Design of

Diesel Power Plant

TABLE OF CONTENTS
 Title Annex

Statement of the Problem………………………………………..

Load Curve & Schedule of Load…………………………………

Design Computation … …… ……………………………………

1. Cooling Water System

2. Air Starting System
3. Foundation
4. Fuel Oil System
5. Lube Oil System
6. Piping System
7. Cost Analysis

Plan Maintenance System…………………………………...

1. PMS Sample
2. Manufacturer’s Maintenance Information

Daihatsu Generator Information … … … … … … … … .

Fuel Oil/Lube Oil Information… … … … … … … … … ..

Air Compressor Manufacturer Information………………..

Lube Oil Purifier Manufacturer Information………………

Piping/Main Components/Plant Layout……………………

STATEMENT OF THE PROBLEM

 A proposed Diesel Electric Power Plant has an average daily load as
shown.

A. MUNICIPAL LOAD

Time Daily Load Sunday Load

12mn – 3am 400kw 400kw

3 – 5am 500kw 500kw
5 – 7am 700kw 500kw
7 – 10am 900kw 900kw
10 – 12nn 1400kw 1600kw
12nn – 3pm 1000kw 1000kw
3 – 5pm 1500kw 1000kw
5 – 8pm 1900kw 2000kw
8 – 10pm 1500kw 1500kw
10 – 12mn 800kw 500kw

B. INDUSTRIAL LOAD

Time Daily Load Sunday Load

12mn – 6am 800kw 400kw
6am – 2pm 1200kw 400kw
2pm – 10pm 1000kw 400kw
10pm – 12mn 800kw 400kw

C. COMMERCIAL LOAD

Time Daily Load Sunday Load

12mn – 6am 150kw 200kw
6am – 2pm 300kw 400kw
2pm – 10pm 700kw 400kw
10pm – 12mn 800kw 200kw

In the design of the power plant the following are to be considered:

a.) Maximum number of units including stand-by units.

b.) Nominal speed of diesel engine units shall range from 600 to 720 rpm.

c.) A medium degree of protection is guaranteed to the consumers which

means one unit is reserved to be kept running and sharing the load
equally with the other unit.

DETERMINE THE FOLLOWING:

A.)

1.) The annual duration curve.

2.) The most suitable number of units and their sizes including:

a.) Graphical representation of the schedule of the operation of

your choice super imposed on the daily load curve.

b.) Complete specification of each unit.

B.) Design the cooling system by assuming that the raw water is at 85F
and the allowance raise in temperature is 20F at which:

1.) Specify the type of cooling water pump.

2.) Draw the schematic diagram of the cooling system labeling all
the pertinent and important pieces of equipment.

3.) Design the sheet and tube heat exchanger.

C.) Specify the size of the units necessary for the air starting system.
Assume the required starting pressure to be 250psig. Draw the schematic
diagram of the air starting system.

D.) Design and layout the fuel oil system of which the following are to be
determined:

1.) Number and sizes at the fuel oil storage.

2.) Daily fuel consumption.

3.) Size and type of fuel pump.

E.) Draw the pie chart showing the distribution of cost per kw-hr
generated.

F.) Make the assembly drawing of the plant.

DESIGN COMPUTATION

A.) DAILY LOAD (for Weekdays)

- Based from the given data:

 LOAD (KW)
TIME
Municipal Industrial Commercial Combined

12:00 MN 400 800 150 1350

1:00 – 2:00 400 800 150 1350

2:00 – 3:00 400 800 150 1350

3:00 – 4:00 500 800 150 1450

4:00 – 5:00 500 800 150 1450

5:00 – 6:00 700 800 150 1650

6:00 – 7:00 700 1200 300 2200

7:00 – 8:00 900 1200 300 2400

8:00 – 9:00 900 1200 300 2400

9:00 – 10:00 900 1200 300 2400

10:00–11:00 1400 1200 300 2900

11:00-12:00 1400 1200 300 2900

12:00 – 1:00 1000 1200 300 2500

1:00 – 2:00 1000 1200 300 2500

2:00 – 3:00 1000 1000 700 2700

3:00 – 4:00 1500 1000 700 3200

4:00 – 5:00 1500 1000 700 3200

5:00 – 6:00 1900 1000 700 3600

6:00 – 7:00 1900 1000 700 3600

7:00 – 8:00 1900 1000 700 3600

8:00 – 9:00 1500 1000 700 3200

9:00 – 10:00 1500 1000 700 3200

10:00-11:00 800 800 800 2400

11:00-12:00 800 800 800 2400

12:00 MN 400 800 150 1350

TOTAL 25800 24800 10650 61250

DAILY LOAD (for Sundays)

- Based from the given data:

LOAD (KW)
TIME
Municipal Industrial Commercial Combined

12:00 MN 400 400 200 1000

1:00 – 2:00 400 400 200 1000

2:00 – 3:00 400 400 200 1000

3:00 – 4:00 500 400 200 1100

4:00 – 5:00 500 400 200 1100

5:00 – 6:00 500 400 200 1100

6:00 – 7:00 500 400 400 1300

7:00 – 8:00 900 400 400 1700

8:00 – 9:00 900 400 400 1700

9:00 – 10:00 900 400 400 1700

10:00–11:00 1600 400 400 2400

11:00-12:00 1600 400 400 2400

12:00 – 1:00 1000 400 400 1800

1:00 – 2:00 1000 400 400 1800

2:00 – 3:00 1000 400 400 1800

3:00 – 4:00 1000 400 400 1800

4:00 – 5:00 1000 400 400 1800

5:00 – 6:00 2000 400 400 2800

6:00 – 7:00 2000 400 400 2800

7:00 – 8:00 2000 400 400 2800

8:00 – 9:00 1500 400 400 2300

9:00 – 10:00 1500 400 400 2300

10:00-11:00 500 400 200 1100

11:00-12:00 500 400 200 1100

12:00 MN 400 400 200 1000

TOTAL 24500 10000 8200 42700

ANNUAL OPERATING HOURS

- For weekdays we multiply 313 days per year to the total number of
hours/days it operates for a certain load.

Let: D = 313 weekdays/year

Actual load hours operation

KW Rating Operating Hours Hrs/Yr

1350 4 hrs/day (D) 1252

1450 2 hrs/day (D) 626

1650 1 hrs/day (D) 313

2200 1 hrs/day (D) 313

2400 5 hrs/day (D) 1565
2500 2 Hrs/day (D) 626
2700 1 hr/day (D) 313
2900 2 Hrs/day (D) 626
3200 4 hrs/day (D) 1252
3600 3 hrs/day (D) 939
Total Hrs 7825

- Sundays we multiply 52 Sundays/year to the total number of hrs/yr it

operates for a certain load.

Let: F = 52 Sundays/year

Actual Load Hrs Operation (Sunday Load)

Generator Operating Hours Hrs/Yr

1000 4 hrs/day (F) 156

1100 5 hrs/day (F) 260

1300 1 hr/day (F) 52

1700 3 hrs/day (F) 156

 1800 5 hrs/day (F) 260

2300 2 hrs/day (F) 104

2400 2 hrs/day (F) 104

2800 3 hrs/day (F) 156

Total Hrs 1248

TOTAL OPERATING HOURS

Actual Load:

Weekdays = 7825 hrs

Sundays = 1248 hrs

Total Operating hrs = 9073 hrs

ANNUAL Kw-Hr CONSUMPTION

Combined Load Hrs/Yr Annual Kw-Hr

1000 156 156000

1100 260 286000
1300 52 67600

1350 1252 1690200

1450 626 907700

1650 313 516450

1700 156 265200

1800 260 46800

2200 313 688600

 2400 1669 4005600

2300 104 239200

2500 626 1565000

2700 313 845100

2800 156 436800

2900 626 1815400

3200 1252 4006400

3600 939 3380400
TOTAL 21525500
B.) DESIGN OF COOLING SYSTEM

From Kent’s Mechanical Engineer’s Handbook, Power

Volume(s) page 13-12, the usual outlet temperature range is from 140 to
180°F. Most engines are equipped with circulating water systems that
limit the temperature rise through the engine to about 10 to 15°F, by
vigorous circulation of water. Using a temperature rise of 35°F as stated
in the test Power Plant Engineering by Frederick Morse on page 178,
temperature rise in the engine ranges from 35 to 45°F.

Given:

Cooling Tower Side

outlet water temperature = 85°F
inlet water temperature = 85°F + 20°F = 105°F

Engine Side
outlet water temp. = 135°F
inlet water temp. = 100°F
(from Power Plant Engineering by Morse, pg. 178)

1. Flow rate of cooling water in each engine from pg. 178 P.P.E. by
Morse

W = 326 (Bhp)
(t2 – t1)

Where:
 W = cooling water
Bhp = rated brake hp
t1, t2 = outlet, inlet temperature

a. For one of 3 units 1260 Bhp unit

WA = 326 gal/hr-hp (1260 hp)

(135-100)

WA = 11,736 gal/hr

b. For one unit 2010 Bhp unit

WB = 326 (2010Bhp)
(135-100)

WB = 18,728.4 gal/hr

Total engine cooling water at peak load

WT = WA + WB (3)

WT = 18728.4 + 11,736(3)

WT = 53,936.40 gal/hr
= 898.9 gal/min

2. By energy balance in the heat exchanger, we can determine the

cooling tower circulating water (WW, in gpm)

Energy in = Energy out

WH (tWA) + Wt (ta) = WH (tWb) + Wt (tb)
WW (tWb – tWa) = Wt (ta - tb)
898.93(135-100) = WW (105-85)
 WW = 1573.13 gpm

3. Cooling Tower Calculation

assume:
barometric pressure = 14.1 psig
coming air = 92°F db, 82°F wb
leaving air = 95°F db, 90% RH
make-up water = 60°F
raw water, t1 = 105°F, t2 = 85°F

for entering air for leaving air

h1 = 46.36 BTU/lb h2 = 60 BTU/lb
V1 = 14.6 ft3/lb V2 = 14.7 ft3/lb
SH1 = 0.0212 lb H2O/lb dry air SH2 = 0.034 lb H2O/lbdry air

Condition of water
hW1 = 73.03 BTU/lb
hW2 = 53.08 BTU/lb
hmu = 28.08 BTU/lb

By energy balance in the cooling tower:

Energy In = Energy Out

1(h1) + Wmu (hmu) + WW (hW1) = 1(h2) + WW (hW2)

but:
Wmu = SH2 - SH1
Wmu = 0.034 - 0.0212
Wmu = 0.0128 lb H2O/lb dry air

From energy balance equation:

 1(46) + 0.0128 (28.08) + WW (73.03) = 1(60) + WW (53.09)
46.36 + 73.03 WW = 60 + 53.08 WW
WW = 0.684 lb H2O/lb dry air

Weight of air flowing, Wa

Since 13,104.17 lbs/min needed, the airflow is:

Wa = 13,104.17lb of H2O/min
0.684 lb of H2O/ lb dry air

Wa = 19,158.147 lb of air/min

Weight of airflow, Va
Va = 19,158.147 lb of air/min (14.6 ft3/lb of air)

Va = 279,708.94 ft3/min

GPM of make-up water, Wmu

Wmu = 0.0128 lb H2O/lb dry air (19,158.147 lb air/min)

8.33 lb/gal

Wmu = 29.43 GPM

Using Evaporative Cooling Tower:

hot water temperature = 105°F

cold water temperature = 85°F
wet bulb temperature = 80°F

and from KENT’S Mechanical Engineer’s Handbook page 9-25, Fig. 6

 Water Concentration Factor = 1.8 gpm/ft2

For the area of the cooling tower

Area Cooling Tower = Total water to be cooled

Water concentration factor

Area = 1573.13 gpm

1.8 gpm/ft2

Area of Cooling Tower = 873.96 ft2

Capacity of Fan to be used; assume 100% performance from pg. 9-26,

fig.7 of KENT’S

hp/ft2 = 0.042

then,
Fan hp = (0.042 hp/ft2) (873.96 ft2)

Fan hp = 36.7hp  37 hp

For the effective filling depth = 22 ft.

assume:
wind velocity of 3 mph

Length = 873.96 ft2

12 ft

Length = 72.83 ft
 For the Cooling efficiency

Cooling efficiency = ta – tw = 105 – 85

tc – twb 105 – 80

Cooling efficiency = 0.8696 x 100%

Cooling Efficiency = 80%

SPECIFICATIONS OF COOLING TOWER

SPECIFICATIONS OF COOLING TOWER

AREA 873.96 ft

LENGTH 72.83 ft

WIDTH 12 ft

HEIGHT 22 ft

Determining the Cooling Water Circulating Pump

Specification:

Condition:
- The most suitable pump to be employed is a centrifugal pump
because of its capability of delivering cooling tower of high head
volume.
- Provide two units Cooling Water Circulating Pump , one pump as
back up incase failure of the other pump running.

assuming:

head = 10 ft
Capacity = 898.93gal/min
thus,

Rated hp = ( 898.93 ) ( 10 ) / 3960

Rated hp = 2.27 hp ; use: 2.5 hp

Assume 75% efficiency of the pump

Thus, the size of the motor = 2.5/.75 = 3 hp

Use 3hp direct coupled – 2 Units Centrifugal Pump

Determining the Raw Water Circulating Pump Specification:

Condition:
- The most suitable pump to be employed is a centrifugal pump
because of its capability of delivering cooling tower of high head
volume.
- Provide two units Raw Water Circulating Pump , one pump as back
up incase failure of the other pump running.

assuming:

head = 20 ft
Capacity = 1573.13gal/min
thus,

Rated hp = ( 1573.13 ) ( 10 ) / 3960

Rated hp = 3.9 hp ; use: 4 hp

Assume 75% efficiency of the pump

Thus, the size of the motor = 4/.75 = 5.3 hp

Use 5.5hp direct coupled – 2 Units Centrifugal Pump
C.) DESIGN OF AIR STARTING UNIT

Condition:
- Will take 1 minute to start the engine as per manufacturer at
250psig
- The plant is composed of 4 units engine, the biggest engine is the
Gen no. 2 with a capacity of 1500Kw each. We will based the
required air capacity of the plant on the biggest generator.
- The bore and stroke of the Gen no. 2 : 260mm x 380mm
- Firing order in Gen no. 2 : 1 – 2 – 4 – 6 – 5 – 3 , indicating that
to run the engine with starting air is required to accommodate 6
cylinder within 1 minute.

Determining the Volume of the combustion area of engine:

V = 3.14 x r2h
= 3.14 x (260/2)2 x 380 x (0.0394in/mm) 3

= 1233.98in3 x (1/12in)3
= 0.714 ft3 x 6 cylinder = 4.284 ft3

However, it will take 1 minute to run the engine:

Thus,

Determining the Capacity required:

Cair = V/t = 4.284/1m

Starting Air Required = 4.284 cfm

In determining the capacity of the Air Reservoir:

Condition:

- A Two (2) Air Reservoir will be provided to insure continues

operation of the plant in case failure of the other tank.
- Capacity of Air Reservoir is based by allowing at least 5 air
starting times of the required air capacity of the four engine as
to ensure that failure of the initial starting, the plant can again
 restart the engine without refilling operation or running the
compressor.
- Maximum internal pressure of the Air Reservoir is 250PSIG.

Thus:

Air Reciever Capacity = 5 x 4.284 x 4

= 85.69 cfm

Assuming it will take 10minutes to build up pressure of Air Reciever

at 250psig:

Volume of Air Reciever = 85.69 /10

8.569 ft3

Assume:

Using Cylindrical with spherical segment at both end Tanks:

D
 H L H

V = 2(3.14H/24)(3D2 +4H2) + 3.14D2/4 (L)

Assume: L = 5H = 5ft
Substitute in equation.

Thus:

V = 4.7D2 + 0.523 = 85.69cfm

Thus,

D = (84.64)1/2 = 4.2ft

4.2 ft

Determining the thickness plate of the Air Reciever:

Assume:

C1020 Annealed material

N = 90% Joint/Welded Efficiency
n = 4, factor of safety
Su = 57 ksi From Table AT7 Design of Machine Elements by Faires

And,

t = pD /2StN

Where:
 t – thickness of the spherical pressure vessel
p – Internal Pressure, 250PSIG
D – inside diameter
St – Allowable Stress
N – Factor of Safety

St = Su/4 = 57,000/4 = 14,250lbs

Thus,

t = (250 + 14.7) 4.2 x 12 / 2 (14250)(.9) =

0.52n or 13mm

Specification of the Air Reciever:

Volume 8.569ft3
Cylindrical with spherical
Type
segment at both end
Quantity 2 units

Diameter 4.2 ft

Material/plate thickness C1020 annealed, 13mm

Determining the Horsepower of Air Compressor:

Condition:
- We allow 2 units Air Compressor as one unit serve as spare
compressor in case the running compressor encountered
breakdown.
- Direct drive coupling motor. With automatic cut in and cut off
pressure setting at 30kg/cm2.
- Provide 1 pc Safety Valve for each tank with a pop up setting
pressure of 1.5 x time tank internal pressure

From Kents Mechnical Engineering Handbook page 1-46, the

estimate shafthorsepower for multistage compressor can be
determined using the Fig.21:
However, following required parameters are needed:

Pressure Ratio: 264.7/14.7 =18

Square Root of Pressure Ratio = 4.2

k = 1.406 From Table 1 p1-40 Kents MEH

using Fig 21:

Thus,

Shaft HP/million cf/24hr = (94hp/1 x 106cf/24hr) x 2 x 1.3

= 5.8556 x 10-3hp-hr/ft3

As per Fig. 21, if two stage, multiply by 2 and add 3% for cooler
loss.

Thus,

Bhp of Air Compressor = 5.8556 x 103 x 85.69 x 60

= 30hp

Assume Compressor Efficiency 90%

Thus, The motor Hp ratings = 30/.9 = 33hp

 24Kw

D.) COMPUTATION OF GENERATORS FOUNDATION:

Condition:
- Please see attached generator bed dimension and weights.
- Bed soil is found to be gravel and sand.

1. Generator no. 1, 3 & 4 (850kw)

Total weight of the unit = 17.6 Mtons

From Table 4-4 p.105 by PPE Morse
The safe bearing power of gravel and sand is 78 – 98tons/m 2, use
90 tons/m2 and half of this as the allowable stress.

From Table 4-5 p108,Ppe by Morse, the weight of machine

foundation per bhp for this type of engine is 570kg/bhp

Thus.

Total weight of unit and foundation:

= 17,600kg + 850/.746 x 570

= 667,063.8kg

Base area of the foundation:

= 667,063.8kg/45,000
 = 14.8m2

Consider the following combination:

W = 6m
L = 12m

The depth of the foundation:

d = Vc/Ac

Vc = Wc/Dc = 649,463.8/2660 = 244.159m3

Thus, d = 244.159/6(12) = 3.4m

Determining the Materials required:

FROM Table 4-1 Regarding the Data on concrete mixes,

The required mixture for foundation is 1:3:5 as follows:

Sand = 0.52m3
Cement = 6.2 sacks
Stone = 0.86m3

Thus,

For Volume required in Cement:

= 244.8 x 6.2 = 1,528 sacks

For Volume of Sand:

= 244.8 x 0.52m3 = 127.3m3

For Volume of Stone:

= 244.8 x 0.86m3 = 210.5m3

Specification of the Foundation for generator 1,3 & 4

Width (W) 6m

Length(L) 12m
 Depth(d) 3.4m

Volume of Cement 1,528 sacks

Volume of Sand 128m3

Volume of Stone 211m3

2. Generator no. 2(1500kw)

Total weight of the unit = 27.5Mt

From Table 4-4 p.105 by PPE Morse
The safe bearing power of gravel and sand is 78 – 98tons/m 2, use
90 tons/m2 and half of this as the allowable stress.

From Table 4-5 p108,Ppe by Morse, the weight of machine

foundation per bhp for this type of engine is 570kg/bhp

Thus.

Total weight of unit and foundation:

= 27,500kg + 1500/.746 x 570

= 1,173,612.6kg

Base area of the foundation:

= 1,173,612.6kg/45,000
= 26.1m2

Consider the following combination:

W = 6m
L = 16m

The depth of the foundation:

d = Vc/Ac

Vc = Wc/Dc = 1,146,112.6/2660 = 430.86m3

Thus, d = 430.86/6(12) = 5.13m

Determining the Materials required:

FROM Table 4-1 Regarding the Data on concrete mixes,

The required mixture for foundation is 1:3:5 as follows:

Sand = 0.52m3
Cement = 6.2 sacks
Stone = 0.86m3

Thus,

For Volume required in Cement:

= 430.86 x 6.2 = 2,672 sacks

For Volume of Sand:

= 430.86 x 0.52m3 = 227m3

For Volume of Stone:

= 430.86 x 0.86m3 = 371m3

Specification of the Foundation for generator 2

Width (W) 6m

Length(L) 14m

Depth(d) 5.13m

Volume of Cement 2,672 sacks

Volume of Sand 227m3

 Volume of Stone 371m3

E.) DESIGN OF FUEL OIL SYSTEM

1. Fuel Storage Tank

KW-hr consumption of fuel per year = 21525500 kw-hr/yr

Plant Capacity Factor = 21525500 kw-hr/yr _____

8760 ( 1500 + 850(3) )

Plant Capacity Factor (PCF) = 60.6%

From Morse, P.P.E. ; pg. 164; Fig. 6-15

Fuel Consumption : Minimum = 2.5 KW-hr/L

Maximum = 3.5 KW-hr/L

Use : max. value for design purposes , 3.5 KW-hr/L

Annual Fuel Consumption

= 21525500 KW-hr/yr
3.5 KW-hr/L

Annual Fuel Consumption = 6,150,142.85 L/yr

Using fuel oil of 33o API and assuming the average fuel oil of 80oF.
o
API = 141.5 ____ - 131.5
S.G. at 60o/60

S.G. at 60o/60 = 141.5

33o + 131.5

Specific Gravity of Fuel Oil 2 60o = 0.8602

Assuming the annual fuel consumption is 6,150,142.85L/yr

Monthly Fuel Consumption = 6,150,142.85 L/yr

12 months/yr

Monthly Fuel consumption = 512,511.9 L/month

Providing a 100% contingency to ensure adequate supply of fuel

Total Volume of fuel = 512,511.9 L/month x 2 months

Total Volume of fuel = 1,025,023.88 L

Dimensions of Bulk Storage Tank

Condition:
- Assume Diameter = 10m, This is depends to the allocated lot
area of the plant.
- Density of Fuel Oil = 1.89lb/L
- Allow two units of tanks.

D
 

Capacity required is = 1,025,023.88 Ltrs

Volume equivalent = 1,025,023.88/1000ltr/m3
= 1,025m3

Allowing 2 units Storage Tanks:

Volume of each tanks = 513 m3

Determining the Height = 513(4)/3.14(10) 2 = 6.5m

Determining the thickness plate of the Storage Tanks

Assume:

C1020 As rolled material

N = 95% Joint/Welded Efficiency
n = 5, factor of safety
Sy = 49 ksi From Table AT7 Design of Machine Elements by Faires

And,

t = pD /2StN

Where:

t – thickness of the spherical pressure vessel

p – Internal Pressure = density x height
= 1000x.8602 x2.2 x 6.5 x 39.37/39.373 = 7.9psi
D – inside diameter
St – Allowable Stress
N – Factor of Safety
 St = Sy/5 = 49000/5 = 9800lbs

t = (7.95)10x39.4in/m ) / 2 (9500)(.95) =

0.173in or 4.4mm
Say 5mm thickness

Specification of Cylindrical Fuel Storage Tanks:

Quantity 2 Units

Height 6.5m

Diameter 10m

Plate thickness 5mm

Materials C1020 Asrolled

Daily Fuel Consumption

Determining the daily fuel oil consumption of each Generator

1. Generator no. 1 (850kw)

Average Rated Load = 770.83 kw
Rated Capacity = 850 kw
Percent Rated Load = 770.83/850 = 91%

From Figure 6-15, PPE by Morse

Fuel Oil Consumption @ 91% Rated Load

 Min = 0.24kg/kw-hr
Max = 0.25kg/kw-hr
Using the max value for computation porposes:

Daily Fuel Oil Consumption = 770.83 x 0.25 x 24

= 4624.98 kg/0.8602(1000)

= 5.37m3 x 1000ltrs/m3

= 5,376.63 ltrs/day

2. Generator no. 2 (1500kw)

Average Rated Load = 1083.33 kw
Rated Capacity = 1500 kw
Percent Rated Load = 1083.33/1500 = 72%

From Figure 6-15, PPE by Morse

Fuel Oil Consumption @ 91% Rated Load

Min = 0.22kg/kw-hr
Max = 0.26kg/kw-hr

Using the max value for computation porposes:

Daily Fuel Oil Consumption = 1083.33 x 0.26 x 24

= 6759.99 kg/0.8602(1000)

= 7.8422m3 x 1000ltrs/m3

= 7842.2 ltrs/day

3. Generator no. 1 (850kw)

Average Rated Load = 716.6 kw
Rated Capacity = 850 kw
Percent Rated Load = 716.6/850 = 84%

From Figure 6-15, PPE by Morse

Fuel Oil Consumption @ 91% Rated Load

Min = 0.225kg/kw-hr
 Max = 0.245kg/kw-hr

Using the max value for computation porposes:

Daily Fuel Oil Consumption = 716.6 x 0.245 x 24

= 4,213.6 kg/0.8602(1000)

= 4.8984m3 x 1000ltrs/m3

= 4,898.4 ltrs/day

4. Generator no. 1 (850kw)

Average Rated Load = 600 kw
Rated Capacity = 850 kw
Percent Rated Load = 600/850 = 71%

From Figure 6-15, PPE by Morse

Fuel Oil Consumption @ 91% Rated Load

Min = 0.21kg/kw-hr
Max = 0.249kg/kw-hr

Using the max value for computation porposes:

Daily Fuel Oil Consumption = 600 x 0.249 x 24

= 3,585.6 kg/0.8602(1000)
= 4.168m3 x 1000ltrs/m3

= 4,168 ltrs/day

Summation of all generator daily consumption:

= 5,37663 + 7,842.2 + 4,898.4 + 4,168

= 22,285.2 ltrs/day consumption for all generator

Determining the size of the Fuel Oil day tank:

Condition:
- The Fuel Oil Day Tank should be provided alarm indicating the
high level and low level of the fuel oil in the day tank.
- The transfer pump are to be automatically controlled by a cut in
cut out level switch of the day tank.
 - Day tank are to be installed at least 20ft above the generators
were the fuel supply going to the engine will be carried out due to
gravity.

Using the Dimension of Fuel Oil Tank by PPE by Morse Page 459

Since Capacity required per day is 22,285.2 ltrs

Use the Day Tank Size as follows:

Diameter 2.44m

Height 5.08m

Capacity 23,720ltrs

Weight 2905kg

6.35mm
Plate Thickness

Determining the capacity of the Fuel Oil Transfer Pmp:

Condition:
- The most suitable pump to be employed is a gear pump because of
its capability of delivering fuel oil of constant volume.
- Provide two units Fuel Oil Transfer Pump , one pump as back up
incase failure of the other pump running.
- The motor is controlled by a cut in and cut out level float switch in
the day tank.

assuming:

head = 20 ft
density of fuel = 1.89 lb/L
required to fill up the day tank within 30minutes
required capacity of day tank = 22,285.2ltrs
thus,

Pump Capacity = 22,285.2ltrs

30 min
Pump Capacity = 742.8 Ltrs/min

Rated hp = 1.89 ( 742.8 ) ( 20 ) / 33000 ft-lb/hp-min

 Rated hp = 0.85 hp ; use: 1 hp

Assume 75% efficiency of the pump

Thus, the size of the motor = 1/.75 = 1.3hp

Use 1.5hp direct coupled – 2 Units Gear Pump

Determining the capacity of the Fuel Oil Delivery Transfer

Pmp:

Condition:
- The most suitable pump to be employed is a gear pump because of
its capability of delivering fuel oil of constant volume.
- Provide two units Fuel Oil Delivery Transfer Pump , one pump as
back up incase failure of the other pump running.
- The motor is controlled by a cut out level float switch in the day
tank.

assuming:

head = 8m = 26.24ft
density of fuel = 1.89 lb/L
required to fill up the day tank within 60minutes
required capacity of day tank = 512511.9ltrs
thus,

Pump Capacity = 512511.9ltrs

120 min
Pump Capacity = 4270.9 Ltrs/min

Rated hp = 1.89 ( 4270.9 ) ( 26.24 ) / 33000 ft-lb/hp-min

Rated hp = 6.4 hp ; use: 6.5 hp Vane Type

Developed Head = 6.5(1714)(3.78)/4270.9 = 9.86psi

Assume 75% efficiency of the pump

Thus, the size of the motor = 6.5/.75 = 9hp

Use 9hp direct coupled – 2 units Vane Pump

F) LUBE OIL SYSTEM

Condition:
- Provide two(2) units Lube Oil Circulating Pump for the Lube Oil
System for each generator, One(1) unit will serve as back up
incase the running lube oil pump failed.
- Use Gear Type Pump, please see appendix re sample pump for
lube oil pump.
- As per Manufacturer, the lube oil consumption of generator as
follows:
Generator no. 1,3 & 4(850kw) = 3.5 ltrs/hr
Generator no. 2(1500kw) = 4 ltrs/hr
- Provide a Main L.O Storage tanks for lube oil at least 1.5 month
supply for the whole generator.
- Provide a Sump Tank for each generator with capacity of at least
one month supply for each generator.
- Provide a two(2) units L.O. Purifier, to ensure purification of L.O.

Determining the Annual Lube Oil Consumption of 4

Generators:

1) Generator no. 1(850Kw)

Annual L.O. Consumption = 3.5 x 7512 = 26,292 ltrs

2) Generator no. 2(1500Kw)

Annual L.O. Consumption = 4 x 8136 = 32,544ltrs

3) Generator no. 3 (850Kw)

Annual L.O. Consumption = 3.5 x 6882 = 24,087 ltrs

4) Generator no. 4 (850kw)

Annual L.O. Consumption = 3.5 x 3439 = 12,036.5ltrs

Total Annual L.O. Consumption = 94,959.5 ltrs

Monthly L.O. Consumption = 94959.5/12 = 7,913.20 ltrs

Determining the L.O. Storage Tank Capacity and

Specification:

Condition:
- Provide a L.O. Storage tanks at least 1.5 months to ensure
continuos operation incase failure of supplier to supply L.O.
- Since the monthly L.O. consumption of the 4 generators is
7,913.20ltrs, the capacity of the L.O. Storage Tanks is 1.5 x
7913.20ltrs = 11,860ltrs
- As the height of the tank is only 2.54m, the pump of the
Supplier’s delivery tanks transfer pump can carry out the
transferring of delivered L.O. to the Storage Tank.

Using the Dimension of Oil Tank by PPE by Morse Page 459

Since Capacity of the L.O. Storage Tanks is 11860 ltrs

Use the size as follows:

Diameter 2.44m

Height 2.54m

Capacity 11860ltrs

Weight 1844kg

Plate Thickness 6.35mm

Determining the L.O. Sump Tank for Each Generator:

- L.O. Sump Tank served a sump of the lube oil coming from the
engine output. This are to be installed underneat the engine.
- The Lube Oil will temporary stored in the sumptank and
eventually will pump out by the L.O. Circulating Pump and
- The capacity of the L.O. sump tank is at least one month supply
of the L.O. required by the engine. 7,913ltrs/4 generators
Say 2000ltrs per generator

Assume:
L.O. Density: 0. 81g/cm3
Diameter = 1m
 Length = 2000ltrs/(1000)3.14x (1 /2)2 = 2.5m

Determining the capacity of the Lube Oil Circulating Pump:

Condition:
- The most suitable pump to be employed is a gear pump because of
its capability of delivering fuel oil of constant volume.
- Provide two units L.O. Circulating Pump, one pump as back up
incase failure of the other pump running.

assuming:

head = 2m = 6.56ft
density of fuel = .81 lb/L
As per Manufacturer the flow rate of the L.O. is 21.3m 3/hr-
cylinder
thus,

Pump Capacity = 21.3 x 1000 x 4 x 6/60 = 8520lpm

Rated hp = .81 ( 8520 ) ( 6.56 ) / 33000 ft-lb/hp-min

Rated hp = 1.3 hp ; use: 1.5 hp Gear Type

Assume 75% efficiency of the pump

Thus, the size of the motor = 1.5/.75 = 2hp

Use 2hp direct coupled – 2 units Gear Pump

Determining the Specification of the L.O. Purifier:

Condition:
- One Purifier for each generator, however their will a inter
connected piping between each purifier as incase failure of the
other purifier, the other purifier can be utilized.
- Attached is Specification of Mitsubishi SelEjector Type Purifier.
 - Use Model Type SJ25T @ 4550 ltr/hr rate (Please see attached
appendix)

G.) PIE CHART WITH DISTRIBUTION OF

COST PER kW–Hr GENERATED

DISTRIBUTION COST

For the Plant Use Factor (PUF)

1492 kW (10) hrs. = 14920 KW-hr

1194 kW (21) hrs. = 25074 KW-hr
895 kW (26) hrs. = 23270 KW-hr
424 kW (28) hrs. = 11872 KW-hr
1194 kW (17) hrs. = 20298 KW-hr

Total = 95434 x 365

TEP = 34833410 KW-hrs

PUF = 21525500 KW-hrs x 100 = 61.80%

34833410 KW-hrs

FIXED ELEMENT

1. Capital Cost of Power Plant:

Cost of engine and generator set

As per verbal information from the distributor of the engine,

the cost of the unit as follows:

Generator no. 1, 3 & 4 (850Kw) = 3 x 8,000,000php

= 24,000,000php
Generator No. 2 (1500Kw) = 15,000,000php
 Cost of Engine and generator set = P 39,000,000.00

Assuming cost of installation is 45% to the cost of engine and

generator set,

therefore :

Capital Cost of Power Plant = 39,000,000.00 .

0.45

Capital Cost of Power Plant = 86,000,000.00 pesos

2. Capital Cost of Primary Distribution System

Assuming that the capital cost of primary distribution system

is 20% of the

Capital cost of the power plant. = 0.2 (39,000,000.00 php )

Capital Cost of Primary Distribution System = 7,800,000.00php

3. Interest, Taxes and Insurance Rates

From pg. 68, P.P.E. by Morse ; Taxes and insurance and

frequently lumped together in cost estimate and are placed than 2%
to 5% of the cost estimate per annum. Assume and use the average
value 3.5%

Taxes and Insurance

= ( 0.035 ) ( 39,000,000.00 + 7,800,000.00 )

Taxes and Insurance = 16,411,110.8 pesos

4. Operation

By assuming a consistent depreciation each year, we use the

straight line method to compute for the depreciation charge, D from
pg. 71, Eg. 3-1; P.P.E. by Morse

where:

D = P–S D= depreciation charge

n P= principal sum
S= final salvage value
n= terms in years = 30 years
but

S = 0.15 P

therefore:

D = P - 0.15P . = 0.85P .
n n
D = 0.85 (46,800,000.00 ) .
30

D = 1,326,000.00 pesos

5. Management Cost

Assume this cost to be P 200,000 monthly

Management Cost = P 200,000/month x 13 month/year

Management Cost = P 2,600,000.00 annually

6. Maintenance Cost
 Assume the cost of maintaining the plant is 10% of annual
depreciation cost.

Maintenance Cost = ( 0.1 ) ( 1,326,000.00 pesos )

Maintenance Cost = 132,600.00 pesos

ENERGY ELEMENT

1. Cost of Fuel

Since we know the annual fuel oil consumption, from the

appendix in the fuel oil/lube oil, the Shell price of regular fuel oil is
11.194 php/ltrs.

Thus,

Fuel Cost = 6,150,142.50 ltrs x 11.194php/ltrs

Fuel Cost = 68,844,695.50 pesos/year

2. Cost of Lubricating Oil

Since we know the annual lube oil consumption, from the

appendix in the fuel oil/lube oil, the BPprice of regular fuel oil is 55
php/drum.

Thus,

Lube Cost = 94,959.5 ltrs x drum/210ltrs x 55php/drum

Lube Cost = 24,870.34 pesos/year

3. Make-up Water consumption

As per verbal confirmation from the MWSS, the price of water is

0.65php/m3, since we know the required capacity of water for the
plant.
 Thus

= 21525500 kW-hr . x 1380 gal . x 0.035 x 60 min .

year 2800 kW-min hr

= 22278892.5 gal . x 0.133368 ft3 . x m3 .

yr gal 35.3 ft3

Make up water consumption = 84172.56 m3. x P 0.65 .

yr m3
Cost of Make up water = 54,712.16pesos/year

CUSTOMER ELEMENT

1. Depreciation

Assume that the cost of secondary distribution system is the

80% 0f of the Primary Cost ( 20% of Capital Cost ). Lifetime is 24
years and salvage value is 5% of the first value.

D = 0.85P / n

D = 0.85 [ 0.8 ( 7,800.000.00) ]

24

D = 221,000.00 pesos

2. Interest, Taxes and Insurance

Assuming the same consumption as before

Cost = 0.0358 ( 0.8 ) ( 7,800.000.00 ) = 223,395.00 pesos

3. Maintenance and Inspection

 Assuming depreciation of 10% per annum

Cost = 0.0358 ( 0.8 )( 7,800.00.00 )( 0.1 ) = 22,339.2 pesos

4. Labor Cost of collecting revenues

Assuming there are 20 employees having a monthly salary of

7000 pesos each.

Cost = 20 ( 7000 ) ( 12 ) = 1,680,000.00 pesos

5. Publicity

Assuming that the plant allot an amount of 11000 pesos per

annum for publicity.

PROFIT

The approximate rate of return prescribed in most cases is

between 4% and 6½%. Using 6½%. The profit will be:

Profit = 0.04 (86,000,000.00 + (2)7,800,000.00)

Profit = 4,064,000.00pesos/Yr