation:

Where:

wb = width of bedplate [m]

we = width of the engine [m]



Soil Stress

Soil Stress

Soil Stress

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



For cement:

1 x 6.2 x 1.70 m3 = 10.54 m3

For sand:

3 x 0.52 x 1.70 m3 = 2.65 m3

For gravel:

5 x 0.86 x 1.70 m3 = 7.31 m3



For Reinforcing Bar:

Using 14 mm diam. rebars

Flexure formula

Eccentricity from mid-base

Y1 = 1/2h = ½ (1.25m) = 0.625m

Y2 = 1/3h = 1/3(1.25m) = 0.42m

A1 = Lf x h = (5 m)(1.25 m) = 6.25 m2

A2 = ½ Lf x b

Where:



b

if b < wf, then wf = b; use b = wf = 2.5 m

A2 = ½ Lf x b = ½ (5 m)(2.5 m) = 6.25 m2

∑A = A1 + A2 = (6.25 + 6.25) m2 = 12.5 m2

∑AY = A1Y1 + A2Y2 = [(6.25)(0.625) + (6.25)(0.42)] m3 = 6.53 m3

C

m =

For Bolts:

Diameter = 1/8 x (bore) = 1/8 x (150mm) = 18.75 mm

Length = 7/8 x (stroke) = 7/8 x (160 mm) = 140 mm

Use L = 30D (from ASME code)

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 = 100 ksi = 100, 000 psi; Fy = 7 (max. for shock)

Tbolts

No. of bolts



Design for Fuel Tank

For 800 kW Generator Set (Per Unit 1, 2, 3, 4 and 5 )

Type of Oil: Diesel Fuel Oil

Specific Gravity = 0.917 @ 60°F

(From Power Plant Theory and Design by P.J. Potter, Table 5-4, and p.187)

Generator Output (EP) = 800 kW

Specific Fuel Consumption

Where:

BP

(For 1800 rpm & 494.73 kW Ave. Load)

(From Power Plant Theory and Design by P.J. Potter, Figure 9-27, p.445)

BP

Specific Fuel Consumption

Plant Operation = 24 hrs/day

Engine Operating Hours/day = 18 hrs/day



Expected Fuel Delivery Schedule = every 15 days

% Rated Capacity

From PPE by F.T. Morse, Fig 6-15, p.164

Max. fuel consumption = 0.25 kg/kW-hr

Min. fuel consumption = 0.21 kg/kW-hr

Volume of Day Tank

Where:

mF = daily fuel consumption [kg/day]

ρF = density of fuel = 917 kg/m3

mF = max. fuel consumption x BP x engine operating hours/day

= (0.25 kg/kW-hr) (818 kW) (18 hrs/day)

= 3681 kg / day

Dimension of Day Tank



(From the above equation)

Assume:

HDT = 2DDT = 2 (1.37 m) = 2.74 m

Thickness of Fuel Day Tank

Where:

PT = pressure inside tank

Where:

γfuel = 8.996 kN/m3

PT = 2.74 m x 8.996 kN/m3 = 24.65 kN/m2 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%

Storage Tank for 30 days operation



Dimension of Storage Tank

(From the above equation)

Assume:

HST = 2DST = 2 (4.25 m) = 8.5 m

Material for Fuel Tank: AISI No. 321 (stainless steel)

Thickness of Fuel Storage Tank

Where:

PT = pressure inside tank

Where:


PT = 8.5 m 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 = Design factor of safety

F.S.y = 2 (for stainless steel from DME by V.M. Faires Table 1.1, p.20)

n = 75%



Transfer Pump from Fuel Storage Pump to Day Tank

Assumption:

Desired Operating Time for Fuel Pump = 1 hr/day

ηp = 72%

Power input for Unit 1, 2, 3, 4 and 5

Where:

EPi = electrical power input [kW] or [hp]


TDH = total dynamic head [m]

Q = volume flow rate [m3/s

Where:

VDT = volume of fuel at day tank [m3/s]t = time of pump operation [sec]

= 0.00111 m3/s



1 hp is used for unit 1 transfer pump

Design for Heat Exchanger

For 800 kW Generator Set (Per Unit 1, 2, 3, 4 & 5)

Theoretical and Actual Limits of Cooling Water and Jacket Water

(From PPE by F.T. Morse, p.178)

tji = jacket water inlet temperature = 37.8 °C

tjo = jacket water outlet temperature = 65.6 °C

tcwi = cooling water inlet temperature = 32.2°C

tcwo = cooling water outlet temperature = 54.4 °C

LMTD

Δtmax = (65.6 – 54.4) °C = 11.2 °C

Δtmin = (37.8 – 32.2) °C = 5.6 °C

LMTD

Qj = mj x cpj x Δtj

Where:

Qj = heat rejected from jacket water = 358.9 kW (from catalog)

mj = mass of jacket water

Δtj = temp. Difference of jacket water= (65.6 – 37.8) °C = 27.8 °C

Cpj = 4.187 kJ / kg-K (for water)



A

Where:

A = surface area of heat exchanger

U = overall coefficient of heat transfer

LMTD = log mean temp. Difference

Solving for U (from PPT & D by P.J. Potter, Fig. 8-9, p.351 and p. 352)

Where:

= coefficient of heat transfer

Ft = temp. Correction factor

Fm = tube material and thickness correction factor

Fc = cleanliness factor

Fp = prime mover factor

Tube Specifications:

Material: Aluminum Brass 18 BWG ¾”

Water Velocity = 9 ft/s

Ft = 1.08

Fm = 0.96

Fc = 0.85

Fp = 1.0



C = 270

Where:

mcw = mj = 11,088 kg/hr

υ = specific volume of circulating water @ t

From steam table @ 51.7 °C (by interpolation)

υ = 1.01295 L/kg



From PPT & D by P.J. Potter, p. 357

“For each ¾” No. 18 BWG tube will pass 1.042 GPM/1 fps”

Where:

0.1963 ft2/lin. ft = outside surface area of ¾” tube (18 BWG)

(From PPT & D by P.J. Potter, Table 8-1, p.353)



Design for Cooling Tower

For 800 kW Generator (Per Unit 1, 2, 3, 4 and 5)

BP = 818 kW = 1,096.51 hp

Installation Data:

t2 = engine water into heat exchanger (in) = 65.6 °C

t1 = engine water into heat exchanger (out) = 37.8 °C

tb = cooling water to heat exchanger = 32.2 °C

ta = cooling water to heat exchanger = 48.9 °C (max. state of humidified air)

Make-up water = 15.6 °C ; 29.4 °C DB & 21.1 °C WB (@ atmospheric condition)

Using the formula (from PPE by F.T Morse, eq. 6-16, p. 178)

Where:

W = cooling water [1 / hr)

Bhp = rated brake horsepower

t1 & t2 = inlet & outlet water temperatures [°C]

Let ww = water flow in the cooling tower circuit



From PPE by F.T. Morse, p. 181

The theoretical maximum humidified state of the air leaving is 48.9 ° C at 100 % humidity.

Assume 5.5 °C differential and 90% RH

From Psychometric Chart @ 29.4 °C DB & 21.1 °C WB:

SH1 = 0.0123 kg

h1 = 79.088 kJ/kg

Using the formula (from PPE by F.T Morse, eq. 6-19 & 6-20, p. 182)

Where:

Td = dry bulb temperature [°C] = (48.9 – 5.5) °C = 43.4 °C

RH = percent relative humidity

Ps = saturation pressure of water vapor @ td

Pa = atmospheric pressure [kg/cm2]

hg = enthalpy at td, dry and saturated [J/kg]

From Steam Table @ 43.4 °C:

Ps = 0.0895 kg/cm2 (converted value)

Hg = 2,580,140 J/kg



Using the formula (from PPE by F.T Morse, eq. 6-17 & 6-18, p. 177)

Mass balance for cooling tower:

Heat balance for cooling tower

Ww = 1.7 kg water / kg dry air (from above equation)

From Psychometric Chart

Since υair @ 29.4 °C & 21.1 °C = 0.862 m3/kg

= 60 %

From PPE by F.T. Morse, p. 182

Recommended Type: Natural Draft Cooling Tower



Cooling Tower Pipe

; QCTP = mcw (υf @ 32.2 °C)

From Steam Table (by interpolation)

υf = 1.00506 L/kg = 0.0010506 m3/kg

Velocity of water @ HX = Velocity of water at cooling tower

9 ft/s = 2.74 m/s

;

Material Specification (from PSME code, p.200)

Size: 1 ½ in. Inside Dia.: 1.5 in Wall thickness: 0.2 in

Schedule: 80x Outside Dia.: 1.9 in



Cooling Tower Pump

PCT = (QCTP)(γwater)(TDH)

Assume z = 2 m ; TDH = 2 m

PCT = (0.00324 m3/s)(9.807 kN/m3)(2 m) = 0.064 kW = 0.085 hp

Assume ηp = 75 %

Fan Power of Cooling Tower

Fan Capacity

QA = mAυA

Where:

mA = mass of air = 1.59 kg/s

υA = specific vol. of air

ρA = density of air @ standard condition = 1.2 kg/m3



Cooling Tower Floor Area

Concentration of Water = 80 L/min-m2

;

Variable Load Calculations

(We use 3200kW from catalog 800kw X 4 genset)



Catalogue



Perspective View



Side View



Top View

List of Materials

Materials QuantityCement 3675Gravel 435Anchor Bolts 1/8 x 7/8 3315Renforcing Bars 14mm x 20ft 65Aluminum Brass Tube 3/4" 120

List of Equipments

Equipment Quantity800kW Diesel Genset (IDLC 800-2M) 5

Fuel Transfer Pump 1hp 5

Cooling Tower Pump 0.11hp 10

Cooling Water Fan 0.27hp 10



Heat Exchanger



Cooling Tower



Fuel Tank



Machine Foundation



Rizal Technological University

Boni Ave., Mandaluyong City


Mechanical Engineering Department

In partial fulfillment

Of the course requirements on

ME 54L - Power Plant Design Lab

Submitted by:

Submitted to:

Engr. Gerry Cabrera

Submitted on:

March 14, 2011

power plant design part iii

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