600MW COAL-FIRED POWER PLANT LOCATED AT BRGY.

BULACAN,
MABINI BATANGAS

A capstone Design Project

Presented to the Faculty of Petroleum Engineering Department

College of Engineering, Architecture and Fine Arts

BATANGAS STATE UNIVERSITY

Gov. Pablo Borbon Main Campus II

Alangilan, Batangas City

In Partial Fulfillment

Of the Requirements for the Degree of

Bachelor of Science in Petroleum Engineering

by

ALDEA, JENUEL

BAMBA, THEA MAY E.

VILLANUEVA, JOHN PHILIP N.

PetE-5201

May 2021

i
 TABLE OF CONTENTS
Page

TITLE PAGE i

TABLE OF CONTENTS ii

LIST OF FIGURES v

LIST OF TABLES vii

CHAPTER

I INTRODUCTION AND ITS BACKGROUND

Introduction 1

Source of Raw Materials 3

Products 4

Proposed Plant Location 6

Demand Outlook 7

Market Share 12

Design Objectives 15

Plant Process 16

Definition of Terms 17

II PROCESS DESIGN LAYOUT

Process Flow Diagram 19

Piping and Instrumentation Diagram 20

Plant Layout 21

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III TECHNICAL ASPECTS

Sources of Raw Materials 23

Equipment Functions 26

Material Balance and Energy Balance 53

IV ECONOMIC ANALYSIS

Timeline of Construction of the Plant 60

Building Cost 63

Vehicle Cost 66

Pipeline Construction 68

Equipment Cost 69

Installation/Commissioning 71

Engineering Cost 72

Fire and Safety Cost 73

Labor Cost 73

Maintenance and Repair 77

Other Utilities 77

Product Prices 78

Expected Annual Cash Inflow 79

V ENVIRONMENTAL AND SAFETY ASPECTS

Environmental Management System 85

Prevention of Soil Contamination 88

Prevention of Water Contamination 88

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 Hazardous Chemical Control Activities 91

Recycling of Waste Materials 94

Hazard and Hazard Control 95

VI SUMMARY OF FINDINGS, CONCLUSION AND RECOMMENDATION

Summary of Findings 102

Conclusion 103

Recommendation 104

iv
 LIST OF TABLES

Table No. Title Page

1 Demand outlook of BATELEC 6

2 Design Specification of Belt Conveyor 22

3 Design Specification of Heat Exchanger 24

4 Design Specification of Condenser 25

5 Design Specification of Turbine 26

6 Design Specification of Flash Tank 28

7 Design Specification of Pump 29

8 Design Specification of Separator/Evaporator 30

9 Design Specification of Economizer 31

10 Design Specification of Feed Water Tank 33

11 Design Specification of Air Separation Unit 34

12 Design Specification of Generator 35

13 Design Specification of Coal Burner 37

14 Design Specification of Coal coiler 38

15 Design Specification of Coal Pulvurizer 39

16 Mass Balance Calculations: Mass 40

v
 and Heat Balance for each State Point

17 Summary of Design Calculations 47

18 Coal Composition 48

19 Project Schedule 53

20 Project Schedule 54

21 Cost of Buildings 56

22 Vehicle cost 60

23 Pipeline Construction Cost 60

24 Equipment Cost 61

25 Total Installation Cost 62

26 Total Engineering Cost 63

27 Fire and Safety Cost 64

28 Operating Labor Cost for Technical Department 65

29 Operating Labor Cost for Production Department 65

30 Operating Labor Cost for Marketing Department 66

31 Operating Labor Cost for Human Resource Department 66

32 Operating Labor Cost for Accounting Department 67

33 Operating Labor Cost for Maintenance Department 68

34 Operating Labor Cost for Supply Chain Department 69

35 Total Annual Operating Labor Cost 69

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36 Total Annual Operating Cost 70

37 Total Maintenance and Repair Cost 70

38 Total Installation Cost 70

39 Annual Total Product price of Coal 71

40 Total Direct Cost 71

41 Total Indirect Cost 72

42 Total Indirect Cost 72

43 Total Fixed Capital Investment 72

44 Annual Manufacturing Cost 73

45 Total Variable Cost 74

46 Summary of Overall Total Cost 76

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 LIST OF FIGURES

Figure No. Title Page

1 Summary Table of Coal in Philippines 2

2 Coal Statistics in Philippines 3

3 Location of Propose Site 5

4 Area of the Propose Site 5

5 Seismic map of the Proposed Location 7

6 Process Flow Diagram - Water Steam Cycle system 11

7 Process Flow Diagram - Flue Gas Desulphurisation system 12

8 Process Flow Diagram - Deashing system 12

9 Process Flow Diagram - Raw and 14

Demineralised Water system

10 Piping and Instrumentation Diagram: Condenser 15

11 Piping and Instrumentation Diagram: Polishing Plant 16

12 Piping and Instrumentation Diagram: Feedwater Tank 17

13 Piping and Instrumentation Diagram: Boiler 18

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14 Piping and Instrumentation Diagram: Turbine 19

15 Coal 20

16 Location of Semirara Mining and Power Corporation 21

17 Belt Conveyor 22

18 Condenser 24

19 Turbine 26

20 Flash Tank 27

21 Pump 28

22 Separator/Evaporator 30

23 Economiser 31

24 Feed Water Tank 32

25 Air Separation 33

26 Generator 35

27 Coal Burner 36

28 Coal Boiler 37

29 Coal Pulvurizer 39

30 Layout of the Plant 51

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 LIST OF TABLES

Table No. Title Page

47 Demand outlook of BATELEC 6

48 Design Specification of Belt Conveyor 22

49 Design Specification of Heat Exchanger 24

50 Design Specification of Condenser 25

51 Design Specification of Turbine 26

52 Design Specification of Flash Tank 28

53 Design Specification of Pump 29

54 Design Specification of Separator/Evaporator 30

55 Design Specification of Economizer 31

56 Design Specification of Feed Water Tank 33

57 Design Specification of Air Separation Unit 34

58 Design Specification of Generator 35

59 Design Specification of Coal Burner 37

60 Design Specification of Coal coiler 38

61 Design Specification of Coal Pulvurizer 39

62 Mass Balance Calculations: Mass 40

x
 and Heat Balance for each State Point

63 Summary of Design Calculations 47

64 Coal Composition 48

65 Project Schedule 53

66 Project Schedule 54

67 Cost of Buildings 56

68 Vehicle cost 60

69 Pipeline Construction Cost 60

70 Equipment Cost 61

71 Total Installation Cost 62

72 Total Engineering Cost 63

73 Fire and Safety Cost 64

74 Operating Labor Cost for Technical Department 65

75 Operating Labor Cost for Production Department 65

76 Operating Labor Cost for Marketing Department 66

77 Operating Labor Cost for Human Resource Department 66

78 Operating Labor Cost for Accounting Department 67

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79 Operating Labor Cost for Maintenance Department 68

80 Operating Labor Cost for Supply Chain Department 69

81 Total Annual Operating Labor Cost 69

82 Total Annual Operating Cost 70

83 Total Maintenance and Repair Cost 70

84 Total Installation Cost 70

85 Annual Total Product price of Coal 71

86 Total Direct Cost 71

87 Total Indirect Cost 72

88 Total Indirect Cost 72

89 Total Fixed Capital Investment 72

90 Annual Manufacturing Cost 73

91 Total Variable Cost 74

92 Summary of Overall Total Cost 75

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 CHAPTER I

INTRODUCTION AND IT’S BACKGROUND

A. Introduction
As the economy of the country grows. Its energy consumption grows too.
Philippines has rural population of 53% of the total population and 94% of the total
population have access to electricity. (energypedia) The country’s total peak
demand in 2019 was recorded at 15,581 MW, which is 799 MW or 5.4% higher
than the 14,782 MW in 2018 (DOE). The distinctive feature of the energy demand
structure in the Philippines is that the transport sector consumes more than 50%
of the country’s energy demand, and that three quarters of the latter is used for
road transportation. In addition to the fact that transportation fuel accounts for large
portion of energy consumption, oil has been widely used by industrial users. Thus,
petroleum products accounts for about 70% of the primary energy requirement,
and one quarter is borne by electricity.(jicareport) As social modernization
progresses, demand for electricity and gas may increase in future. Considering the
importance of power industry in the overall development of the country, power
sector has been given high priority in the country’s development plans. Everyone
experience brownout or the drop in voltage in an electrical power supply system.
These outages have wide-ranging effects on the economy. Households would
experience no electricity for a few minutes or even for hours, causing great
inconvenience; businesses would have higher costs by way of lost revenue and
reduced productivity; and investors would be hesitant to do business, leading to
reduced investments. This scenario could have been avoided had there been more
power plants available to compensate for those undergoing unscheduled
shutdowns or maintenance. Data from the Department of Energy (DoE) showed
there are 126 power plants in Luzon grid alone as of end-2018 with installed and

1
 dependable capacities of 16,133.06 MW and 14,641.76 MW, respectively
(bworldonline,2019). However, results of a study from the Energy Regulatory
Commission (ERC) released in May showed that up to 72% of these power plants
are at least 16 years or older, which may have contributed to the grid’s power
deficiency. Older plants require more frequent maintenance and repairs and may
be more prone to unscheduled outages. Building more efficient, high tech power
plant will help solve this problem.

B. Sources of Raw Materials

The fuel to be used will be sub-bituminous coal from Semirara Coal and
Mining Corporation. The data below shows the ultimate analysis of sub-bituminous
coal from Semirara. Through the data gathered, the researchers were able to
determine the properties that may affect the overall plant operations.
Hydrogen = 4.318%
Carbon = 56.556%
Nitrogen = 1.038%
Sulfur = 0.752%
Oxygen = 16.336%
Ash = 21%
The Philippines has proven reserves equivalent to 15.6 times its annual
consumption. This means it has about 16 years of Coal left (at current consumption
levels and excluding unproven reserves).

2
 Figure 1. Summary Table of Coal in Philippines

Figure 2. Coal Statistics in Philippines

C. Products

The Philippines produces 100 to 130 million tons of combustion wastes annually
at coal-fired power plants. Regulations control the handling of solid wastes from the
boiler and pollution-control equipment at coal-fired power plants. In most cases, these
materials are disposed of in landfills. However, reuse of coal combustion wastes as
byproducts is permitted and 40 to 60 million tons (10 to 15%) are recycled annually
according to the American Coal Ash Association.

Boiler slag is produced in coal-fired power plants that use wet-bottom boilers. It
forms from melted minerals left over from coal combustion. This molten ash is
quenched with water to form a solid, black, glassy waste product, called slag. Boiler
slag is commonly re-purposed as a useful combustion byproduct. The slag material
can be ground into particles which are used as roofing granules and blasting grit, and
for snow and ice control (like sand) (Kalyoncu and Olson, 2001; American Coal Ash
Association, 2016).

3
 Bottom ash is produced in dry-bottom boilers, which are the most common types
of boilers in coal-fired power plants. Bottom ash consists of the melted minerals left
over from coal combustion. The ash settles on the walls and at the base of the boiler
as a gray, sandy material. The ash is periodically removed and disposed of in landfills
or re-purposed as a useful coal-combustion byproduct. Approximately 15 million tons
of bottom ash are produced annually in the United States, and 10 to 15% is recycled
as useful byproducts. Bottom ash is used in many ways but mostly (1) as road base;
(2) for snow and ice control (like sand); (3) in structural fills; (4) in cement and grout;
and (5) in mining applications such as mine fills, where permitted (Kalyoncu and
Olson, 2001; American Coal Ash Association, 2016).

Fly ash is the fine particulate (including ash, dust, soot, and cinders) material
produced from coal combustion. It consists of the mineral matter in the coal which did
not combust in the furnace, and did not settle to the bottom of the boiler as bottom
slag or bottom ash. It is carried upward with gaseous by-products from the furnace
into the flue gas. Fly ash can be captured in an electrostatic precipitator or filter
baghouses. Between 50 and 70 million tons of fly ash are produced in the United
States annually. A little more than half of the fly ash is disposed of in landfills, but 40
to 45% (more than 20 million tons) is re-cycled as useful byproducts. Fly ash is used
in many ways but mostly (1) to make concrete and grout; (2) for use in structural fills;
(3) for waste stabilization (thickening, solidifying); (4) in cement production; and (5) in
mining applications such as mine fills, where permitted (Kalyoncu and Olson, 2001;
American Coal Ash Association, 2016).

D. Proposed Plant Location

Bulacan, Mabini, Batangas

Coordinates (13.748242111171766, 120.95136432156899

4
 Figure 3. Location of Propose Site

Figure 4. Area of the Propose Site

The site is near a community where labor supply maybe acquired.

Bulacan is a barangay in the municipality of Mabini, in the province of Batangas.

5
 Its population as determined by the 2015 Census was 1,351. This represented
2.92% of the total population of Mabini. The site is near the highway where
transportation of personnel and equipment will be much easier; it is also near the
sea so jetty can be constructed and can be source of water supply for some
applications. The site also is far from active faults.

E. Demand Outlook

The following data necessary for the load projection were gathered from the
Department of Energy (DOE) distribution utility profile particularly the distribution utilities
operating in Batangas Province: BATELEC I, BATELEC II, FBPC, and IEEC. The Manila
Electric Company (MERALCO) was also added to the load projection. The data were
gathered to determine the forecast of the electrical consumption of the target locations.

Year BATELEC I BATELEC II FBPC IEEC MERALCO TOTAL

2019 69.93958701 165.59 9.44 4.75 7372.97 7622.7

2020 72.7511584 172.41 9.37 4.90 7608.91 7868.3
2021 75.67575497 179.52 9.30 5.06 7852.39 8121.9
2022 78.71792032 186.91 9.23 5.22 8103.67 8383.7
2023 81.88238072 194.61 9.16 5.39 8362.98 8654
2024 85.17405242 202.63 9.09 5.56 8630.60 8933.1
2025 88.59804933 210.98 9.02 5.74 8906.78 9221.1
2026 92.15969092 219.67 8.95 5.92 9191.80 9518.5
2027 95.86451049 228.72 8.89 6.11 9485.93 9825.5
2028 99.71826381 238.14 8.82 6.31 9789.48 1 10142
2029 103.726938 247.96 8.75 6.51 10102.75 10470

Table 1: Demand outlook of BATELEC

Source: Department of Energy

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 Figure. 5 Seismic map of the Proposed Location

The data gathered from DOE showed the projected load from 2015- 2029 for
BATELEC I, BATELEC II, IEEC, and MERALCO. At 2019 the total projected load is equal
to 7622.7MW and after 10 years the projected load will increase to 10470MW. The power
demand has an average growth rate of 9.64% starting from 245.65 MW to 327 MW
averaging 309.21 MW for 10 years.

Assuming no other power plants will provide the additional demand, the proposed
600 MW power plant will reach its capacity within the next 2 years of operation upon the
finishing of construction within the next 10 years.

F. Market Share

As economies in Asia Pacific grow rapidly, so does the demand for power. At the
same, there is increasing urgency to limit the impact of power generation to the
environment. Yet, structural changes must be well planned and based on long-term
visions with tangible milestones. Therefore, critical to the energy transition process is
upgrading existing power plants and their controls to provide cleaner and more flexible
power, in part to address the intermittent nature of power generation renewables.

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G. Design Objective

The main objective of this project is to design a coal-fired power plant having a
plant capacity of 600 MW located at Brgy. Bulacan, Mabini Batangas. Specifically, the
designers aim to come up with the desired plant wherein the following objectives must be
met.

1. Present and evaluate the design and development of the projected 600 MW coal
fired power plant taking into account of the following considerations:

1.1. Energy Balance

1.2. Overall Efficiency

1.3. Work Output

2. Provide technical design specifications for the different components of the coal
fired power plant, presenting the proper data for the plant calculations,
schematic diagrams, process flow diagrams, plant lay-out, and particular type
of plant components considering the required engineering codes, standards and
appropriate specifications to be utilized as a part of the advancement of the
proposed coal-fired power plant.

3. Evaluate the economic viability of the three proposed design options as well as
the comparison of equipment through calculations of economic indicators:

3.1. Payback period

3.2. Rate of Return/Rate of Investment

4. Evaluate the proposed design considering the environmental impact and

elaborating the socio-economic benefits and outcomes of the project,

H. Brief Discussion of the Plant Process

Coal is shipped to the port area where it will be conveyed in the coal yard for
storage prior to being transported to the main power generating units. The first process

8
of this power plant is where the pulverized coal is fed into the boiler and it is burnt in the
furnace. The flue gasses and ash formed during combustion will be treated accordingly.
The water present in the boiler drum changes to high pressure steam. From the boiler the
high-pressure steam passed to the super heater where it is again heated up to its dryness.
This super-heated steam strikes the turbine blades with a high speed and the turbine
starts rotating at high speed. A generator is attached to the rotor of the turbine and as the
turbine rotates it also rotates with the speed of the turbine. The generator converts the
mechanical energy of the turbine into electrical energy. The electrical energy will be
amplified by a transformer and will then be transferred to the switch yard. After striking on
the turbine the steam leaves the turbine and enters into the condenser. The steam gets
condensed with the help of cold water from the cooling tower. The condensed water with
the feed water enters into the economizer. In the economizer the feed water gets heated
up before entering into the boiler. This heating of water increases the efficiency of the
boiler. The exhaust gases from the furnace pass through the super heater, economizer
and air pre-heater. The heat of this exhaust gases is utilized in the heating of steam in
the super heater, feed water in the economizer and air in the air pre-heater. After burning
of the coal into the furnace, it is transported to ash handling plant and finally to the ash
storage. The electricity produced by the generator are then stored at transformers before
distributing it to the consumers

I. Definition of terms

Brownouts - is an intentional or unintentional drop in voltage in an electrical power

supply system. Intentional brownouts are used for load reduction in an emergency.

Coal - a combustible black or dark brown rock consisting mainly of carbonized

plant matter, found mainly in underground deposits and widely used as fuel.

Exhaust stack - a type of chimney, a vertical pipe, channel or similar structure

through which combustion product gases called flue gases are exhausted to the
outside air.

9
Generator - a generator is a device that converts motive power into electrical
power for use in an external circuit.

Generator drive shaft - a rotating shaft which transmits torque in an engine.

Outages - A power outage is a short- or long-term state of electric power loss in a

given area or section of a power grid

Reserves - Natural gas reserves refer to large deposits of natural gas which,
based on geological surveys and engineering studies, are thought to exist to a very
high degree of certainty.

Steam - Steam is water in the gas phase. This may occur due to evaporation, to
due to boiling, where heat is applied until water reaches the enthalpy of
vaporization

Steam turbine - is a device that extracts thermal energy from pressurized steam
and uses it to do mechanical work on a rotating output shaft

Turbine - a machine for producing continuous power in which a wheel or rotor,

typically fitted with vanes, is made to revolve by a fast-moving flow of water, steam,
gas, air, or other fluid.

Voltage - Voltage is the pressure from an electrical circuit's power source that
pushes charged electrons (current) through a conducting loop, enabling them to
do work such as illuminating a light

10
Chapter II – Process Design Layout

A. Process Flow Diagram

Figure 6. : Process Flow Diagram - Water Steam Cycle system

11
Figure 7. : Process Flow Diagram - Flue Gas Desulphurisation system

12
Figure 8. Process Flow Diagram - Deashing system

13
Figure 9. Process Flow Diagram - Raw and Demineralised Water system

14
B. Piping and Instrumentation Diagram

Figure 10. Piping and Instrumentation Diagram: Condenser

15
Figure 11. Piping and Instrumentation Diagram: Polishing Plant

16
Figure 12. Piping and Instrumentation Diagram: Feedwater Tank

17
Figure 13. Piping and Instrumentation Diagram: Boiler

18
Figure 14. Piping and Instrumentation Diagram: Heat Exchanger

19
Figure 15. Piping and Instrumentation Diagram: Turbine

20
Chapter III – Technical Aspects

a. Sources of Raw Materials

The main raw materials include coal it is important as a source of energy as
it is used for power generation,to supply energy to industry as well as for domestic
needs. “Coal is a combustible dark-brown to black organic sedimentary rock that
occurs in coal beds or coal seams” (Speight, 2012). Coal is made up primarily of
carbon with variable amounts of sulphur, oxygen, nitrogen, and hydrogen and may
as well contain gases and mineral matters as a portion of the coal matrix. Coals
around the world show essential differences in their chemical and physical
properties (Guerrero, 2012).This is linked to constituent minerals, organic matter,
and the geological process, which it has undergone over the years. Its is also
important as a raw material as it is used to make coal tar and coal gas.it is also
essential for smelting iron ore in blast furnace. It is a combustible black or dark
brown rock consisting mainly of carbonized plant matter, found mainly in
underground deposits and widely used as fuel.

Figure 15. Coal

Source: geology.com

20
 b. Location
The Semirara Mining and Power Corporation is a mining company based in the
Philippines. The company, a subsidiary of DMCI Holdings, operates its main coal
mine in Semirara Island and is the biggest coal producer in the Philippines
accounting for 92 percent of the total national production as of 2015. SPMPC’s
primary mining site is in Semirara Island where it has operated numerous coal
mines. It operated the Unong Pit in Semirara Island until 2000 and the Panian Pit
until 2016. It opened the Narra and Molave Pit in the islands as replacements.

Figure 16. Location of Semirara Mining and Power Corporation

Source:http://www.semiraramining.com

C. Equipment Function and Specification

A. Belt Conveyor

Belt conveyors help in the transportation of large volumes of coal over long
distances. They come with an endless rubber, balata or canvas belt running over pulleys
or a pair of end drums, with rollers (idlers) at regular intervals for support. The return idlers
that help in the support of the empty belt are plain and fall widely apart.

21
 Figure 17. Belt Conveyor

Source: Alibaba

Table 2: Design Specification of Belt Conveyor

Design Specification
Equipment Category Transportation

Requirement 1000kg

Capacity 208 metric tons/h

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 Size 1600*520*1000mm

Manufacturer/ Model FM-3D3

B. Heat Exchanger

Figure 18. Heat Exchanger

Heat exchangers are devices designed to transfer heat between two or more fluids—
i.e., liquids, vapors, or gases—of different temperatures. Depending on the type of heat
exchanger employed, the heat transferring process can be gas-to-gas, liquid-to-gas,
or liquid-to-liquid and occur through a solid separator, which prevents mixing of the fluids,
or direct fluid contact.

23
 Design Specification
Equipment Category Treatment

Requirement 700 cubic meter

Capacity 100 metric tons

Size 2m Diameter x 10m Long

Manufacturer/ Model GE Steam Power

Table 3: Design Specification of heat exchanger

C. Condenser

Figure 19. Condenser

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 Condensers are employed in power plants to condense exhaust steam from
turbines and in refrigeration plants to condense refrigerant vapours, such as ammonia
and fluorinated hydrocarbons. The petroleum and chemical industries employ
condensers for the condensation of hydrocarbons and other chemical vapours. In distilling
operations, the device in which the vapour is transformed to a liquid state is called a
condenser. All condensers operate by removing heat from the gas or vapour; once
sufficient heat is eliminated, liquefaction occurs.

Design Specification
Equipment Category Treatment

Requirement 1000 cubic meter

Capacity 405 metric tons

Size 3 m W / 12 m L

Manufacturer/ Model GE Steam Power

Table 4: Design Specification of Condenser

D. Turbine

A turbine is a device that harnesses the kinetic energy of some fluid – such
as water, steam, air, or combustion gases – and turns this into the rotational motion
of the device itself. These devices are generally used in electrical
generation, engines, and propulsion systems and are classified as a type of

25
 engine. Coal-fired plants produce electricity by burning coal in a boiler to produce
steam. The steam produced, under tremendous pressure, flows into a turbine,
which spins a generator to create electricity. The steam is then cooled, condensed
back into water and returned to the boiler to start the process over.

Figure 20. Turbine

Design Specification
Equipment Category Process

Requirement 8.33 – 15 MMTPA

Capacity 60 MW

Size 15 m Diameter

Manufacturer/ Model Toshiba

Table 5: Design Specification of Turbine

26
 E. Flash Tank

Figure 21. Flash Tank

A flash tank serves as a collection system for a variety of condensate drain lines.
Flash tanks receive high pressure condensate which is then exposed to a low pressure
steam source. When this occurs, a certain percentage of condensate will “flash” to steam
at the lower pressure. This steam can be “recycled” on other low pressure steam heat
transfer devices. Smaller in size than traditional flash tanks, flash separators utilize
cyclonic action to instantly separate steam and condensate.

Design Specification
Equipment Category Collection

Requirement 369 cubic meter

Capacity 5000-7000 L

Size 10 ‘ -20’ / 30 square ft

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 Manufacturer/ Model Qingdao Inc/ Hammer

Table 6: Design Specification of Flash Tank

F. Pumps

Figure 21. Pumps

Pumps collect saturated water from the condenser hot well and pumps it either to
a deaerating heater or back into the boiler feed pump. It operate at extremely low suction
pressures. For this reason these pumps are often located at the lowest level of any pump
in the power plant and installed in a suction can that is below ground level.

Design Specification
Equipment Category Transportation

Requirement 1000 Pa

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 Capacity 1000-3000 Pa

Size/ Weight 300 kg

Manufacturer/ Model Alibaba

Table 7: Design Specification of Pumps

G. Separator/Evaporator

A steam separator, sometimes referred to as a moisture separator or steam drier, is

a device for separating water droplets from steam. The simplest type of steam separator
is the steam dome on a steam locomotive. Stationary boilers and nuclear reactors may
have more complex devices which impart a “spin” to the steam so that water droplets are
thrown outwards by centrifugal force and collected. All separators require steam traps to
collect the water droplets that they remove.

Design Specification
Equipment Category Treatment

Requirement 50m3 /h

Capacity 80 m3/h

29
 Size 10x20 m

Manufacturer/ Model GEA

Table 8: Design Specification of Separator/ Evaporator

Figure 22. Separator/Evaporator

H. Economiser

Economisers are mechanical devices intended to reduce energy consumption, or

to perform useful function such as preheating a fluid. The term economizer is used for
other purposes as well. Boiler, power plant, heating, refrigeration, ventilating, and air
conditioning (HVAC) uses are discussed in this article. In simple terms, an economizer is
a heat exchanger.

30
 Design Specification
Equipment Category Process/Treatment

Requirement 5000 pph

Capacity 5000-8000 pph

Size 10x15x8 m

Manufacturer/ Model Alibaba

Table 9: Design Specification of Economiser

Figure 23. Economiser

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 I. Feed Water Tank

Figure 24. Feed Water Tank

It is a power plant component used to pre-heat water delivered to

a steam generating boiler. Preheating the feedwater reduces the irreversibilities involved
in steam generation and therefore improves the thermodynamic efficiency of the
system. This reduces plant operating costs and also helps to avoid thermal shock to the
boiler metal when the feedwater is introduced back into the steam cycle.

Design Specification
Equipment Category Treatment

Requirement 1500 cubic meter/hr

Capacity 2000 m3/h

32
 Size 10x15 m

Manufacturer/ Model EWT Water Technology

Table 10: Design Specification of Feed Water Tank

J. Air Separation Unit

Figure 25. Air Separation

An air separation plant separates atmospheric air into its primary components,
typically nitrogen and oxygen, and sometimes also argon and other rare inert gases.

The most common method for air separation is fractional distillation. Cryogenic air
separation units (ASUs) are built to provide nitrogen or oxygen and often co-produce
argon. Other methods such as membrane, pressure swing adsorption (PSA) and vacuum
pressure swing adsorption (VPSA) are commercially used to separate a single
component from ordinary air. High purity oxygen, nitrogen, and argon, used
for semiconductor device fabrication, require cryogenic distillation. Similarly, the only

33
viable source of the rare gases neon, krypton, and xenon is the distillation of air using at
least two distillation columns.

Design Specification
Equipment Category Process

Requirement 6000 t/d

Capacity 5000-8000 t/d

Size 13x13x10 m

Manufacturer/ Model FS-Elliott

Table 11: Design Specification of Air Separation Unit

K. Generator

In electricity generation, a generator is a device that converts motive power

(mechanical energy) into electrical power for use in an external circuit. Sources of
mechanical energy include steam turbines, gas turbines, water turbines, internal
combustion engines, wind turbines and even hand cranks.

34
 Figure 26. Generator

Design Specification
Equipment Category Electrical

Requirement 500kVA

Capacity 25 to 800kVA(60Hz)

Size 10 x 8 meters

Manufacturer/ Model NIPPON SHARYO

Table 12: Design Specification of Generator

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 L. Coal Burner

Figure 27. Coal Burner

A coal burner (or pulverized coal burner) is a mechanical device that burns pulverized
coal (also known as powdered coal or coal dust since it is as fine as face powder in
cosmetic makeup) into a flame in a controlled manner. Coal burner is mainly composed
of pulverized coal machine, host of combustion machine (including combustion chamber,
automatic back and forth motion system, automatic rotation system, the combustion air
supply system) control system, ignition system, the crater and others.

Design Specification
Equipment Category Treatment

Requirement 500 kg /hr

Capacity 1000kg /hr

36
 Size 12x 16 meters

Manufacturer/ Model Alibaba

Table 13: Design Specification of Coal Burner

M. Coal Boiler

Figure 28. Coal Boiler

A pulverized coal-fired boiler is an industrial or utility boiler that generates thermal

energy by burning pulverized coal (also known as powdered coal or coal dust since it is
as fine as face powder in cosmetic makeup) that is blown into the firebox.

The basic idea of a firing system using 37ulverized fuel is to use the whole volume of
the furnace for the combustion of solid fuels. Coal is ground to the size of a fine grain,
mixed with air and burned in the flue gas flow. Biomass and other materials can also be

37
added to the mixture. Coal contains mineral matter which is converted to ash during
combustion. The ash is removed as bottom ash and fly ash. The bottom ash is removed
at the furnace bottom.

Design Specification
Equipment Category Treatment

Requirement 650 cubic meter

Capacity 800 m3/hr

Size 8x5x3 meters

Manufacturer/ Model Henan Yuanda Boiler Corporation

Ltd.

Table 14: Design Specification of Coal Boiler

38
 N. Coal Pulvurizer

Figure 29. Coal Pulvurizer

Pulverizers (coal pulverizer) are used to pulverize pieces of coal into fine particles
(100μm) before placing into a boiler, to ensure efficient combustion. Pulverizers have
three functions, pulverization, drying and classification. The classification function plays
the important role of ensuring that only fine particles of the pulverized coal are sent to the
boiler. Within a rotating-type classifier, fine particles are passed through while coarse
particles are eliminated by utilizing the relative balance of centrifugal force and centripetal
force produced by a blade rotating at several dozen rpm and the flow of air.

Design Specification
Equipment Category Treatment

Requirement 850 kg/hr

Capacity 1250 kg/hr

Size 7x5x 3 meters

Table 15: Design Specification of Coal Pulvurizer

39
 D. Mass Balance and Energy Balance Computations

Mass(Steam) Pressure
State Point Enthalpy kJ/kg Temp °C
kg/s (bar a)

1 200 125.7458 30 0.05

2 200 125.7458 30 0.05

3 200 126.6531 30 10

4 200 126.6531 30 10

5 60 129.3848 30 40

6 140 129.3848 30 40

7 140 129.3848 30 40

8 60 633.8126 150 30

9 200 129.3848 30 40

10 80 125.7458 30 0.05

11 280 719.9761 170 22

12 280 920.6374 215 22

13 280 953.3827 220 310

14 335 1328.2491 300 310

15 335 3484.4226 600 260

16 280 3069.2941 350 50

17 55 3069.2941 350 50

18 280 3713.3422 620 50

19 280 125.7458 30 0.05

Table 16. Mass Balance Calculations: Mass and Heat Balance for each State Point

40
 Diagrams Calculations

m1 = m2

Condenser 200 kg/sec = 200 kg/sec to

m1 m2 Pump

m2 = m3
Pump P-101
200 kg/sec = 200 kg/sec to
m2 m3
Polishing Plant

m3 = m4

Polishing Plant 200 kg/sec = 200 kg/sec

m3 m4
Polishing to Pump P-102

m4 = m5 + m6
m6
200 kg/sec = 60 kg/sec to Air
Pump P-102 Separator unit + 140 kg/sec to
m4 m5
E-102

m6 = m7

Heat Exchanger 140 kg/sec = 140 kg/sec to Heat

m6 E-102 m7 Exchanger E-103

41
 Air Separator Unit m5 = m8
m5 System m8
60 kg/sec = 60 kg/sec to Low
Pressure Heat Exchanger E-103

m7 + m8 = m9
140 kg/sec to 60 kg/sec = 200
m10 kg/sec to Heat Exchanger E-103

Heat Exchanger
m9 E-103
m11 m9 + m10 = m11
200 kg/sec + 80 kg/sec = 280
kg/sec to Feed Water

Tank

m11 = m12
280 kg/sec = 280 kg/sec to Boiler
Feed water tank
Feed water Pump
m11 m12

Tank

m12 = m13
Boiler Feed water
280 kg/sec = 280 kg/sec to
m12 Pump m13
High Pressure Heater

Pump

Tank

42
 m17

m13 + m17 = m14

High Pressure
280 kg/sec + 55kg/sec = 335
m13 Heater E-104 m14 kg/sec to kg/sec to Boiler

Tank

m14 = m15
Boiler m15
335 kg/sec = m16
= 335 kg/sec to High
m14 m15 Pressure Turbine
370 kg/sec = 370 kg/sec to
High Pressure Turbine

Tank

m16
m15 = m16 + m17
High Pressure
335 kg/sec = 55 kg/sec to E-
m15 Turbine m17
104 + 280 kg/sec to Reheater
E-105

Tank
m16 = m18
280 kg/sec = 280 kg/sec to
Heat exchanger
m16 m18 Intermediate Pressure Turbine
E-105

Tank

43
 m18 = m19
Intermediate
Pressure Turbine 280 kg/sec = 280 kg/sec to
m18 m19
Low Pressure Turbine

Tank

m20 = m11 + m1
Low Pressure
Turbine 280 kg/sec = 80 kg/sec + 200
m19 m1
kg/sec to condenser

Tank
m10

44
Energy Balance

Pump Work h2m

Wp1 = (h3 – h2)*(m2)

P-101
= (126.6531 - 125.7458)*(200)

= 0.18146 MW Wp1 h3

Wp2 = (h5 – h4)*(m4) h4

= (129.3848 - 126.6531)*(200) P-102

= 0.18146 MW

Wp2 h5
h12

Wp3 = (h14 – h12)*(m11)

P-103
= (1328.2491 - 920.6374)*(280)

= 114.131276 MW Wp3 h14

Wp = W p1 + W p2 + W p3

= 0.18146 MW + 0.54634 MW + 114.131276 MW

Wp = 114.859076 MW

45
Turbine Work h15

WT1 = (h15 – h16)*(m15)

Turbine
= (3484.4226 – 3069.2941)*(335)

= 278.136095 MW h16 W T1

h18

Turbine
WT2 = (h18 – h17)*(m18)

= (3713.3422 – 3069.2941)*(280) h17 W T2

= 360.666936 MW

WT = W T1 + WT2

= 278.136095 MW + 360666.936 MW

WT = 638.803031 MW

Heat Rejected by Condenser h3

Qcondenser = (h2 - h3)*(m1)

Condenser
= (125.7458 – 126.6531)*(200)

= -0.18146 MW Qcondenser h2

46
Heat Added by Heat exchangers

Total Heat Added = (h5 - h3)*(m6) + (h11 - h10 - h9)*(m9 + m10) + (h14 -h13 - h19)*

(m17 + m13) + (h8 - h18)*(m16) + (h15-h14)*(m14)

= (129.3848 – 126.6531)*(140) + (719.9761-125.7458 -129.3848)*

(200+ 80) + (11328.2491 – 953.3827 - 125.7458)*(280 + 55) +

(633.8126 –3713.3422)*(280) + (3484.4226- 1328.2491)*(335)

Total Heat Added = 1408.372007 MW

Table 17. Summary of Design Calculations

Parameters Design
Heat Added 1408.372007 MW
Work of Turbine 600 MW
Work of Pump 114.859076 MW
Net Work 485.140924 MW
Thermal Efficiency 0.344469303

The work produced by the turbine is 600MW and the total mass of steam required
to produce the output is 335 kg/s. The calculations show that design has the thermal
efficiency of 34.4469303%.

47
Fuel Computations

Coal Composition
Hydrogen 4.4100%
Carbon 58.2900%
Nitrogen 1.0000%
Sulfur 0.7300%
Oxygen 16.5000%
Ash 19.0700%
Table 18. Coal Composition

Higher Heating Value

𝑂
HHV = 33820 C + 144212(H - 8 )+9304S

= 33820*(0.5829) +144212(0.0441- 0.1650 /8)+9304*(0.0073)

HHV = 23166.9739 kj/kg

Heat Added
Fuel Consumption = HHV

23166.9739
= 23166.9739

Fuel Consumption = 75.99028757 kg/sec

Emission Calculation

Carbon oxides emission

Mcox = mass of Carbon * mf

= 0.5829 * 75.99028757

48
 Mcox = 162.4140416 kg/sec

Nitrogen oxides emission

MNox = mass of Nitrogen * mf

= 0.0100 * 75.99028757

MNox = 2.496823734 kg/sec

Sulfur oxides emission

Msox = mass of Sulfur * mf

= 0.0073 * 75.99028757

Msox = 1.109458198 kg/sec

Ash Disposal

Ash = mass of Ash * mf

= 0.1907 * 75.99028757

Ash = 14.49134784 kg/sec

Air-Fuel Ratio

𝑂
A/F = 11.5C + 34.5( H - 2 ) + 4.3S

0.1650
= 11.5 (0.5829 + 34.5(0.0441- ) + 4.3S
2

= 7.54 kgair/kgfuel

49
Pulverized coal fired boilers run with an average of 20% excess air to burn the fuel
completely:

A/FActual = A/F ( 1 + Percent Excess Air)

= 7.54 * 0.2

= 7.74 kgair/kgfuel

50
 Chapter IV

ECONOMIC ANALYSIS

This chapter presents all the required calculations and data regarding the
financial aspects of the proposed 600MW Coal-Fired Power Plant Located at Brgy.
Bulacan, Mabini Batangas. These calculations and data will be used to know if the plant
is economically viable.

A. Timeline of Construction of the Plant

Figure 30. Layout of the Plant

51
 Timeline of Construction Plant

PROJECT SCHEDULE
YEAR

2021 2022 2023

Working Activities
J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
AE A P A U U U E C O E A E A P A U U U E C O E A E A P A U U U E C O E
N B R R Y N L G P T V C N B R R Y N L G P T V C N B R R Y N L G P T V C

Planning of Plant
Design and
Feasibility Study
Approval of Loan
from Banks

Acquisition of
Land
Registration of
Corporation and
Securing of the

52
Required Permit

Canvassing and
Selection of
Machinery

Table 19: Project Schedule

PROJECT SCHEDULE

YEAR

2024 2025 2026 2027-

Working
Activities J F MA M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
A EA P A U U U E C O E A E A P A U U U E C O E A E A P A U U U E C O E
N BR R Y N L G P T V C N B R R Y N L G P T V C N B R R Y N L G P T V C

Procurement
and
Construction
Stage

53
Commissionin
g and Dry-run
Stage
Hiring and
Training of
Employees

Operation
Stage

Table 20: Project Schedule

54
B. Building Cost

According to the Philippine Statistics Authority (PSA), the current cost per square
meter estimate is Php 9,000 in the region of CALABARZON and Php 4,200 in
Mabini, Batangas.

Source: https://estimationqs.com/building-costs-per-square-metre-in-the-
philippines/#:~:text=The%20region%20of%20Calabarzon%20comes%20in%20at%
209%2C000%20per%20m2

1. Plant Utilities
Building Cost = (Total m2 of the building) (Php 4,200 / m2)
Building Cost = (600m2) (Php 4,200 / m2)
Building Cost = Php 2,520,000.00
2. Production Building
Building Cost = (Total m2 of the building) (Php 4,200 / m2)
Building Cost = (1300m2) (Php 4,200 / m2)
Building Cost = Php 5,460,000.00
3. Administration Building
Building Cost = (Total m2 of the building) (Php 4,200 / m2)
Building Cost = (400m2) (Php 4,200 / m2)
Building Cost = Php 1,680,000.00
4. Warehouse Building (Raw Materials Storage)
Building Cost = (Total m2 of the building) (Php 4,200 / m2)
Building Cost = (700m2) (Php 4,200 / m2)
Building Cost= Php 2,940,000.00

5. Laboratories
Building Cost = (Total m2 of the building) (Php 4,200 / m2)
Building Cost = (400m2) (Php 4,200 / m2)
Building Cost= Php 1,680,000.00

55
6. Maintenance Building
Building Cost = (Total m2 of the building) (Php 4,200 / m2)
Building Cost = (450m2) (Php 4,200 / m2)
Building Cost= Php 1,890,000.00
7. Fire House
Building Cost = (Total m2 of the building) (Php4,200/ m2)
Building Cost = (300m2) (Php 4,200/ m2)
Building Cost= Php 1,260,000.00
8. Canteen
Building Cost = (Total m2 of the building) (Php 4,200/ m2)
Building Cost = (250m2) (Php 4,200/ m2)
Building Cost= Php 1,050,000.00
9. Gymnasium
Building Cost = (Total m2 of the building) (Php 4,200/ m2)
Building Cost = (400m2) (Php 4,200/ m2)
Building Cost= Php 1,680,000.00
10. Clinic
Building Cost = (Total m2 of the building) (Php 4,200/ m2)
Building Cost = (200m2) (Php 4,200/ m2)
Building Cost= Php 840,000.00

11. Gate House/ Guard House

Building Cost = (Total m2 of the building) (Php 4,200/ m2)
Building Cost = (150m2) (Php 4,200/ m2)
Building Cost= Php 630,000.00

Table 21. Cost of Buildings

Total Area of the

Building Description Building (m2) Cost (Php)

56
 Plant Utilities 600 2,520,000.00

Production 1,300 5,460,000.00

Building

Administration 400 1,680,000.00

Building

Warehouse Building 700 2,940,000.00

(Raw Materials Storage)

Laboratories 400 1,680,000.00

Maintenance 450 1,890,000.00

Building

Fire House 300 1,260,000.00

Canteen 450 1,050,000.00

Gymnasium 400 1,680,000.00

Clinic 200 840,000.00

Gate House/ 150 630,000.00

Guard House

TOTAL 5,350 21,630,000.00

57
C. Vehicle Cost

1. Trailer truck

The cost assumption of one (1) Trailer Truck from Hebei Chenyang

Automobile Trading Co., Ltd. is Php 1,941,600.00.

Source: www.alibaba.com

Vehicle cost = (Number of Vehicles) (Cost of Vehicle)

Vehicle cost = (3) (Php 1,941,600.00)

Vehicle cost = Php5,824,800.00

2. Tanker Truck

The cost assumption of one (1) Tanker Truck from Qingdao Transauto

Sales Co., Ltd. is Php 2,534,784.00.

Source: www.alibaba.com

Vehicle cost = (Number of Vehicles) (Cost of Vehicle)

Vehicle cost = (2) (Php2,534,784.00)

Vehicle cost = Php 5,069,568.00

58
3. Forklift

The cost assumption of one (1) Forklift from Jiangsu Jingxin Lifting

Equipment Ltd. is Php 354,855.00.

Source: www.alibaba.com

Vehicle cost = (Number of Vehicles) (Cost of Vehicle)

Vehicle cost = (2) (Php354,855.00)

Vehicle cost = Php 709,710.00

4. Fire Truck

The cost assumption of one (1) Fire Truck is Php1,275,000.00.

Source: www.alibaba.com

Vehicle cost = (Number of Vehicles) (Cost of Vehicle)

Vehicle cost = (2) (Php1,275,000.00) Vehicle cost = Php2,550,000.00.

Vehicle Quantity Cost per Unit (Php) Total Cost (Php)

Trailer truck 3 1,941,600.00 5,824,800.00

Tanker truck 2 2,534,784.00 5,069,568.00

59
 Forklift 2 354,855.00 709,710.00

Fire Trucks 2 1,275,000.00 2,550,000.00

TOTAL 10 6,106,236.00 14,154,078.00

Table 22: Vehicle cost

D. Pipeline Construction

Pipeline construction follows once the design is completed and all approvals are
granted. The construction includes the process of landholder engagement and
access approvals, surveying and fencing, clear and grade, stringing, bending,
welding and nondestructive testing, joint coating, trenching, lowering in and
padding, backfilling, hydrostatic testing, restoration and signage.

This includes cost for fittings, pipe, valves supports, piping covers labor and other
terms involved in the complete construction of all piping used directly in the process.
According to the table of piping costs, the total pipeline construction cost follows the
formula: Total Pipeline Construction Cost = Material Cost + Labor Cost

Let Material Cost = 9% of Total Purchased Equipment Cost; and

Let Labor Cost = 7% of Total Purchased Equipment Cost

Table 23. Pipeline Construction Cost

Type of Cost Percentage Total Purchased Cost (Php)

Equipment Cost (Php)

60
 Material Cost 9% 233,596,514.75 21,023,686.3275

Labor Cost 7% 233,596,514.75 16,351,756.0325

Total Pipeline 37,375,442.36

Construction Cost

E. Equipment Cost

Table 24. Equipment Cost

Number Total Cost (Php)

Equipment Cost per Unit(Php)
Required

Belt Conveyor 2 1,512,060.00 3,024,120.00

Heat 4 238,722,550.00 954,890,200.00

Exchanger
Condenser 1 2,597,298.00 2,597,298.00

Turbine 1 38195608.00 38195608.00

Flash Tank 1 14353800.00 14353800.00

8 23923000.00 191,384,000.00
Pumps
1 3,225,090.00 3,225,090.00
Separator/Evaporator

61
 Economiser 1 3,588,750.00 3,588,750.00

Feed Water tank 2 2,598,255.00 5196510.00

Air Separation Unit 1 3,225,090.00 3,225,090.00

Generator 1 3, 746, 655.00 3, 746, 655.00

Coal Burner 1 4, 636, 665.00 4, 636, 665.00

Coil Boiler 1 4,761,075.00 4,761,075.00

Coal Pulvurizer 1 3, 746, 655.00 3, 746, 655.00

TOTAL 24 348,832,551.00 1,230,121,336.00

F. Installation/Commissioning

The Installation/Commissioning Cost according to

Design and Calculations of Chemical Engineering Projects should be 47%
of total purchased equipment cost. For the estimation, Let Installation Cost =
(47%)(Total Purchased Equipment Cost)

Installation Cost = 0.47 x (Php1,230,121,336.00)

Installation Cost = Php 578,157,027.90

Table 25. Total Installation Cost

Total Equipment Cost Percentage of Total Installation Cost

Installation Cost (Php)

62
 Php1,230,121,336.00 47% 578,157,027.90

G. Engineering Cost

According to Design and Calculations of Chemical Engineering Projects, the

Engineering Cost should be 30% of total purchased equipment cost. For the
estimation,

Let Engineering Cost = (30%)(Total Purchased Equipment Cost)

Engineering Cost = (30%) (Php1,230,121,336.00)

Engineering Cost = Php369,036,400.80

Table 26. Total Engineering Cost

Total Equipment Cost Percentage of Total Engineering Cost

Installation Cost
(Php)

Php1,230,121,336.00 30% 369,036,400.80

63
 H. Fire and Safety Cost

Table 27. Fire and Safety Cost

Fire and Safety Number Cost per Equipment Total Cost of

Required Equipment (Php)
Equipment (Php)

Fire extinguisher 30 1,530.00 45,900.00

Fire Alarm System 4 20,400.00 45,900.00

Automatic Sprinkler 2 92,750.00 185,500.00

System

Fire Proof Clothing Suit 10 2,142.00 21,420.00

(Set)

Personal Protective 110 3,500.00 385,000.00

Equipment (Set)

TOTAL 156 120,322.00 638,720.00

I. Labor Cost

Operating Labor

For every payroll period, employers must withhold (i.e. deduct) taxes from
the payroll of their employees. Withholding tax is a mandatory tax on the gross

64
 value of an employee’s salary. “Gross” means the value before any payroll
deductions have been made
Table 28. Operating Labor Cost for Technical Department

Position Number of Monthly Annual Salary Annual Tax Total Annual

Employees Salary (Php) (Php) Deduction Operating Cost
(Php) (Php)
President 1 280,000.00 3,360,000.00 993,419.00 2,366,581.00

Vice President 1 220,000.00 2,640,000.00 748,619.00 1,891,381.00

Plant Manager 1 85,000.00 1,020,000.00 217,419.00 802,581.00

Engineering 1 80,000.00 960,000.00 198,219.00 761,781.00
Manager
QA/ QC 4 30,000.00 360,000.00 32,011.00 1,311,956.00
Engineer
Health and
Safety Officer 6 30,000.00 360,000.00 32,011.00 1,967,934.00
Laboratory 1 48,000.00 576,000.00 88,367.00 487,633.00
Manager
Laboratory 4 23,000.00 276,000.00 12,671.00 1,053,316.00
Technician
TOTAL 19 796,000.00 9,552,000.00 2,322,736.00 10,643,163.00

Table 29. Operating Labor Cost for Production Department

Position Number of Monthly Annual Annual Tax Total Annual
Employees Salary Salary (Php) Deduction Operating Cost
(Php) (Php) (Php)

65
 Production 1 80,000.00 960,000.00 198,219.00 761,781.00
Manager
Production 35 23,000.00 276,000.00 12,671.00 9,216,515.00
Operators
Process 5 30,000.00 360,000.00 32,011.00 1,639,945.00
Engineer
Process 5 23,000.00 276,000.00 12,671.00 1,316,645.00
Technicians
TOTAL 46 156,000.00 1,872.000.00 255,572.00 12,934,886.00

Table 30. Operating Labor Cost for Marketing Department

Position Number of Monthly Annual Annual Tax Total Annual

Employees Salary Salary (Php) Deduction Operating Cost
(Php) (Php) (Php)
Sales and 1 80,000.00 960,000.00 198,219.00 761,781.00
Marketing
Manager
Market
Research 3 23,000.00 276,000.00 12,671.00 789,987.00
Analyst
TOTAL 4 103,000.00 1,236,000.00 210,890.00 1,551,768.00

Table 31. Operating Labor Cost for Human Resource Department

66
 Position Number of Monthly Annual Annual Tax Total Annual
Employees Salary Salary (Php) Deduction Operating Cost
(Php) (Php) (Php)
Human
Resource 1 80,000.00 960,000.00 198,219.00 761,781.00
Manager
Human
Resources 6 23,000.00 276,000.00 12,671.00 1,579,974.00
Officers
Medical 5 18,000.00 216,000.00 5,339.00 1,053,305.00
Officer/Staff
TOTAL 12 121,000.00 1,452,000.00 210,890.00 3,395,060.00

Table 32. Operating Labor Cost for Accounting Department

Position Number of Monthly Annual Annual Tax Total

Annual
Employee Salary (Php) Deduction Operating Cost Php) (Php)
General 1 45,000.00 540,000.00 78,647.00
Accountant
Staff 2 28,000.00 336,000.00 26,731.00 618,538.00
Accountant
Internal Auditor 2 23,000.00 276,000.00 12,671.00 526,658.00

TOTAL 5 96,000.00 1,152,000.00 118,049.00 1,606,549.00

461,353.00

67
 Position Number of Monthly Annual Annual Tax Total Annual
Employees Salary (Php) Salary (Php) Deduction Operating
(Php) Cost (Php)
Maintenance 1 80,000.00 960,000.00 198,219.00 761,781.00
Manager
Maintenance 10 23,000.00 276,000.00 12,671.00 2,633,290.00
Technician
TOTAL 11 103,000.00 1,236,000.00 210,890.00 3,395,071.00

Table 33. Operating Labor Cost for Maintenance Department

Maintenance Department

Table 34. Operating Labor Cost for Supply Chain Department

Position Number of Monthly Annual Annual Tax Total Annual

Employees Salary Salary (Php) Deduction Operating Cost
(Php) (Php) (Php)
Supply Chain 1 80,000.00 960,000.00 198,219.00 761,781.00
Manager
Purchasing 1 18,000.00 216,000.00 5,339.00 210,661.00
Officer
Warehouse 1 38,000.00 456,000.00 55,967.00 400,033.00
Manager

68
 Logistic 1 30,000.00 360,000.00 32,011.00 327,989.00
Supervisor
TOTAL 4 166,000.00 1,992,000.00 291,536.00 1,700,464.00

Table 35. Total Annual Operating Labor Cost

Department Total Monthly Annual Annual Tax Total Annual

Number of Salary (Php) Salary (Php) Deduction Operating
Employees (Php) Cost
(Php)

Accounting 5 96,000.00 1,152,000.00 118,049.00 1,606,549.00

Human 12 121,000.00 1,452,000.00 210,890.00 3,395,060.00
Resource
Maintenance 11 103,000.00 1,236,000.00 210,890.00 3,395,071.00
Marketing 4 103,000.00 1,236,000.00 210,890.00 1,551,768.00
Production 46 156,000.00 1,872.000.00 255,572.00 12,934,886.00
Supply Chain 4 166,000.00 1,992,000.00 291,536.00 1,700,464.00
Technical 19 796,000.00 9,552,000.00 2,322,736.00 10,643,163.00
TOTAL 101 1,421,000.00 15,360,000.00 3,190,898.00 35,226,961.00

Table 36. Total Annual Operating Cost

J. Maintenance and Repair

The annual maintenance costs for plants are high, typically 5 to 15 per cent
of the installed capital costs according to Design and Calculation of Chemical
Engineering Projects.

69
 Table 37. Total Maintenance and Repair Cost

Total Equipment Cost Percentage of Total Maintenance and

Installation Cost
Repair Cost (Php)

Php1,230,121,336.00 5% 615,060,668.70

K. Other Utilities

This cost category covers other utilities needed in the operation process.
These will normally be supplied from a central facility and this will include water, coal
and compressed air and electricity. According to Design and Calculations of Chemical
Engineering Projects, utility costs amount to 10 to 20 percent of the total purchased
equipment cost. For the estimation of Utility Cost, Let Utility Cost = (20%) (Total
Purchased Equipment Cost).

Utility Cost = (20%) (Php1,230,121,336.00)

Utility Cost = Php 246,024,267.20

Total Equipment Cost Percentage of Total Installation Cost (Php)

Installation Cost

Php1,230,121,336.00 20% 246,024,267.20

Table 38: Total Installation Cost

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L. Product Prices

The target plant production for the proposed 600 MW Coal-Fired Power Plant is
12.8M tons per year.

Wholesale Selling Price of Coal = Php 8,118,000 per MW

Selling Price per Plant Capacity Annual Plant Annual Total Product
MW per day (MW) Capacity (MW) Price of Coal

Php8,118,000.00 14,400 15,356,800 Php1,246,665,024.00

Table 39: Annual Total Product price of Coal

M. Expected Annual Cash Inflow

Table 40. Total Direct Cost

Type of Cost Total Cost

Building Cost 21630000.00

Installation/Commissioning Cost 578157027.00

Instrumentation and Control (20% of 246024267.2

Equipment Cost)
Pipeline Construction Cost 37,375,442.36

TOTAL DIRECT FIXED COST 883,186,737.5

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 Table 41. Total Indirect Cost

Type of Cost Total Cost

Construction Cost (6% of Direct Cost) 2,242,526.542

Contingency Cost (3% of Direct Cost) 7,380,728.016

Engineering Cost 369,036,400.8

TOTAL INDIRECT FIXED COST 378,659,655.4

Table 42. Total Indirect Cost

Type of Cost Total Cost Percentage (%) Working Capital

(Php)

Equipment Cost 233,596,514.75 5 11,679,825.74

Direct Fixed Cost 250,425,507.31 5 12,521,275.00

Indirect Fixed Cost 92,617,250.08 5 4,630,862.50

TOTAL WORKING 28,831,963.24

CAPITAL (Php)

Table 43. Total Fixed Capital Investment

Type of Cost Fixed Capital Investment (Php)

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 Equipment Cost 1,230,121,336.00

Direct Fixed Cost 883,186,737.5

Indirect Fixed Cost 378,659,655.4

Working Capital 28,831,963.24

TOTAL FIXED CAPITAL INVESTMENT 25,207,099,692.00

Variable Cost:

Table 44. Annual Manufacturing Cost

Raw Materials Annual Amount Requirement Cost (Php)

Water 30,134.4 9, 661,172,832.00

Coal 15,765 tons 7, 800,007,375.00

Oxygen Gas 2,150,181.818 m3 6, 550,187,129.00

TOTAL 24,011,367,336.00
MANUFACURING

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 Table 45. Total Variable Cost

Type of Cost Total Cost (Php)

Manufacturing Cost (Cost of Raw 24,011,367,336.00

Materials)

Other Utility Cost 246,024,267.20

Operating Cost 35,226,961.00

Maintenance and Repair Cost 615,060,668.70

Supervision Cost (5% of Operating Cost) 1,761,348.05

TOTAL VARIABLE COST 24,909,440,583.74

Salvage = 15% of Equipment Cost

Salvage = (15%) (Php1230121336.00)

Salvage = Php 184518200.4

Local Tax = 12% of Total Fixed Capital Investment

Local Tax = (12%) (Php25,207,099,692.00)

Local Tax = Php 3024851963.00

Insurance = 8% of Total Fixed Capital Investment

Insurance = (8%) (Php25,207,099,692.00)

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Insurance = Php 2016567975.00

Plant Overhead = 50% of (Operating Cost + Maintenance Cost + Supervision Cost)

Plant Overhead = (50%) ( Php35,226,961.00 + Php615,060,668.70+ Php1,761,348.05

)

Plant Overhead = (50%) ( Php 652048977.80)

Plant Overhead = Php 326024488.90

Taxes = 30% of Annual Income

Taxes = (30%) (Php 1,246,665,024.00)

Taxes = Php 3,739,999.00

Total Investment = Total Variable Cost + Total Fixed Capital Investment + Taxes

Total Investment = Php 24,909,440,583.74 + 25,207,099,692.00+ 3739999507.00

Total Investment = Php 5,385,653,978.00

• Expected Annual Cash Inflow

Production per day: 14,400 MW

Production per Year: 15,356,800 MW

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 Price per MW: Php 8,118,000.00

Annual Income = Php 1,246,665,024.00

Total Annual Income = Annual Income – Taxes

Total Annual Income = Php 1,246,665,024.00– Php 3,739,999.00

Total Annual Income = Php 1,242,925,025.00

• Payback Period

Payback Period = Total Investment / Total Annual Income

Payback Period = Php5,385,653,978.00 / Php1,242,925,025.00

Payback Period = 4.33 approximately 4 years

Table 46. Summary of Overall Total Cost

Overall Total Cost

Description Cost (Php)

Building 21,630,000.00

Engineering 369,036,400.80

Equipment 1,230,121,336.00

Fire and Safety 638,720.00

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 Installation/Commissioning 578,157,027.90

Labor 35,226,961.00

Maintenance and Repair 615,060,668.70

Pipeline Construction 37,375,442.36

Vehicle 14,154,078.00

Other Utilities 246,024,267.20

Overall Total Cost (Php) 3,147,424,901.00

CHAPTER V

ENVIRONMENT AND SAFETY ASPECTS

Environmental Management Systems

a. Air Emission

Main Stack emissions from coal-fired power plant are sulphur dioxide, nitrogen
dioxide, carbon dioxide and traces of other gases that are present in insignificant
concentrations.

The NOx emissions are controlled by the low Nox firing system and the Selective
Catalytic Reduction System (SCR), using anhydrous ammonia. The purpose of the SCR
is to reduce the Nox in the flue gas by mixing vapour ammonia with flue gas at the boiler
outlet. The SCR System is composed of three layers of catalyst within a catalyst chamber.

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The reduction reaction takes place as the gases pass through the catalyst chamber with
the Nox being reduced to nitrogen and water vapour.

Flue gas 78esulphurization is achieved by the limestone-gypsum wet method. This

process technology uses limestone slurry as sorbent and at the end product gives
gypsum. The process is composed of the following main parts: the flue gas
78esulphurization system; the reagent storage and preparation system; and the gypsum
dewatering and storage system.

Particulate Matter

Electrostatic Precipitator cleans the flue gas from the dust/fly ash released during
the combustion process in the boiler. The flue gas is routed to the ESP through ductwork
and an inlet nozzle. At the inlet of the ESP, gas distribution screens are provided to ensure
uniform distribution of the flue gas over the entire cross section of the ESP. While the dust
loaded flue gas passes through the ESP, the dust is precipitated by charging the dust
particles under the influence of high voltage electric field created by the transformer
rectifier sets. The collected dust is then rapped off from the electrodes through the rapping
mechanism.

Ash Production and Handling

The purpose of the de-ashing system is to remove and collect the ash produced
by the coal combustion in the boiler furnace. There are two types of ash: bottom ash; and
fly ash.

Bottom ash

For bottom ash, the heaviest and largest ash is collected at several locations:
bottom ash from the furnace, ash collected under the economizer and ash collected under
the inlet duct to the SCR. A submerged scraper conveyor is provided under the furnace

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bottom hopper section for the removal of the furnace bottom ash. This uses a drag chain
and flight conveyor of heavy construction submerged in a water trough below the furnace.
The ash is evacuated mechanically on a continuous basis so there is no long-time storage
in the water impoundment beneath the furnace. After discharge from the submerged
scraper conveyor in a dewatered condition, ash is dumped into the diverter grizzly screen
for further particle size reduction. Finally, the bottom ash is transported by conveyors to
an elevator. From the top of the elevator a conveyor delivers the ash into the Bottom Ash
Silo. The silo is emptied by truck.

Fly ash

Fly Ash Fly ash is driven within the flue gas is collected and removed in the ESP
and collected in the ESP hoppers. From the hoppers, the fly ash is transported by the fly
ash handling Fly ash is delivered in the fly ash silo.

Waste Water Management System

Waste Water Treatment systems shall be designed and installed to treat all
industrial waste generated from the plant during operation. The waste water treatment
plant shall be designed to cater to regular waste during operation and irregular waste
during outages.

Discharge water quality from each of the treatment system shall be monitored for key
constituents of concern in accordance with constituents treated and the regulatory
requirements. Waste water shall be rerouted back to the waste water treatment system
for further treatment should the treated water quality fail to meet the required limits.

The waste water treatment system shall cater to all oily and chemical waste water from
the entire Plant including but not limited to the boiler, steam turbine, transformers, pumps,
tanks, fuel and chemical unloading facilities, vessels drainage and heat exchangers
drainage, onsite and external ash pond leachate and ash pond rain runoff.

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The treated waste water monitoring location should be selected with the objective of
providing representative monitoring data. Effluent sampling stations shall be located at
the final discharge, as well as at strategic upstream points prior to merging of different
discharges.

B. Prevention of Soil Contamination

The company will provide information on this, confirming that solid wastes will be
sent to landfills of appropriate design for the materials concerned, and that monitoring to
guard against environmental harm.

a. Prevention of Water Contamination

Any industrial effluent generated from the Plant shall be treated to comply with
DENR Administrative Order No:2016-08 on Water Quality Guidelines and General
Effluent Standards (Class SC) IFC 2008 EHS Guideline for Thermal Power Plants) before
discharging downstream the treatment facility. For surface waters three types of
monitoring are required by the company:

• Surveillance – to validate the characterization pressure and impact assessments, detect

long-term trends;

• Operational – to help classify those water bodies which are at risk of failing to meet good
status; and

• Investigative – to ascertain the cause and effects of a failure to meet ‘good status’ where
it is not clear

For each surface water body, they will assess as appropriate:

• Biology (plankton/phytobenthos, macrophytes, invertebrates and fish);

• Hydro-morphology;

• Physico-chemical (including organic pollutants); and

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• Priority and priority-hazardous substances.

For groundwater, the monitoring requirements cover:

• Groundwater resources through a water level monitoring network;

• Surveillance and operational monitoring of chemical status

The Plant design shall comply with the following requirements for effluents:

 Oil contaminated effluents including rainwater falling in potentially contaminated

areas (such as oil filled transformer bunds) shall be treated by an oil water
separator. Separated oil shall be collected in a waste oil storage pit for off-site
disposal. Separated water shall be routed for further treatment (if required) and
discharged into the seawater outfall system.
 Chemically contaminated effluents shall be routed to a neutralization plant where
they are to be neutralized by acid and caustic dosing. Neutralized effluent shall be
routed for further treatment (if required) and discharged into the seawater outfall
system.
 Industrial effluents shall be routed to a waste water treatment plant (WWTP) for
appropriate treatment prior to discharge into the seawater outfall system.
 Sanitary and domestic wastewater shall be routed to a sewage treatment plant and
treated before discharging to the seawater outfall system. Any waste sludge shall
be removed from site via tanker.
 Any waste effluent which is not suitable for treatment and discharge shall be
collected on site in suitable sumps for offsite disposal.

Effluent Treatment

Chemical effluents that mainly arise from the demineralized water production plant
and the polishing plant are neutralized before being discharged to the Waste water
treatment plant (WTP).

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 In the WWTP the chemical and industrial effluents are combined and their pH
raised through the addition of hydroxide.

The effluents are then sent to the precipitation tank where sulphide addition along
with the raised pH leads to the conversion of soluble heavy metal salts to insoluble
salts which precipitate.

The precipitation process generates very fine particles which are hard to remove,
so the stream is sent to the flocculation tank where the addition of chemical coagulants
in conjunction with low-sheer mixing promotes contact between the particles, and
allows them to clump together into larger heavier particles which can settle at a faster
rate. The mixture is sent to a sedimentation tank where the heavy metal containing
floc settles to the bottom and can be removed as a sludge. The sludge is sent to a
filter press to recover the solids which are sent for off-site treatment.

The liquid from the sedimentation tank passes to a buffer tank before the biological
treatment section where the ammonia in the effluent is treated in a two-step process.

Liquid from the buffer tank passes through a heat exchanger and undergoes pH
adjustment with acid addition before entering the Nitrification basin. Here the ammonia
is converted to nitrite and then to nitrate – the nitrification process. This process is
mediated by bacteria which require oxygen for growth and the metabolism of nitrogen,
and so must proceed under aerobic conditions.

Following nitrification the effluent’s pH is adjusted by caustic addition prior to the

second step of the process – denitrification, the conversion of nitrate to nitrogen gas.
This process is also mediated by bacteria, but must proceed under anaerobic
conditions, with the dissolved oxygen level at or near zero. Methanol is added to
provide the bacteria with a carbon food source which they metabolise to carbon
dioxide.

Following the denitrification process a Flotation basin separates the organic solids
generated in the process from the effluent as a sludge which is sent to a filter press
for solid separation. Clear effluent is released to the water discharge point.

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 Treated water is mixed with cooling water effluents (mainly the cooling tower
blowdown) before being discharged to the Drax water discharge system. The sludge
are removed by truck.

a. Hazardous Chemical Control Activities

The treatment of unwanted chemicals (by-products):

A. Republic Act No. 6969

This is the act known as the “Toxic Substances and Hazardous and Nuclear
Wastes Control Act of 1990”. An act which regulates, restricts or prohibits
importation, manufacture, processing, sale, distribution, use and disposal of
chemical substances and mixtures that present unreasonable risk and/or injury to
health or the environment; to prohibit the entry, even in transit, of hazardous and
nuclear wastes and their disposal into the Philippine territorial limits for whatever
purpose; and to provide advancement and facilitate research and studies on toxic
chemicals.
Under this act it is said that, “an inventory of chemicals that are presently
being imported, manufactured, or used; indicating, among others, their existing
and possible uses, test data, names of firms manufacturing or using them, and
such other information as may be considered relevant to the protection of health
and the environment is kept. Other issues in the act include monitoring and
regulating of 92 importation, manufacture, processing, handling, storage,
transportation, sale, distribution, use and disposal of chemical substances and
mixtures that present unreasonable risk or injury to health or to the environment in
accordance with national policies and international commitments.

Safety

A. Process Safety Management

Detection and Alarm System

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 The layout design of the detection systems was informed by a scenario based
identification of potential hazards. The layout design process included:

 Identification of CO2 process hazard areas (internal and external) and non-
process fire and utility hazard areas;
 Determination of the hazard characteristics; and
 Determination of required detector type, principle of operation and location.

Diverse detector types will be provided including for detection of gas leak, gas
migration and smoke (instrument building). Primary emergency communication to
personnel will be through the local alarm system. Audible alarms will be provided
including separate alarm tones for fire (smoke) detection, CO2 detection and
evacuate facility. Audible alarms are supplemented by visual alarms at process
piping areas. Personnel will have UHF hand portable radios. Communications with
third parties will be facilitated by the analogue telephone located in each instrument
building.

B. Emergency Response System

On Site Emergency Plan

An emergency plan must have the following objectives:

 containing and controlling incidents so as to minimize the consequences, and

to limit damage to human health, the environment and property;
 implementing the necessary measures to protect human health and the
environment from the consequences of major accidents;
 communicating the necessary information to the public and to the services or
authorities concerned in the area; and
 Providing for the restoration and clean-up of the environment following a major
accident.

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 Off-site Emergency Plan

The external emergency plan details the roles to be carried out by emergency
services, local authorities and other external organisations in the event of a major
accident. This includes the arrangements established to help with the emergency
response on site. The degree of planning should be proportionate to the probability
of a major accident and consequences of the accident occurring. The responsibility
for the Off-site emergency lies with the Local Authority. However the facility
operator has to liaise with the local authority and provide information to support the
off-site emergency plan.

C. Protection of Marine Environment

The 1982 United Nations Convention on the Law of the Sea (Article 1.1.4)
defines marine pollution as “the introduction by man, directly or indirectly, of
substances or energy into the marine environment, including estuaries, which
results or is likely to result in such deleterious effects as harm to living resources
and marine life, hazards to human health, hindrance to marine activities, including
fishing and other legitimate uses of the sea, impairment of quality for use of sea
water and reduction of amenities” (Nordquist & Nandan, 2011). Besides, “marine
contamination changes the physical, chemical, and biological characteristics of the
oceans and coastal zones, and potentially threatens marine organism,
ecosystems, and biodiversity and affects thus the quality and productivity of marine
ecosystems” (Wilhelmsson, Thompson, Holmström, Lindén, & Eriksson-Hägg,
2013). In this regard, the contamination causing damage or negative impact on
marine ecosystems is called pollution. The final impact of pollution on marine
resources depends on the intensity (acute or chronic), form and location of the
contamination. Likewise, some species, ecosystems and marine environments are
more sensitive to pollution than others. “Coal is an organic sediment that contains
inorganic constituents such as heavy metals, which can be very toxic to marine

85
 organisms” (Siboni, Fine, Bresler, & Loya, 2004). Therefore, it could be
hypothesized that unburnt coal could be a marine pollutant. For example, a study
carried out at the contiguous coal shipping terminal at the Lambert’s Point Docks
in Norfolk, Virginia confirmed that “along with the particulate coal, arsenic
associated with the coal is also enriched in these soils by 2 to 20 times over upper
crustal abundances, and by ∼five times over estimated background soil As
concentrations” (Bounds & Johannesson, 2007). It has long been recognized that
“arsenic is one of the most toxic elements and has serious effects on plants,
animals and human health” (Kucuksezgin, Gonul, & Tasel, 2014).

D. Health and Safety Considerations

A. Fire Prevention and Protection – covers the potential cause of fire(reason)

For protection of the plant against fire, all yards and plant will be protected by any
one or a combination of the following systems:

 Hydrant system
 Automatic high velocity and medium velocity sprinkler system
 Existing fire fighting facilities would be integrated with the proposed system
to ensure central control from the existing fire station
 Portable and mobile chemical extinguishers

In view of vulnerability to fire and its importance in the running of the power station,
effective measures are to be taken to tackle fire in the following susceptible areas:

i) The cable galleries, and

ii) Coal handling areas, mainly coal conveyors, transfer points.

For containment of fire land preventing it from spreading in cable galleries, unitwise
fire barriers with self-closing fire resistant doors will be provided. The ventilation systems,

86
if provided in the cable galleries, would be so interlocked with the fire alarm system that
in the event of a fire the ventilation system is automatically switched off. Also to avoid
spreading of fire, all cable entries/openings in cable galleries, tunnels, channels, floors,
barriers etc. would be sealed with non-inflammable/fire resistant sealing material.

a. Safety – prevention

Personnel Safety

For safety of working personnel the following steps will be undertaken.

 All easily accessible moving parts in the plant will be securely fenced.
 There will be arrangement for prompt power cut from transmission
equipment, if necessary.
 Every hoist, crane etc. will be properly maintained and examined at intervals
 All working places will have safe means of access and exit.
 Emergency fresh water bath will be provided in the hazardous chemical
handling areas e.g. storage areas and operating unit areas
 All personal safety equipment like gloves, helmet, goggles etc. will be worn
in the required place.
 Boilers will be examined in proper manner by proper authority as per
statutory requirement

PROTECTION FOR EQUIPMENT PROTECTION AGAINST

HAND a) Leather gloves Cuts due to handling
b) Asbestos gloves Heat radiation
c) Electrical resistance Electrical shock
gloves Contact with oil & grease
d) Canvas gloves etc. Falling of hot slag
e) Hand sleeves
LEG a) Leg-guards Welding sparks
b)Leather safety boots

87
 c) Asbestos safety boots Striking by objects, fall of
objects and stepping on
sharp or hot objects
Heat radiation, stepping hot
or sharp objects and
stepping on sharp or hot
objects
EYE a) Spectacle type goggles Foreign bodies entering the
with plain shatter proof lens eyes and reflected arc rays
HEAD a) Fibre Helmet Fall of objects/hitting
against objects during
construction, maintenance
etc
EAR a) Ear plugs or muffs High noise level
NOSE a) Dust protection mask Fine dust particles
Table 46. Personnel Safety

C. Health – exposures

Occupational exposures

Dust is a major occupational hazard as large quantity of coal is used and a

huge amount of fly ash is generated. Noise is a recognized hazard, due to
operations of turbine generators, auxiliaries, boilers, crushers, pulverizers, pumps,
motors, compressors, diesel engines, vibrators, etc. It was observed that the
turbine floor is very noisy. In the plant areas the operators, supervisors and
executive engineers work in a centralized segregated control room. However,
cleaning personnel and maintenance workers are generally exposed maximally to
noise hazards. The surrounding areas of high noise machinery were identified as
noise prone areas of the plant and the workers movements are restricted. The

88
turbine and boiler areas were found to be the heated zone in the plant, besides
furnace operations.

Protections Measures for Health and Safety

The following measures will be adopted for protecting health and ensuring
safety of workers.

 Trained first-aid personnel, with appliances

 Pre-employment medical examination
 Periodical medical examination
 Maintenance of records
 Use of personal protective measures
 Emergency preparedness
 Mock drill
 Occupational Health Center
 Curative management with investigation and treatment facilities
 Environmental monitoring
 Hazards communication and controls – alarms, display warning signs,
instructions
 Occupational health and safety training and education
 Health and safety policy
 Safety inspection/ audits surveys

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 CHAPTER VI

PROJECT MANAGEMENT

This chapter contains the management of the proposed project plant as well as the
time frame of the project plant and the necessary measures to maintain and assure the
quality of the electricity produced.

I. PRELIMINARIES
a. Planning Stage
The planning stage is one of the most crucial aspects of deciding how a
project will be carried out and operated. All necessary planning, materials,
equipment, and contrast will be addressed during this stage. The selection
of the planning team and plant projects would be based on the design as
well as the plant's feasibility.
The site preparation is also included in the planning stage. The necessary
legal documentation for the proposed plant location property, as well as
the legal permits required before the plant can be built, are part of the site
planning stage. It would be easier for the plant to operate in the long run if
the rules are followed and adequate environmental protection is given
ahead of time.
Another aspect of the planning stage is the calculation of the plant's time
schedule and expense in order to identify the tasks that must be
completed. As well as identifying the deliveries of the plant's necessary
equipment. It will also assist in having a logical sequence of events and
maximizing the allotted time on the construction time frame once it begins.
b. Basis of Design Stage
The design stage will be built around the process's optimal efficiency. This
will include the production volume and pace. Benefit maximization can be
greatly enhanced by optimizing the efficiency of the process flow. The
design stage also takes into account the plant's feasibility, ease of access
to each site, and the operation. The area can be reduced and the plant's
protection ensured by providing an open venue. Provided that the plant

90
 should have an assured danger and health protection, the safety and
comfort of the plant employees should also be considered as the basis of
the design. A facility is available for the employees' health conditions as
well as any potential injuries that might occur.
A facility for an office, a guard house, and parking space is also included
in the design layout. The water supply and treatment waste water
collection plant is situated near the seashore. This can also be used to
move raw materials, machinery, and finished goods.
c. Design stage layout
At this stage, there is a proposed design layout for the plant, that can be
used as a guide in selecting the best design layout to be provided by the
selected team. Bidding will be used to pick the winning team.
The requirements for choosing a design layout are determined by the
plant's efficiency and the cost. The first step in construction management
is to complete the design stage layout. The building will begin after the
final design stage layout is completed.

II. CONSTRUCTION MANAGEMENT

a. Complete Design Stage
The blueprints for the plant layout and the materials specification
are included in the complete design stage. To oversee the building, a
blueprint of the plant layout is given. Another reason is for protection, as
getting the blueprint would make it easier to solve any problems that can
arise in the event of an emergency. Engineers will also oversee the
building to ensure that the layout is right. Material requirements include
the machines, machinery, and other raw materials needed for the plant's
construction. The materials requirements will assist in determining the
equipment and machines will be required for the plant's construction.

91
 This stage also includes the requirements for the process
equipment that will be installed in the plant, as well as the reliability,
volume, and dimensions of the equipment.

b. Procurement and Construction Stage

The proposed plant is located in Brgy. Bulacan, Mabini, Batangas in the
seashore. The gathering of the raw materials of coal can be gathered from
the Semirara Mining Corporation located at Semirara Island tinogboc and
will be shipped through trucks and Cargo ships. The supplies of raw
materials, equipment and machineries can also be delivered be using
seaport since it is also accessible in the plant location. Having an accessible
on the main road and on a seaport is a great advantage for not have a delay
on the construction timeline.

III. Quality Assurance and Control

Quality Assurance

Quality Assurance (QA) will be undertaken to ensure that project activities are
planned, controlled, performed, verified and documented in such a way that all specified
contractual requirements are met.

The project activities will be required to demonstrate compliance with QA

requirements, based on the International Organisation for Standardisation (ISO)
Management Systems.

All project activities scope will comply with the relevant codes and standards in
force with safety, legal and other regulations (local and national), acts and legislation in
force in the Philippines.

92
 The plant will be designed in accordance with Good Industry Practice (GIP) to
enable it to be constructed, installed, commissioned, operated and maintained in a
prudent and safe manner, compliant with Philippine regulations and legislation.

The project activities will ensure that a safe and operationally robust design is
achieved that allows the project to be executed in accordance with the project
programme, within budget and to meet its operational performance objectives.

Quality Control

Quality requirements should be clear and verifiable, so that all parties in the project
can understand the requirements for conformance.

In addition to on-site inspections, samples of materials will commonly be tested

by specialized laboratories to insure compliance. Inspectors to insure compliance with
regulatory requirements will also be involved. Common examples are inspectors for the
local government's building department, for environmental agencies, and for occupational
health and safety agencies.

On-site quality assurance and quality control includes:

 Review of specifications, procedures and specified standards utilized on the

construction site
 Monitoring materials testing
 Monitoring storage methods and preventive maintenance systems of plant
equipment before and during installation

Off-site quality assurance and quality control includes:

 Review of the design, specifications, drawings and specified standards to assure

compliance with the applicable regulatory requirements
 Organization of QA training courses

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 CHAPTER VII
SUMMARY OF FINDINGS, CONCLUSION AND RECOMMENDATION
This chapter presents the summary of findings, conclusion and
recommendation on the design for the proposed 600 MW Coal-Fired Power Plant.
Summary of Findings
After the analysis and evaluation of all the data gathered. The proposed
location of 600 MW Coal-Fired Power which is at Barangay Bulacan, Mabini,
Batangas was to be feasible and advantageous for the construction and operation
of the proposed power plant. The transmission of the generated electricity of the
proposed power plant for the Luzon Grid will be the responsibility of the National
Grid Corporation of the Philippines (NGCP) and this company will distribute the
generated electricity to the customers of the Batangas province electric
cooperatives namely; BATELEC I, BATELEC II, First Bay Power Corporation
(FBPC) and Ibaan Electric Engineering Corporation (IEEC) will transmit the
generated electricity to within reach provinces.
Conclusion

The proposed coal-fired power plant appeared in all aspects of design

consideration in designing a power plant. Plant factors were determined high and
satisfactory viable for the design to be considered acceptable. Having a
background and a broad technical knowledge about this kind of steam power plant
would be a great advantage to come up with a better and acceptable design. All
equipment and miscellaneous facilities were satisfactorily designed and evaluated.
Technical information has been at hand through the use of related references and
the use of the internet, which provides the equipment catalogue and it is based on
the manufacturer’s specifications to get the best design possible for the proposed
power plant.

Recommendation

For the improvement and development of the proposed 600 MW Coal-Fired

Power Plant, the following recommendations were brought up:

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1. Further research and evaluation of the present technologies, equipment, and
operation of existing power plants are essential for more advanced and progressive
design.

2. The proponents should be more familiar with each of the equipment specifications
and it’s functions which are important in designing and constructing a power plant.

3. Assessment of the environmental impact of the plant should be evaluated following

the guidelines presented by the power development program of the national energy
policy

4. Additional information through consultation with the concerned person helps the
proposed power plant to enhance the design and make it possible and presentable
for the actual plant construction.

5. Economic analysis must be done for the designed power plant for a better
presentation of profits to attract more investors.

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 Republic of the Philippines
BATANGAS STATE UNIVERSITY
Gov. Pablo Borbon Main Campus II, Alangilan, Batangas City
College of Engineering, Architecture and Fine Arts www.batstate-u.edu.ph Telefax: (043) 300-4404 locs. 106-118

SUMMARY OF COMMENTS, SUGGESTIONS, AND REVISIONS

CHAPTER PAGE NO. COMMENTS AND SUGGESTIONS ACTIONS TAKEN

Include Equipment codes and Tag number in the Equipment codes and Tag
P&ID of the proposed Number were now
Plant Design included in the P&ID
14
Chapter 2 The process of the P&ID was
15-20 Make and Separate the presentation of P&ID by separated by section including
Section of the process the equipment code and
specification
Verified by:

Engr. Robert A. Ilagan

Panel

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