HARNESSING ENERGY. EMPOWERING COMMUNITIES.

Forced-Air Cooling
Proposed Design,
System for Steam
Installation,
Turbine for
Operation and
3x135MW CFB of
Maintenance of
FDC-MPC,
Back-up AC
Villanueva Misamis
Auxiliary Oil Pump
Oriental

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 1 INTRODUCTION & COMPANY
PROFILE

2 ENGINEERING REPORT
PROPER

Outline
3 ENGINEERING ECONOMICS

4
EVALUATION, OBSERVATION,
CONCLUSION AND
RECOMMENDATIONS

5
GLOSSARY OF TERMS,
BIBLIOGRAPHY, REFERENCES,
APPENDICES
CHAPTER 1 : INTRODUCTION

1 General Introductory Statement

2 Brief History of the Power Plant

3 Subject of the Report

4 Organization

5 Location

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION

General Introductory Statement

Project A: Project B:
➢The power plant is expected to run uninterrupted ➢The Thermal power plant outages, plant layups and
unless a program such as PMS is scheduled. Any system shutdowns are part of the power plant's
unforeseen stoppage is a huge loss to company. overall availability program. It is important to
As such, redundancy equipment is sometimes maximize the shutdown duration in order to start
needed when that particular system could directly earlier than the forecast schedule.
cause big impact if fail.
➢The Forced-Air Cooling System will provide
➢The back-up AC Auxiliary Oil Pump will be the additional cooling air (hot air lower than internal
additional security when the current pump fail. This temperatures) to hasten the process. The project is
ensure continuity of operations and prevent huge composed of blower, electric heater, safety
losses like damage turbine bearings, turbine instruments, temperature controller, and is mobile
blades, as well as damage turning gear trains for ease of transportation.
during run-up.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION

Brief History of Power Plant

FDC Misamis Power Corporation (FDC Misamis) is a special purpose company established to
undertake the development and operation of the 3x135MW Circulating Fluidized bed coal fired
thermal power plant in the PHIVIDEC Industrial Estate, in Villanueva, Misamis Oriental (formerly
Green Renewable Power Holdings, Inc. then Strong Field Energy Corporation) is a wholly owned
subsidiary of FDC Utilities, Inc. which are the utilities and infrastructure arm of the Filinvest
Development Corporation (FDC).

Filinvest’s flagship power project stared its commercial operations in 2016 and has three (3)
generating units with a total capacity of 405MW gross. Located at the PHIVIDEC area in Misamis
Oriental, the power plant uses the latest in clean coal technology: the Circulating Fluidized Bed
(CFB) boiler technology. Considered as the cleanest process to burning coal, the technology is also
known for having higher steam generator efficiency thus lowering carbon emissions. FDC Misamis
Power Corporation helps drive progress for com munities in Mindanao.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION

Location of Power Plant

AREA OF MY PROJECTS
MAIN BLOCK – TURBINE HALL

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION

Subject of Reports
Current and Proposed back-up AC Forced-Air Cooling System for Steam
Auxiliary Oil Pump Turbine:

EXISTING AC AUXILIARY
LUBE OIL PUMP

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION

Subject of Reports
EXAMINE:
Bearing Failure
Bearing failure occurs due to abrasion, bond
failure, cavitations erosion, corrosion, fatigue,
overheating, surface wear, structural damage.

This failure may cause a further damage

specially when the rotor is rotating at 3600
rpm without proper lubrication.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION

Subject of Reports
EXAMINE: Temp

Longer Shutdown
Duration
Natural Convection takes longer period to
bring down the temperature to minimum to
allow maintenance team to start their
activities.

With Force Convection, we can maximize the

allowable ramp rate and hasten the cooling Time
down process.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION
Table of Organization

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION
Geographical Location
FDC-MPC is located at Brgy.
Tambobong-Balacanas,
Villanueva, Misamis Oriental,
9002.

MAIN BLOCK

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION
Location of Project A CONTROL & LUBRICATION
SYSTEM

Project A: Back-up AC Auxiliary Oil Pump

Located inside Main Block near Turbo-Generator.

MAIN BLOCK

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 1: INTRODUCTION
Location of Project B
Project B: Mobile Forced-Air Cooling System for
Steam Turbine located at Main Block

MAIN BLOCK

ENTRY
EXIT
HARNESSING ENERGY. EMPOWERING COMMUNITIES.
CHAPTER 2 : Engineering Proper

1 Objective of the Engineering Report

2 Importance of the Engineering Report

3 Limitation, Technical Data

4 Proposed Projects A and B

5 Calculation for the Project A and B

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2: ENGINEERING REPORT
Objective of Engineering Report

Back-up AC Auxiliary Oil Pump

The engineering report primarily aims to provide knowledge on the proper approach in designing an AC Auxiliary
Lube Oil Pump as back-up unit in Lube Oil System for Unit 1, 2, & 3. In lieu to this, the following are the specific
objectives:

❖ To design a back-up AC Auxiliary Lube Oil Pump for Unit 1, 2, & 3 as additional cooling Pump during Turbine
Start-up and Shutdown;
❖ To outline the installation, commissioning, operation, and maintenance consideration of a backup
circulating water pump; and,
❖ To determine the cost and feasibility of the project.
The specific objectives above shall be the basis for the development of the document and technical report for the
study

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2: ENGINEERING REPORT
Objective of Engineering Report
Mobile Forced-Air Cooling System for Steam Turbine
The engineering report primarily aims to provide knowledge on the proper approach in designing a Mobile Forced-
Air Cooling System for Steam Turbine for Unit 1, 2, & 3. In lieu to this, the following are the specific objectives:

❖ To identify the type of cooling system appropriate to the steam turbine application without causing harm to
the equipment.
❖ To formulate and elaborate in details the design, installation, commissioning, operation and maintenance of
the FDCMPC steam turbine force-air cooling system.
❖ To determine the technical requirements, specification and calculation for the application of forced-air
cooling of the FDCMPC steam turbines.
❖ To determine the feasibility of the proposed project to the FDCMPC steam turbine.
The specific objectives above shall be the basis for the development of the document and technical report for the
study

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2: ENGINEERING REPORT
Importance of Engineering Report
Project A: Back-up AC Auxiliary Oil Mobile Forced-Air Cooling System for
Pump Steam Turbine

The proposed back up unit takes over when the existing AC Overhauling of steam turbine is as complicated as it is, and would
Auxiliary Oil Pump fail to start or malfunction during operation. take long time to disassemble/assemble, and with a little help from
The loss of lubrication of rotating parts could bring huge the proposed system could lessen these burdens. The machine is
damage and profit loss to the company. assembled on a mobile support which allows to use a single system
to provide forced cooling air to different turbines in the plant, if
desired. Since excessive thermal stress is generated on the surface,
it is necessary to introduce air at a temperature slightly lower than
that of the Steam Turbine’s metal temperature to gradually cool the
metal. Therefore, the electric heater is used to preheat the air, and
the air is forcibly fed directly into the steam turbine, or after
temporarily storing it.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2: ENGINEERING REPORT
Limitations of Engineering Report
Project A: Back-up AC Auxiliary Oil Pump
This report limits only on the design of back-up AC Auxiliary Lube Oil Pump each unit for a 3x135MW CFB at FDC- Misamis Power Corporation at
Tambobong- Balacanas, Villanueva, Misamis Oriental. It only includes design calculation, pump, and piping lay-out, flowsheet and selection of
available pump catalogue or performance model. All civil works, electrical works and instrumentations pertaining to AC Auxiliary Lube Oil Pump
system are not part of the design such as Motor Control Center (MCC) and logic or signal diagram. Since each unit is identical to the others, all
processes and expenses for this report are the same.

Mobile Forced-Air Cooling System for Steam Turbine

The study and document shall only be limited to the steam turbines of the FDCMPC plant and requirements for the project proposal of steam
turbine cooling system. This includes the design, specification, installation and commissioning, operation and maintenance, as well as the project
costing and its return for the entire project scope. The test of the performance of the project, from data and practice, shall be applicable after
realization of the project and will eventually be part of the asset long term plant health program. For the engineering economy (Chapter 3), the
computation of costs shall be based from the 2022 data figures or before the implementation of Whole Sale Electricity Spot Market (WESM) for the
Mindanao.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2: ENGINEERING REPORT
Technical Data
Manufacturer ALSTOM
Current AC Auxiliary Oil Pump

Type/Model DKY2-1N30U
MOTOR PUMP

Steam Turbine
Speed 3600 RPM
Manufacturer WEG Manufacturer ALLWEILER
Power Output 135,000 KW (142,000 KW)
Power, kW 30 Power, kW 17.1
Rotating Direction Counter clock wise
Speed, RPM 3550 Speed, RPM 3520 Live Steam Pressure 132.4 barA
Rated Flow,
Hertz, Hz 60 79.2 Live Steam Temperature 540 C
m3/h
Reheat Steam Pressure 2.52 barA
Voltage, V 480 Head, m 54.8
Reheat Steam Temperature 540 C
Current, A 45.4 Sp. Gravity 0.848
Main Steam Flow 420 kg/sec

Exhaust Steam Pressure 0.083 bar

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

CHAPTER 2A: ENGINEERING REPORT
Back-up AC Auxiliary Oil
Pump

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Appendix A: Drawing

Allweiler NSSV Series

Vertical Pump

1 Strainer / Suction strainer (optional) 8 Covering/Sole plate

2 Impeller 9 Safety guarding
3 Volute casing 10 Motor
4 Pump-side bearing 11 Pressure pipe
5 Connection piece 12 Check valve (optional)
6 Shaft 7 Drive-side bearing

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Appendix A: Drawing

AC Auxiliary Oil Pump Location

MAIN BLOCK
Steam
Turbo – Generator
Set-up

HYDRAULIC AND LUBRICATION

SYSTEM

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Back-Up AC Auxiliary Oil Pump
TAPPING POINT

PUMP BASE PLATE

Back-up AC Pump Location and Tapping point

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

At rated speed of 3600 RPM CHAPTER 2A: ENGINEERING REPORT

MAIN OIL PUMP

HP IP LP G
TURNING GEAR M

JACKING OIL PUMP

AC AUXILIARY OIL PUMP

AC

MAIN OIL TANK

During run down & turning gear, 18 RPM CHAPTER 2A: ENGINEERING REPORT

MAIN OIL PUMP

HP IP LP G
TURNING GEAR M

JACKING OIL PUMP

AC AUXILIARY OIL PUMP

AC 1 AC 2

MAIN OIL TANK

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Flow Diagram
The lubrication system is responsible in lubricating the turbine bearings and turbine gearbox. From main oil tank, the oil is send pass through a series of
filtration system and heat exchangers. The cooling medium of heat exchanger is called close cooling water. The responsible in controlling the temperature is the
mechanical temperature controller AMOT. The oil will then enters the bearing chambers of turbine, generator, and turning gear mechanism, and will return to
the main oil tank afterwards.
HPT HPT-IPT GEN-DE GEN-NDE

13 6 12 7 11
11
8
8 10
10 9
9

ø = 254 mm
v = 0.361 m/s
Z2 = 7 m

H1 = 56 mmWC
ø = 152.4 mm
2 3 Q = 290 GPM
14 v = 1.005 m/s
4 5

Black line = Discharge side of pump

Z1 = 3 m

1 PV = 0.5
` mm Hg
VG 46 Mineral oil
Orange line = Return from Turbine
Z S= 1 m

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
PIPE The pipe that are going to use is still the same as the pipe of the current pump which is a ASME SA403 Stainless
SELECTION Steel, commonly use in Oil and Gas industry.

Pipe velocity refers to the speed at which a fluid (such as a liquid or gas) is flowing through a pipe or conduit. It is
an important parameter in fluid mechanics and engineering, as it affects various aspects of fluid transport, including
pressure drop, energy efficiency, and the ability to carry solid particles or suspended materials.
PIPE πD2
Q = AV A= Description Dimensions
VELOCITY where
4 Baseplate Dimension 45 cm x 74 cm
Given: Return Pipe 254 mm
Q = 290 gal/m or 0.01830 m3/s (design flow) Discharge Pipe of pump 152.4 mm
Ddis = 152.4 mm or 0.1524 m (discharge pipe diameter) Operating Temperature 46 C
Dret = 254 mm or .254 m (return pipe diameter)
Formula to find discharge velocity, Vdis of the pipe: Length of Pipeline 112 m
Density of Oil 848 kg/m3
3
0.01830 𝑚 ൗ𝑠
Vdis = 1.005 m/s Flow Rate 290 GPM = 0.01830 m3/sec
Vdis = 𝜋𝑥 0.1524 𝑚 2
4 Vret = 0.361 m/s Operating Discharge Pressure 2.77 Bars

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Friction head, also known as head loss or hydraulic head loss, is a term used in fluid mechanics and engineering to
describe the loss of pressure and energy that occurs as a fluid flow through a pipe, duct, or conduit due to the
friction between the fluid and the inner surface of the conduit. This loss of pressure is a result of the resistance the
fluid encounters as it moves along the pipe.

FRICTION From Cameron Hydraulic Data by Westaway and Loomis, Chapter 3-3, Using Darcy-Weisbach’s formula for friction
head losses for lubricating oil as follows:
HEAD
𝐋 𝐕2
𝐇𝐟 = 𝐟 𝐱 𝐱
𝐃 2𝐠
Since the pipe diameter changes between points 1 and 2, it is necessary to determine the frictions occurring
between these points; thus, our friction head loss, Hf can be separated into two (2): the pipe friction HFP and the
fitting friction HFF. the friction produced by fittings (for example elbows, isolation valves, etc.) between the same
two points.
𝑳𝒅𝒊𝒔 𝐕 𝟐 𝒅𝒊𝒔 𝑳𝒓𝒆𝒕 𝐕 𝟐 𝒓𝒆𝒕
Hf = HFP + HFF HFP = f (
𝑫
.
𝟐𝒈
+
𝑫
.
𝟐𝒈
)
𝒅𝒊𝒔 𝒓𝒆𝒕

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Use the Moody Diagram Friction Chart, to evaluate the Friction Factor, f, calculate the Reynolds Number for the
fluid flow from Moody’s chart:

Solving for Reynold’s number (Cameron Hydraulic Data, Chapter 3-3): µ = Dynamic Viscosity
𝝆𝑽𝑫 ρ = Density of the fluid
𝑹𝒆 = V = Velocity of the fluid
FRICTION 𝝁 D = pipe diameter
FACTOR Temperature = 46 C

To solve for Reynold’s number, Re, from the

Table 2.4, ISO Grade VG 46 we get the
kinematic viscosity, v, of 46 centistokes (cSt)
and density of 848 kg/m3 at 46 °C. Using the
formula from the book of Pump System
Analysis and pump sizing by J. Chaurette [5],
[11]
Table 2.4: Viscosities and densities of ISO - and equivalent SAE grade oils.
Appendix A:
𝝁 𝒄𝑷 46 𝑥 848
v (cSt) = 103 x 𝒌𝒈 𝜇= 𝝁 = 𝟑𝟗. 𝟎 𝒄𝑷 or 0.039 kg/m-s
𝝆 𝒎𝟑 1000

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Solving for Reynold’s number: The selection of the appropriate formula to determine the friction factor depends on
the flow conditions, specifically the Reynolds number [2]. Generally:
𝑘𝑔 𝑚 For flows with a low Reynolds number (Re < 2,300), the flow is laminar,
848 1.005 0.1524𝑚
𝑚3 𝑠 For flows with a Reynolds number (Re = 2300-4000), the flow is transient.
𝑅𝑒 =
kg For flows with a high Reynolds number (Re > 4,000 to 2,000,000 or more,
0.039
m−s
depending on the application), the flow is turbulent, and the Darcy-Weisbach
equation with the Fanning friction factor is used.
FRICTION Re = 3,330.3
FACTOR
When flow occurs between the Laminar and Turbulent flow conditions (Re 2300 to Re 4000) the flow condition is
known as critical and is difficult to predict. Here the flow is neither wholly laminar nor wholly turbulent. This can
happen due to a range of factors—like surface roughness, change in viscosity due to heat transfer, or
disturbances like noise or vibration—affecting the stability of the flow. Since the system is prone to temperature
change, vibrations and noise due to large rotating equipment where the oil is penetrating, for convenience, we will
consider the flow as to be turbulent.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Calculate the relative roughness of the pipe, ε/DID. ε is the roughness
height of the internal walls of the pipe from Moody’ Chart.

For the pipe we will used pipe material Stainless Steel same as existing
pipe. In Figure 2.19.2, the Pipe roughness of stainless steel is ε =
FRICTION 0.015 x 10-3 meter.
FACTOR
The Colebrook–White equation is defined as f for the Darcy friction
factor, the function of for Reynolds number as Re, pipe relative
roughness expresses as, ε / Dh for both smooth pipes and rough pipes.
[3]
𝜺
𝑹𝒆𝒍𝒂𝒕𝒊𝒗𝒆 𝑹𝒐𝒖𝒈𝒉𝒏𝒆𝒔𝒔 = Figure 2.19.2: Pipe Relative Roughness for fully developed
𝑫𝑰𝑫 flow in circular pipe [11

Relative Roughness = 9.84 x 10-5

We will use the Equivalent to Relative Roughness = 1 x 10-4

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
From figure 2.20 Moody’s Diagram we can get
the friction factor:

The relative roughness is equal to ε = 1 x 10-4.

Using the Moody Chart, a Reynolds number of
FRICTION 3329.68 intersects the curve corresponding to a
FACTOR relative roughness of 1 x 10-4 at a friction 0.043

factor:

Friction of Factor, f = 0.043

Figure 2.20: Moody diagram of using design technical data

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
With this, we can calculate the Pipe’s Friction Head Loss through out the system,
FRICTION 𝑳𝒅𝒊𝒔 𝑽𝟐 𝒅𝒊𝒔 𝑳𝒓𝒆𝒕 𝑽𝟐 𝒓𝒆𝒕
HEAD HFP = f ( . + . )
𝑫𝒅𝒊𝒔 𝟐𝒈 𝑫𝒓𝒆𝒕 𝟐𝒈
LOSS IN 50 𝑚 1.0052 (𝑚/𝑠)2 62 𝑚 0.3612 (𝑚/𝑠)2
PIPE HFP = 0.43 ( . 𝑚 + . 𝑚 )
0.1524 𝑚 2 (9.81 2 ) 0.254 𝑚 2 (9.81 2 )
𝑠 𝑠

𝑯𝑭𝑷 = 𝟕. 𝟗𝟔 𝐦

In fluid mechanics, friction losses occur in pipe systems when fluid flows through various components such as bends,
FRICTION elbows, tees, valves, and other fittings. These losses are due to the resistance encountered by the fluid as it navigates
HEAD changes in direction and velocity. To calculate head losses in a pipe system with various fittings, you need to know the
LOSS IN loss coefficients (K factors) specific to the type and configuration of each fitting. These coefficients are often available
FITTINGS in engineering references and standards, for this report, we’re going to use “Cameron Hydraulic Data” as a reference
for various K factors for our system.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation

FRICTION
HEAD
LOSS IN
FITTINGS Figure 2.22: Hydac International Manufacturer’s Filter Calculation Graph [1]

Figure 2.23.1: K factor for Gradual Contraction (Cameron Hydraulic Data) [3] Figure 2.21. Friction Losses in Pipe Fittings Resistance Coefficient K3 by Cameron
Hydraulic Data [3]

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Equipment Quantity
a Duplex Strainer 2
Duplex Strainer, Hf-str
Duplex Strainer inlet and outlet Gate
b 2
Valves
c Lube Oil Plate Heat Exchangers 2 According to Hydac, The total pressure drop of a filter at a certain
d
Lube Oil Plate Heat Exchangers inlet
2
flow rate Q is the sum of the housing ∆P and the element ∆P and
and outlet Glove Valves
FRICTION is calculated as follows:
e Gears and Bearings Compartments 4
Elbows (90°) & (45°) Entry 5&4
HEAD f
Elbows (90°) & (45°) Return Pipe 3&5
∆Ptotal = ∆Phousing + ∆Pelement
LOSS IN g
Tees in Entry 3
𝑺𝑲 µ
Tees in Exit 4
FITTINGS ∆Pelement = Q x x
𝟏𝟎𝟎𝟎 𝟑𝟎
The data above is the current set up of the Lube
Oil System per unit. This will be the basis for the where:

study. To calculate the losses, we need to solve ∆Phousing – Housing curves is available based on ISO 3968. (See Figure 2.20 A)
SK – Gradient Coefficient (See Figure 2.20 B)
individual’s friction head alphabetically using the Q– Flow Rate = 290 GPM or 1098 L/min
general equation, µ- Oil Viscosity = 46 centistokes = 46 mm2/s

𝒗𝟐
Hf = K 𝟐𝒈

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
The type of filter installed in Lube Oil System of FDC – MPC per unit is Hydac’s RFLD W/HC 2701 CAV 25D1.4/Z-L24-
A0.8-03965799, also known as RFLD 2701 which is lube oil filter elements has a mesh of 25 microns with a capacity of
maximum 2500 L/min. With this, based on the graph of Figure 2.22 A, for RFLD 2700, the ∆Phousing would be 0.05
bars. And for SK, based on figure 2.22 B would be 0.14.
0.14 46 mm2/s
∆Pelement = 1098 L/min x x ∆Pelement = 0.235 bars
FRICTION 1000 30

HEAD ∆Ptotal = ∆Phousing + ∆Pelement

LOSS IN
∆Ptotal = 0.05 bar + 0.235 bar
FITTINGS
∆Ptotal = 0.286 bar or 28,600 kg/m s2 Hf-str = 6.87 meters

Convert to Head in meter by using formula: P = ρ x g x Hstr

28600 𝑘𝑔/𝑚𝑠2
Hf-str = 𝑚
(848 𝑘𝑔/𝑚3)(9.81𝑠2)

Hf-str = 3.43 meters x 2 (Since duplex filter)

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
𝜌𝑣 𝟐 𝑳
Duplex Strainer Inlet and Outlet Valves, Hf-SV ∆PCHANNEL = 4 ˑ f ˑ ˑ
𝟐 𝑫𝒉

𝟒ˑ𝒍ˑ𝒅𝒑𝒍𝒂𝒕𝒆
𝒗𝟐 Dh =
𝟐(𝒍+𝒅𝒑𝒍𝒂𝒕𝒆 )
Hf-SV = 2 x KSV x 𝟐𝒈
FRICTION (1.005𝑚/𝑠)2 ∆PCOLLECTOR = 1.4ˑNpˑ (
𝒎
) ˑ(
𝟏 2 µ -0.17
) ˑ (µ )
Hf-SV = 2 x 0.12 x 𝝅𝑫𝟐
HEAD 2(9.81𝑠2)
𝑚
𝒄𝒐𝒍𝒍𝒆𝒄𝒕𝒐𝒓
𝟒
𝟐𝜌 𝒘

LOSS IN Hf-SV = 0.012 meter

FITTINGS Where:
f -friction factor (-) = 0.043
ρ - density of the fluid (kg/m3) = 848 kg/m3
Lube Oil Plate Heat Exchangers v- velocity of the fluid in between 2 plates (m/s) = 1.005 m/s
Dh - hydraulic diameter
l - width of the plates (m) = 23 in. = 0.48 m
dplate - gap in between 2 plates (m) = 0.001 m
∆P = ∆PCHANNEL + ∆PCOLLECTOR L - plate length (m) – 58 in = 1.47 m
m - mass flow of either cold or hot fluid (kg/s)
Np - number of passes = 1
where: Dcollector - diameter of the collector on the side considered (m) =
∆P - Pressure drop through the exchanger, per side (Pa) 0.1524 m
∆PCHANNEL - Pressure drop through the exchanger channels, in between each plate (Pa) μ- viscosity of the fluid (Pa.s) = 46 cSt = 46 Pa-s
∆PCOLLECTOR -Pressure drop in the inlet/outlet ports of the heat exchanger (Pa)

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
4ˑ𝑙ˑ𝑑𝑝𝑙𝑎𝑡𝑒
Dh = 2(𝑙+𝑑
𝑝𝑙𝑎𝑡𝑒 )
4 𝑥 0.48𝑚 𝑥 0.001𝑚
Dh = 2(0.48𝑚+0.001𝑚)
Dh = 1.2 x 10-3 m
𝜌𝑣 𝟐 𝑳
∆PCHANNEL = 4 ˑ f ˑ ˑ𝑫
𝟐
FRICTION 𝒉

HEAD 𝑘𝑔
861
𝑚
(1.005 )𝟐 1.47 𝑚
∆PCHANNEL = 4 ˑ0.043 ˑ 𝑚3 𝑠
ˑ
LOSS IN 2 0.0012 𝑚

FITTINGS
The two (2) Thermowave TL 650 KBIL is single-pass type of Plate
Heat Exchanger installed in FDC – MPC for each Unit. It has a ∆PCHANNEL = 91615.68 Pa
capacity of 116.9 liters for both medium, water and oil, and has an
operating pressure of 8.0 bars. Each unit is equipped with frames
that can hold up to 190 plates and has a dimension of 19x23x58
inches, with thickness of 5 mm.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
And now, solve for pressure drop in collector, the
mass flow rate can be obtained by the expression:
m = 𝜌𝑣𝐴, a direct relation of velocity, area, and
density. Since all of these are already given, we
can now solve the mass flow, m:

FRICTION m = 𝜌𝑣𝐴
Convert to Head in meter by using formula: P = ρ x g x Hf-HE
𝜋 𝑥 0.15242
HEAD m = 848 kg/m2 x 1.005 m/s x
4
LOSS IN m = 15.54 kg/s
𝒎 𝟏 µ 183231.36 𝑘𝑔/𝑚𝑠2
∆PCOLLECTOR = 1.4ˑNpˑ ( 𝝅𝑫𝟐 ) ˑ( )2 ˑ ( )-0.17 Hf-HE =
FITTINGS 𝒄𝒐𝒍𝒍𝒆𝒄𝒕𝒐𝒓
𝟒
𝟐𝜌 µ𝒘
𝑚
(848 𝑘𝑔/𝑚3)(9.81𝑠2)
15.54 𝑘𝑔/𝑠 1 46 𝑐𝑆𝑡 0.17
∆PCOLLECTOR = 1.4ˑ1ˑ ( 𝜋 𝑥 0.15242 ) ˑ( 𝑘𝑔 )2ˑ ( )
2(848 ) 1 𝑐𝑆𝑡
4 𝑚3
Hf-HE = 22 meters
∆PCOLLECTOR = 2.16 x 10-4 Pa
∆P = 2 (∆PCHANNEL + ∆PCOLLECTOR)
∆P = 2 (91615.68 Pa + 2.13 x 10-4 Pa)

∆P = 183230.72 Pa

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Plate Heat Exchanger Inlet and Outlet Valves, Hf-HEV

𝒗𝟐 Equipment Name Diameter, mm Entry Pipe, mm Exit Pipe, mm

Hf-HEV = 2 x KHEV x 𝟐𝒈
HP Turbine Thrust Bearing 200
FRICTION (1.005𝑚/𝑠)2
Hf-HEV = 2 x 5.1 x 𝑚 HP-IP Journal Bearing 355
2(9.81𝑠2)
HEAD 152.4 254
Generator DE Journal Bearing 355
LOSS IN
Hf-HEV = 0.525 meter Generator NDE bearing 200
FITTINGS
Table 2.6: Size of Bearings

Gears and Bearings Blocks, Hf-GB

Since the diameter of our pipelines are given, as you can see from our Figure 2.24, the pipe’s diameter entering the
blocks is 152.4 mm, while the exit pipe is 254 mm. The area of each block is already given by the product
manufacturer in Table 2.6. These dimensions are important since we are going to calculate the losses of fluid entering
and leaving the blocks.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Gradual Enlargement (Entry) Gradual Contraction (Exit)

By using the formula given by Figure 2.23.2, The same approach used in E-1, but instead of using only
we can now solve the coefficient, K, of each equation 4, we will now use equation 2 for diameter smaller
FRICTION entry point. For entry, the arrangements of pipe than exit pipe i.e., HP-IP Journal Bearing and Generator DE
HEAD are between 45° to 180°, thus, equation 4 will Journal Bearing and use equation 3 for diameter larger that
LOSS IN be used. exit pipe. These equations satisfied the given exit angle of
FITTINGS 𝒅𝟐𝟏
<45°.
K= (1- 𝟐 ) Ɵ 𝒅𝟐𝟏 2
𝒅𝟐 K = 2.6 𝑆𝒊𝒏 (1- 𝟐 )
𝟐 𝒅𝟐
(0.361𝑚/𝑠)2 (0.361𝑚/𝑠)2
(1.005𝑚/𝑠)2 (1.005𝑚/𝑠)2 Hf-EXT = {2 x 0.143 x 𝑚 }+ {2 x 0.151 x 𝑚 }
Hf-ENT = {2 x 0.176 x 𝑚 }+ {2 x 0.665 x 𝑚 } 2(9.81 )
𝑠2
2(9.81 )
𝑠2
2(9.81 ) 2(9.81 )
𝑠2 𝑠2

Hf-EXT = 3.90 x 10-3 meter

Hf-ENT = 0.086 meter
Hf-GB = Hf-ENT + Hf-EXT

Hf-GB = 0.0899 meter

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Elbows, Hf-ELB Tees, Hf-TEE

For calculating elbows, we will now use again the table Entry: KT-en = 3 x 0.30 = 0.90
from Figure 2.19. Given from Table 2.4, we can now Exit: KT-ex = 4 x 0.30 = 1.20
FRICTION solve the K
HEAD 𝒗𝟐 𝒗𝟐
Entry 152.4mm: K90 = 5 x 0.45 = 2.25; K45 = 4 x 0.24 = 0.96 Hf-TEE = KT-en 𝟐𝒈 + KT-ex 𝟐𝒈
LOSS IN Return 254mm: K90 = 3 x 0.45 = 1.35; K45 = 5 x 0.24 = 1.20
FITTINGS Hf-TEE = 0.90
1.0052
+ 1.20
0.3612
𝒗𝟐 𝒗𝟐 2(9.81) 2(9.81)
Hf-ELB = KENT 𝟐𝒈 + KEXT 𝟐𝒈

1.0052 1.0052 0.3612 0.3612

Hf-ELB = 2.25 x
2(9.81)
+ 0.96 x
2(9.81)
+ 1.35 x
2(9.81)
+ 1.20 x
2(9.81)
Hf-TEE = 0.054 meter

Hf-ELB = 0.182 meter

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation

With all these friction head losses, we can now solve the total friction head in our system:

Hf = Hf-STR + Hf-SV + Hf-HE + Hf-HEV + Hf-GB + Hf-ELB + Hf-TEE

FRICTION
HEAD
Hf = 6.77 m + 0.012 m + 1.7 m + 0.525 + 0.0899 m + 0.182 m + 0.054 m
LOSS IN
FITTINGS
Hf = 29.26 meters

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
VELOCITY The kinetic energy of the fluid increases when it leaves the system at a higher velocity than when it enters and
HEAD this requires extra energy. The energy required for the velocity increase is typically small and is often neglected
when the system is submerged according to Chaurette, Jacques of Pump and System Analysis and Sizing.
DIFFERENCE
𝟏
HV = (𝒗𝟐 − 𝒗𝟏 )2 = 0
𝟐𝒈

Our lube oil system is not pressurized since the tank is fully equipped with Vapor Extraction Fan (Exhaust fan) to
create a slightly negative pressure to pull out those non-condensable and combustible gasses. Therefore,
STATIC HEAD
HS = 𝟎

It takes energy to pump fluids from a lower level to a higher one. There is often a significant difference in
ELEVATION elevation between the inlet of a system (point 1), and the outlet (point 14, see slide 26).
DIFFENCE,
HZ
z2 = 7 meters z1 = 3 meters

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
ELEVATION HZ = z2 – z1
DIFFENCE, HZ = 7 meter – 3 meters
Total Head is the measure of a pump's ability
HZ to push fluids through a system. Total Head is
HZ = 4 meters
TOTAL proportional to the difference in pressure at the
DYNAMIC discharge vs. the suction of the pump.
HT = H f + HV + HS + HZ HEAD
TOTAL HEAD HT = 29.26 m + 0 m + 0 + 4 m
LOSS
HT = 33.26 m NET POSITIVE SUCTION HEAD
AVAILABLE (N.P.S.H.A.)

where:
ha - absolute pressure (in feet of liquid) on the surface of the liquid supply level (this will be barometric pressure if
suction is from an open tank or sump; or the absolute pressure existing in a closed tank such as a condenser
hotwell or deaerator).
The formula given by Cameron Hydraulic Data [8],
hvp - The head in feet corresponding to the vapor pressure of the liquid at the temperature being pumped.
hst -
hf -
Static height in feet that the liquid supply level is above or below the pump centerline or impeller eye.
All suction line losses (in feet) including entrance losses and friction losses through pipe, valves and fittings, etc. NPSHa = ha – hvp + hst – hf
𝑝𝑠𝑖 𝑥 2.31
Liquid Head in feet = by same reference above.
𝑆𝑝.𝐺𝑟𝑎𝑣𝑖𝑡𝑦

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Since the suction line pressure gage of the ha = 56 mm WC = 0.0796 psia = 14.6204 psig
𝑝𝑠𝑖 𝑥 2.31
ha =
current AC Auxiliary oil pump is not available, 𝑆𝑝.𝐺𝑟𝑎𝑣𝑖𝑡𝑦
14.6204 𝑥 2.31
we are going to calculate this from the ha =
0.848
available data we have. The suction pipe of
current pump of AC auxiliary oil system is ha = 39.83 feet or 12.14 meter
TOTAL submerged in a tank as well as its impeller as
hvp = 0.50 mm Hg at 46 C of mineral oil
DYNAMIC you can see in the Figure 2.22, the vapor
hvp = 0.00966 psia = 14.69 psig
extraction fan is creating a slight vacuum
HEAD 𝑝𝑠𝑖 𝑥 2.31
pressure inside the tank (56 mm WC hvp =
𝑆𝑝.𝐺𝑟𝑎𝑣𝑖𝑡𝑦
ft
according to manufacturer in Figure 2.28). hvp =
14.69 𝑥 2.31
0.848
Since suction pipe and the impeller is
submerged, and the discharge line is above hvp = 40.02 feet or 12.20 meter
the pump’s center line, we can say the
NPSHa = ha – hvp + hst – hf
Suction static head is positive, and the
velocity head is equivalent to zero as NPSHa = 12.14 m – 12.20 m + 4 m – 0 m
previously stated above. Given the
statement, NPSHa = 3.94 meters

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Pd = 2.80 bars = 40.61 psig
𝑝𝑠𝑖 𝑥 2.31
DISCHARGE HEAD, hd hd = ft
𝑆𝑝.𝐺𝑟𝑎𝑣𝑖𝑡𝑦
14.61 𝑥 2.31 1𝑚
hd = x
0.848 3.28 𝑓𝑡

On an existing installation total discharge head

hd = 33.72 meters
would be the reading of a pressure gage at the
TOTAL discharge flange converted to feet of liquid and
DYNAMIC corrected to the pump centerline plus the TOTAL DYNAMIC HEAD
HEAD velocity head (in feet of liquid) at the point of
gage attachment.
- Chaurette, Jacques of Pump and System Total system head (H)-formerly total dynamic head-is the
Analysis and Sizing. total discharge head (h,) minus the total suction head (h,)
if positive or plus if a suction lift: H = hd – hs (head ) or H =
Since the current AC Auxiliary oil pump has a hd + hs (lift).
discharge pressure gage reading of 2.60-2.80
bars according to the data, we can simply H = hd – hs H = 33.72 meters – 3.94 meters
convert this to head in meter, let’s use 2.80
bars for this computation, H = 29.78 meters or 97.68 feet

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
0.6 x QnW 0.8 x QW 1.0 x QW 1.2 x QW
Water Capacity
(QW) 174 232 290 348
Water Head (HW) 58.68 78.14 97.68 117.22
Water Efficiency 0.47 0.62 0.78 0.94
(EW)
Viscosity of
214.2 214.2 214.2 214.2
Liquid in SSU
CQ from chart 0.98 0.98 0.98 0.98
CH from chart 0.94 0.96 0.97 0.98
CE from chart 0.78 0.78 0.78 0.78
Viscous Capacity
Q W x CQ
170.5 227.4 284.2 341
Viscous Head HW
55.2 75 94.8 114.9
x CH
0.37 0.48 0.61 0.73
Viscous
Efficiency EW x CE
Specific Gravity
0.848 0.848 0.848 0.848
of Liquid
Bhp viscous 4.2 7.6 9.5 11.5

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
BRAKE Approximate brake horsepower and
curve can be determined by use of the
HORSEPOWER
formula provided by Cameron Hydraulic
data:[3]
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑣𝑖𝑠𝑐𝑜𝑢𝑠 𝑥 𝐻𝑒𝑎𝑑 𝑣𝑖𝑠𝑐𝑜𝑢𝑠 𝑥 𝑠𝑝.𝑔𝑟𝑎𝑣𝑖𝑡𝑦
Estimated Bhp =
3960 𝑥 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑣𝑖𝑠𝑐𝑜𝑢𝑠)

284.2 𝑥 94.8 𝑥 0.848

Estimated Bhp =
3960 𝑥 0.61

Estimated Bhp = 9.5 hp

By plotting the corrected flow and head of viscous fluid, 284.3 GPM
(64.6 m3/h) and 94.8 feet (28.9 meters), respectively, using the
Figure 2.30, it will intersect on size 50-160 which give us a detailed
description on Table 2.9 provided by the manufacturer Allweiler. Figure 2.30: Allweiler’s Performance Curve of NSS series at 3500 rpm

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
Impeller specific speed is an index as to the Since the specific speed we obtained is below 4200 rpm, we can
type of impeller when the factors in the above roughly say that we need a centrifugal pump which in this case
formula correspond to its performance at also corresponds to the current AC lube oil pump.
optimum (or best) efficiency point.
𝑟𝑝𝑚 𝑔𝑝𝑚
NS = 𝑸 𝒙 𝝆 𝒙 𝒈 𝒙 𝑯𝑻
𝐻 3/4 𝑷𝒉 =
IMPELLER 3.6 𝒙 106
3550 284.2
SPECIFIC NS =
94.83/4
SPEED HYDRAULIC 64.6 𝑥 848 𝑥 9.81 𝑥 28.9
𝑃ℎ =
NS = 1973 rpm POWER 3.6 𝑥 106

According to specific speed values impellers 𝑷𝒉 = 𝟒. 𝟑𝟖 𝐊𝐖

and pumps can be classified roughly as
follows:
Below 4200 - Centrifugal or Radial type;
Between 4200 and 9000 - Mixed Flow;
Above 900 - Axial Flow.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation

𝐇𝐲𝐝𝐫𝐚𝐮𝐥𝐢𝐜 𝑷𝒐𝒘𝒆𝒓
𝐒𝐡𝐚𝐟𝐭 𝐏𝐨𝐰𝐞𝐫 =
𝑬𝒇𝒇𝒆𝒄𝒊𝒆𝒏𝒄𝒚
𝑷𝒉
𝑷𝒔 =
SHAFT ƞ
POWER 4.38 KW
Ps =
0.78

𝑷𝒔 = 𝟓. 𝟔 𝑲𝑾

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2A: ENGINEERING REPORT
Design Proper: Calculation
MOTOR RATED POWER SYNCHRONOUS SPEED PUMP SELECTION

To summarize the calculation with the

𝐋𝐰 performance curves result, the pump
𝑳𝐃 =
𝐞𝐩 𝐞𝐭
𝟏+𝐚 𝑵 = 𝟏𝟐𝟎 𝐟Τ𝐩 requirements and applicable model
says:
4.38 120 60
LD = 1 + 0.1 N=
2
0.78 1 284 GPM x 29 m x 3600 RPM x 5.7 kW

𝑳𝐃 = 𝟓. 𝟕 𝐊𝐖 N = 3600 rpm From Table 2.11, the Centrifugal

(Radial Flow) Vertical Type Pump and
Single Stage are suit to the choice to
buy at the market based on the
performance parameter and
Performance Curves.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

CHAPTER 2B: ENGINEERING REPORT
Mobile Forced-Air Cooling
System for Steam Turbine

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Appendix B: Drawing

3 days & 15 hrs.

472 °C

Figure 2.9: Unit 3 FDC-MPC 150.08 °C

actual trend last October 19, 2023

(APMS)

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Appendix B: Drawing
Location of Projects’ inlet and outlet ports

Steam Turbo-Generator

Vacuum Breaker Valve

IP/LP Main Stop Valve Drain Pipe

HP Main Stop Valve Drain Pipe

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Appendix B: Drawing
2
1 Hot Air Blower Designed by GE
7

(1) Blower belt drive

(2) Blower
5
(3) Electric motor
(4) Inlet silencer/filter
(5) Control Valve
6
(6) Shock insulation feet
(7) Air intake
8
(8) Air outlet

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Appendix B: Drawing
Direction of Cooling air (Counter-flow)

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Calculation
Shutdown Parameters Allowable Parameters
DESIRED PARAMETERS (Where Maintenance Team can
(Turning Gear Engaged)
safely start their activity)
HP Ave. Rotor Temp 472 °C 150 °C
The goal of the project is to reduce the outage duration as
much as possible. The drying air flow path should be HP Exhaust Temp 405 °C 157 °C

designed to encompass the entire turbine spaces. This can HP Pressure 0 bar 0 bar
be achieved by maintaining a continuous supply of dry air at
IP/LP Surface Temp 324 °C 99 °C
<30% RH from a blower discharging into the condenser hot-
well, providing air flow. LP Exhaust Pressure 1.02 bar 1.01 bar

Condenser Neck Temp 40.7C 34C

Relative Humidity 68% 30% RH

Ambient Temperature 32C 32C

Air Velocity 2 m/s

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Flow Diagram
REHEAT MSV

MAIN STEAM MSV

FORCED-AIR
COOLING SYSTEM
EXIT

HP TURBINE ` IP TURBINE LP TURBINE

FLASH TANK

ENTRY

COLD REHEAT PACV

VACUUM BREAKER VALVE

AREAS AFFECTED BY COOLING

TAL VALVE
PROJECT: FORCED-AIR COOLING SYSTEM
CONDENSER
DRAIN LINE OF MSV; EXIT TO ATMOSPHERE

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Calculation
Convective heat transfer coefficients – hc - depends on type of
SOLVING FOR CROSS SECTION AREA
media, if its gas or liquid, and flow properties such as velocity,
viscosity and other flow and temperature dependent properties. [5]
Here, according to Heat Transfer Formula Sheet, Which in this case, we use air as our medium for cooling. The
Page 3, the formula for convection can be properties of air changes as its temperature increases.
expressed as:

q = hc A ∆T Equipment Surface Area, m²

Steam Turbine, HP, IP, LP 53.5
where:
q = heat transferred per unit time (W, Btu/hr) Surface Condenser 106.4
A = heat transfer area of the surface (m2, ft2)
hc = convective heat transfer coefficient of the
process (W/(m2 °C, Btu/(ft2 h °F))
Other Ancillaries 20.4
∆T = temperature difference between the surface
and the bulk fluid (°C, °F)
Total 180.3

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Calculation
Ti = 150 °C To = 160 °C Tw = 33 °C
HEAT TRANSFER COMPUTATION v = 2 m/s ATAL = 9.42 m2 DTAL = 300 mm

To identify the total heat energy to be removed from Solving for Tm:
the system at certain temperature, we will calculate Tm =
𝑇𝑖 + 𝑇𝑜
=
150 𝐶+160 𝐶
= 155°C
2 2
first the heat generated of individual system.
q = hc A ∆T = hc A (Tw – Tm) – (HMT Data Book, Page 114) Refer to Table 2.3, Dry Air properties at 155 °C
at 1 atm:
where:

q = heat transferred per unit time (W, Btu/hr)

A = heat transfer area of the surface (m2, ft2) Density, ρ 0.835 kg/m3
SHAFT hc = convective heat transfer coefficient of the process (W/(m2 °C,
Btu/(ft2 h °F))
POWER Tw = temperature of the wall
𝑇 +𝑇
Specific Heat, CP 1015.25 J/kg °K
Tm = mean temperature = 𝑖 𝑜
2
Thermal Conductivity, k 0.03476 W/m °K
Assume that air inlet temperature will be
150 °C and the desired outlet Dynamic Viscosity, γ 2.9175 x 10-5 m2/s
temperature rise coming out from that Prandtl Number, Pr 0.7021
equipment will be set to constant +10 °C

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Calculation
HEAT TRANSFER COMPUTATION

Solving for Reynolds Number, Re, from HMT Data

Book, page 111:
𝒗𝑫
where: Re =
𝜸 Nu = Pr0.333 [0.037Re0.80 – (0.037Recr0.80 – 0.664Recr0.50)]
v = velocity, m/s
D = diameter of pipe
γ = dynamic viscosity, m2/s Where:
𝑣𝐷 2 𝑚/𝑠 (0.300𝑚) Recr – critical Reynolds Number (refer to HMT Data Book, Page 114)
Re = = = 20565.5
𝛾 0.000029175 𝑚2 /𝑠
Nu = Pr0.333 [0.037Re0.80 – (0.037Recr0.80 – 0.664Recr0.50)]
Re < 1 x 108, 0.60 < Pr < 60 – Laminar - Turbulent Flow
Nu = 0.70210.333 [0.037(20565.50)0.80 – 8.77]
Thus, according to HMT Data Book, 6th edition, page Nu = 84.97
114, the formula used to solve for Nusselt number, Nu
for smooth pipe at laminar – turbulent constant wall
temperature flow is:

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Calculation
HEAT TRANSFER COMPUTATION

With these, we can now solve the convective heat transfer using the formula for internal flow at smooth pipe from Heat
Transfer Formula Sheet, Page 3,
𝑊
𝑁𝑢 𝑘 84.97 (0.03476𝑚𝐾)
hc = = = 9.85 W/m2 °K
𝐷 0.300 𝑚

We can now solve for heat generated by the equipment,

qTAL = hc ATAL (Tw – Tm)

qTAL = 9.85 W/m2 °K (9.40 m2) [(33 °C – 155 °C) +273 °K]

qTAL =36555.2 watts or 36.56 kW

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Calculation
HEAT TRANSFER COMPUTATION
Air properties at T °C at 1 atm:
Temperature, °C 150 155 165 175

Density, ρ 0.8345 kg/m3 0.835 kg/m3 0.8058 kg/m3 0.7878 kg/m3

Specific Heat, CP 1014.5 J/kg °K 1015.25 J/kg °K 1016.75 J/kg °K 1018.25 J/kg °K

Thermal Conductivity, k 0.034425 W/m °K 0.03476 W/m °K 0.03545 W/m °K 0.0361 W/m °K

Dynamic Viscosity, γ 2.86 x 10-5 m2/s 2.9175 x 10-5 m2/s 3.03 x 10-5 m2/s 3.15 x 10-5 m2/s

Prandtl Number, Pr 0.70275 0.7021 0.7009 0.6998

***Microelectronics Heat Transfer Laboratory – Fluid Properties Calculator

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Calculation
Convective
Nusselt Convective
Reynolds Nusselt Equation Heat Heat
Equipment Ti, °C To, °C Tm, °C Tw, °C Number Heat Transfer
Number Transfer, Generated, kW
equation
W/m2 °K
Nu = Pr0.333 [0.037Re0.80 –
HP Turbine (0.037Recr0.80 – 𝑁𝑢 𝑘
160 170 165 472 71419.10 157.60 hc = 5.29 42.7
Section 0.664Recr0.50)] 𝐷

Nu = Pr0.333 [0.037Re0.80 –
(0.037Recr0.80 – 𝑁𝑢 𝑘
HPT MSV 170 180 175 472 25396.83 93.96 hc = 8.48 14.5
0.664Recr0.50)] 𝐷

Thus, according to HMT,

6th edition, page 127, the
Condenser Neck
Nusselt number, Nu for 𝑁𝑢 𝑘
(Lower and 150 150 150 40.7 215347.05 2.976 hc = 0.043 0.535
smooth rectangular object 𝐷
Upper
where L/D <100 is equal to
2.976

Nu = Pr0.333 [0.037Re0.80 –
LP Turbine 𝑁𝑢 𝑘
150 160 155 80 211482.43 (0.037Recr0.80 – 271.43 hc = 3.06 30.9
Section 𝐷
0.664Recr0.50)]

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Calculation
Convective
Nusselt Convective Heat
Reynolds Nusselt Equation Heat
Equipment Ti, °C To, °C Tm, °C Tw, °C Number Heat Transfer Generated,
Number Transfer,
equation kW
W/m2 °K
Nu = Pr0.333 [0.037Re0.80 –
IP Turbine (0.037Recr0.80 – 𝑁𝑢 𝑘
160 170 165 324 98019.8 0.664Recr0.50)]
184.68 hc = 4.41 19.9
Section 𝐷

Nu = Pr0.333 [0.037Re0.80 –
(0.037Recr0.80 – 𝑁𝑢 𝑘
IPT-LPT MSV 170 180 175 324 22160.66 0.664Recr0.50)]
87.7 hc = 7.92 35.9
𝐷

TOTAL HEAT ENERGY NEED TO DISSIPATE 153.94

Using the formula provided by Sunon Technology , our leading supplier of fans and blowers, The volume of air flow required to
cool an equipment can be determined if the internal heat dissipation and the total rise in temperature allowable are known.
𝟏.𝟕𝟔 𝒒 𝟎.𝟎𝟓 𝒒
Q (ft3/min) = where T = °K; q = kilowatts Q (m3/min) = where T = °K; q = kilowatts
∆𝑻 ∆𝑻

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Sizing
SIZING OF BLOWER

0.05 𝑞 0.05 (153,940 𝑘𝑖𝑙𝑜𝑤𝑎𝑡𝑡𝑠)

Q (m3/min) = =
∆𝑇 472 𝐶−150 𝐶 +273

60𝑚𝑖𝑛
Q (m3/min) = 12.93 m3/min( )
1 ℎ𝑟

Q = 776.17 m3/ hr (CMH) or 455.35 ft3/min (ACFM)

And we can also calculate the mass flow rate that needs to dissipate by using the equation:

m = ρ V; where ρ – kg/m3, V – m3/min

m = 0.179 kg/sec

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Sizing
20+14.7 𝑝𝑠𝑖𝑎
SIZING OF HEATER SCFM = 455.35 x (
14.7 𝑝𝑠𝑖 ) ( 528 °𝑅
) (1.20)
549 27 °𝑅
.

SCFM = 1240 ft3/min or 2108 m3/hr

The acquired CMH is an actual CMH since its derived from
actual temperatures and pressures. In order for us to identify The equation Q/t = (m/t) *cp*ΔT can be approximated for air to:
the capacity of heater, we need to convert the Actual CMH to
Standard CMH. Power [Watts] = (1/3) *SCFM*ΔT [°F]
Power [Watts] = (1/3) (1240 CFM) (302 °F – 89.6 °F)
The Farnam-Custom.com provide us a simple formula:
𝑃𝐴𝑐𝑡𝑢𝑎𝑙
SCFM = ACFM x ( 528 °𝑅
14.7 𝑝𝑠𝑖 ) ( ) S.F Power [Watts] = 87792 watts or 88 kW
𝑇𝐴𝑐𝑡𝑢𝑎𝑙

Using ambient air temperature of 32 °C (89.6 °F) to heat up

to 150 °C (302 °F), and a desired pressure difference of 200
mbar (200 kPag), since we need to overcome the pressure
drops at intake side of blower due to filters. The SF or factor
of safety is usually set to 20% to cope for various losses.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Selection
SELECTION OF BLOWER WITH ELECTRIC HEATER

Volume of air needed to dissipate heat from different

sections as shown in Figure 10 is approximately around
1 455.35 ft3/min (ACFM). The equipment should be
capable to remove heat continuously 0.179 kg/sec at 2
m/sec.
Based from previous calculations, the FDC-MPC steam
2 turbine and ancillaries will need a blower that can remove
at least 153.94 kW of heat.

The overall power rating requirement for the blower can

3 be determined using manufacturer’s performance curve.

The electric heater should be capable to heat the air

4 intake up to 100-200 °C

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Selection
SELECTION OF BLOWER WITH ELECTRIC HEATER

Then the selected Blower with Electric Heater equipment is

the Manvac’s Hot Air Blower which product catalogue is
available below.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Selection
SELECTION OF BLOWER WITH ELECTRIC HEATER

Brand MANVAC
Model 2MV-840-H37
Motor Power 12.6 kW
Frequency 60 hz
Electric Heater 102 kW
Air Volume 1050 m3/hr or 17.5 m3/min
Heating Area 200-300 m2
Dimension 1200mm x 750mm x 760mm
Exhaust Diameter 300mm
Differential Pressure 285mbar
Remarks Automatic Temperature Controller

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Selection
SELECTION OF BLOWER WITH ELECTRIC HEATER

Based from the MANVAC 2MV-840-H37 catalogue and

accessories information, the hose adapter for the outlet air
has a diameter requirement of 300mm (11.5 inches.) The
existing vacuum breaker valve of the FDC-MPC steam
turbine (6 inches) does not much with the selected blower
MANVAC 2MV-840-H37 air outlet (11.5 inches). Thus, the
sizing of hoses will require DN300 or 11.5 inches of the
blower with straight round reducer fitting to DN150 or 6
inches in order to connect the hoses and start blowing. The
straight round reducer fitting adaptor is available from the
market accessory list. The exit route through MSV has a
diameter of DN100 or 4 inches to atmosphere.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Selection
SHUTDOWN DURATION SAVE
Cooling Period = 59.5 hours
Using natural cooldown base on the sample trend from
Chapter 2.4.5., it would technically take 3 days and 5 hours
(87 hours) before we reach the goal temperature of 150 °C
without any help of force cooling equipment. The provided
allowable ramp rate of 7 °K/hr to 10 °K/hr can be
maximized using a force cooling equipment, and can
significantly reduce the temperature without any risk and
reduce as well as the shutdown duration up to 59.5 hours
base on the scenarios stated above. This would save up
27.5 hours of time delay for normal shutdown, and 23.5
hours for force outage or trip unit.
𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 (𝐾) 25h forced cooling
tf = 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑃𝑒𝑟𝑖𝑜𝑑 (ℎ𝑟)
472 °𝐶−150°𝐶 +273 °𝐾
10 °K/hr = 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑃𝑒𝑟𝑖𝑜𝑑 (ℎ𝑟)
5h forced cooling

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Application
HP Turbine Section
MEASURING POINTS

The measuring point required for monitoring of the forced cooling process is shown in Figure 8.1. Cooling of the HP
turbine section is monitored using measuring point MAA10CT905, which is located in the inlet part of the inner casing and
is also used for TSE-monitoring of the HP-shaft. The cooling behavior of shaft and inner casing is derived from this point.
Calculations using Finite-Elements-Method are done previously to ensure that, using a certain cooling ramp rate, radial
and axial clearances remain within permissible values. Figure 2.21 shows the maximum permissible transient for the
measuring point during forced cooling.

IP/LP Turbine Section

The measuring point required for monitoring of the forced cooling process is shown in Attachment 6. Cooling of the IP
shaft is monitored using the inner casing measuring point MAB50CT011, which is located in the inlet area and is also
used for TSE monitoring of the IP-shaft. Calculations using Finite-Elements-Method are done previously to ensure that,
using a certain cooling ramp rate, radial and axial clearances remain within permissible values. Figure 2.22 shows the
maximum permissible transient for the measuring point during forced cooling.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Application
MAA10CT905 MAB10CT905
MAC10CT910
MEASURING POINTS

MAA10CT931 MAC10CT981

LBC10CT001

LCA01CT108
LBH20CT901

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Application
500 °C

450 °C

400 °C

350 °C

300 °C

250 °C

200 °C

150 °C

100 °C
10 h 20 h 30 h 40 h 50 h 60 h 70 h

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Operation and Installation
In connecting the Mobile Forced-air Cooling System, we either connect it by a portable secure container or by
LOCATION AND EXTERNAL

permanently installing this nearby the steam turbine area for quick connect and setup. By practicality, Mobile Forced-air
Cooling System via portable container is the most practical and easiest to maintain thus the following connection for the
dryer unit to the steam turbine shall be followed as;
CONNECTIONS

• Observed all instructions for use provided by the blower manufacturer or supplier.
• Set up the portable blowing unit in the immediate vicinity of the turbine connecting flange for layup force cooling.
• Availability of power on site should be in line with manufacturer's instructions; such as MANVAC: 220 V and 60Hz
with approximately 10 to 15 kW load demand.
• Connect the blowing unit with the connecting flange on the turbine vacuum breaker using a flexible air hose.
• The Mobile Forced-air Cooling System shall be required to open in a suitable outlet for exhaust air. Proper
ventilation of Turbine Hall building, where steam turbines are located, should be in place.
• The blower unit should be indoor installation intended and compliance to any standard require.
Connection and hoses shall be compliance to the manufacturer’s manual and recommendations.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Operation and Installation
Additional Pre-Start up Inspection 1. Check for proper wheel rotation by momentarily
energizing the fan. Rotation is always determined by
Disconnect and lock-out all power switches to fan. Disconnect and secure to the viewing the wheel from the drive side and should
“Off” position all electrical power to the fan prior to inspection or servicing. correspond to the rotation decal affixed to the unit.
Failure to comply with this safety precaution could result in serious injury or One of the most frequently encountered problems
death. with Centrifugal Fans is motors which are wired to
1. Check all fasteners, set screws and locking collars on the fan, bearings, run in the wrong direction. This is especially true
drive, motor base and accessories for tightness. with 3-phase installations where the motor will run in
2. Rotate the fan wheel by hand and assure no parts are rubbing. either direction, depending on how it has been
3. Check for bearing alignment and lubrication. wired. To reverse rotation of a 3-phase motor,
4. Check for coupling alignment. interchange any two of the three electrical leads.
5. Check all the guarding (if supplied) for being securely attached and not
2. Check for unusual noise, vibration or overheating of
interfering with rotating parts.
bearings. Refer to the “Troubleshooting” section of
6. Check all electrical connections for proper attachment.
this manual if a problem develops.
7. Check housing and ductwork, if accessible, for obstructions an foreign
material that may damage the fan wheel. 3. Grease may be forced out of the bearing seals
8. Check that the drain is connected, or plugged, and the housing is being during initial start-up. This is a normal self-purging
properly drained. feature of this type of bearing.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Operation and Installation
For forced cooling, a distinction must be made as a matter of principle between 2 cases:
Case 1: Scheduled shutdown with reduction of main/reheat steam temperature Case 2: Cooling after turbine trip at full output, i.e. at rated MS/RH temperature

Application of Force-air Cooling

1. Check that all steam lines, ahead and downstream of steam turbine, are pressureless, i.e. no flow and roughly atmospheric pressure (1 Barg).
2. Close leak-off steam valve MAW10CG011 (seal steam system). Drains outside turbine including valve-drains should be closed. Drains inside turbine might be opened. HP
evacuation line is to open. Closed cooling water and condenser cooling system stays in operation. The cold reheat check valve has to be closed. HP and IP stop valves remain
closed.
3. The air intake at vacuum breaker will be controlled by the vacuum breaker valve either at DCS monitoring or in local operation. The HP and IP Control Valve or Governing
Valves will control the air exit while maintaining the allowable ramp rate. The drains at HP MSV and IP MSV will be controlled individually by local operators. Figure 2.21 shows
the permissible transient (cooling curves) of the HP inner casing (MAA10CT010). It should not exceed 7-10 °K/h within this cooling range.
4. At the beginning the cooling transient should be checked with all control valves closed to rate the air ingress via turbine shaft seals. If the transient is within or below the
Applicable to both allowed limits, the control valves can be opened to approximately 1-2% always checking the permissible limits.
case 1 and 2. 5. The control valves should always be opened to a position that allows to remain within the limits. In the course of the process the control valves have to be opened more and
more in order to decrease the airflow. The more the temperature approaches the ambient temperature (even with all evacuation devices in operation), the more the ramp rate
might drop below the permissive rates. This time loss is considered in the procedure.
6. Depending on the starting temperature (HP and IP) of the cooling phase, the permissible range is marked by the lines at top and bottom. If the value falls below the limit, the
lines indicate that cooling was too fast and the vacuum breaker valve must be closed and/or the blowing device might be switched off.
7. If the upper limit is exceeded, cooling was too slow. This results in a time loss of approximately 2 hours, as the area above this line becomes relevant for cooling, once the limit
is exceeded. For this reason, the optimum cooling requires permanent monitoring of the measuring points and adaptation of the vacuum breaker valve.
8. Checking transients every half an hour seems to be practically.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Maintenance
Components Inspection/Maintenance
3-6 months >12 months
Inlet Filter and Air Cleaning and servicing of filter and its barrel Replacement of Filter; Repaint of Air Barrel
barrel
Housing and Panel Cleaning of Housing through blowing or dry cloth Repaint if necessary;
Motor Inspection of physical conditions; wiring conditions and Inspection of terminals; IR-testing;
cooling fan. Lubrication
Connecting Hose Cleaning of hose; Check for possible damages; Storage Replacement of Hose;
shall be clear from dusts.
Relief valve Inspection and cleaning of relief valve functionality Replacement if necessary
Fan impeller Cleaning of Fan impeller; Inspection for possible bearing Replacement of Bearing; Replacement of
damage; Loose bolts/screws/Clip/Keys Fan Impeller if necessary;
Caster Wheel Inspection of functionality; Cleaning of wheel Replacement if Necessary;
Heater Coils Cleaning of accumulated dirt; Testing of heater Replacement if necessary;

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 2B: ENGINEERING REPORT
Design Proper: Troubleshooting
Problem Cause Corrective Action
Wheel rubbing (inlet) Adjust wheel. Tighten wheel hub or bearing collars on shaft.
Excessive Noise Bearings Replace defective bearing(s). Lubricate bearings. Tighten collars and fasteners.
Wheel unbalance Clean all dirt off wheel. Check wheel balance, rebalance if necessary.
Fan Check wheel for correct rotation. Increase fan speed. *
Low CFM Duct system
Fan Decrease fan speed.
High CFM Duct system Resize ductwork. Access door, filters, grilles not installed.
Duct system has more or less Change obstructions in system. Use correction factor to adjust
Static Pressure Wrong restriction than anticipated for temperature/altitude. Resize ductwork. Change fan speed. *
Fan Check rotation of wheel. Reduce fan speed.
High Horsepower Duct system Resize ductwork. Check proper operation of face and bypass dampers. Check filters and access doors.

Electrical supply Check fuses/circuit breakers. Check for switches turned off or disconnected. Check for correct supply voltage.
Fan Doesn’t Operate Drive Check for broken belts. Tighten loose pulleys
Motor Assure motor is correct horsepower and not tripping overload protector.
Lubrication Check for excessive or insufficient grease in the bearings.
Overheated Shaft Bearing Mechanical Replace damaged bearing. Relieve excessive belt tension. Align bearings. Check for bent shaft.
System unbalance Check alignment of shaft, motor and pulleys. Check wheel balance, rebalance if necessary.
Excessive Vibration Coupling misalignment
Check alignment between coupling, motor and fan shafts. Any adjustments should be made per coupling
manufacturer’s instructions. Shim only under motor.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

CHAPTER 3 : Engineering Economy

1 Project Cost Estimation

2 Project Operations and Maintenance Cost

3 Gross and Net Income

4 Return of Investment

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Cost Estimate A: Items and Services Costs
Total cost Total cost
Particulars Cost per Unit Quantity Particulars Cost per Unit Quantity
(3 Units) (3 Units)
PROJECT ESTIMATED ITEM COST PROJECT ESTIMATED SERVICES COST
Allweiler’s Vertical Centrifugal Pump Electrical Works Php. 20,000.00 Per Unit Php. 20,000.00
Instrumentation Works Php. 20,000.00 Per Unit Php. 20,000.00
Q = 80 m3/h; H = 54 Meters; P = 17 kW; Php. 250,000.00 Per Unit Php. 750,000.00
Mechanical Works Php. 100,000.00 Per Unit Php. 20,000.00
Type = NSS50-200 W106
Delivery (freight, Taxes,
WEG Electric Motor Php. 1,000,000.00 Php. 1,000,000.00
Customs)
P = 30kW; f = 60 Hz; N = 3600 rpm; Php. 340,000.00 Per Unit Php. 1,020,000.00 Spare Parts:
V=480Volts; IP55 Impeller Php. 60,000.00 Per Unit Php. 180,000.00
Elbow 90 DN 100 Seamless Stainless Pump Sealing Elements Php. 50,000.00 Per Unit Php. 150,000.00
Php. 10,000.00 2 pcs/Unit Php. 60,000.00
Steel 304 (Sch. 40) Bearings Php. 30,000.00 Per Unit Php. 90,000.00
Flanges Stainless Steel 304 Php. 5,000.00 3 pcs/Unit Php. 45,000.00 Miscellaneous charges
Circuit Breaker Php. 50,000.00 Php. 150,000.00 (troubleshooting, Php. 50,000.00 Per Unit Php. 150,000.00
Per Unit diagnostic, training)
Wirings (Local to MCC) Php. 100,000.00 Php. 100,000.00
Pressure Transmitter Php. 300,000.00 Php. 900,000.00 Project Estimated Services Sub-Total Php. 1,630,000.00
Local Pressure Gauge Php. 2,000.00 Per Unit Php. 6,000.00 Sum of Item and Service Cost Php. 4,761,000.00
Wirings (Local to DCS) Php. 100,000.00 Php. 100,000.00
Mark-up (20%) Php. 952,200.00
Project Estimated Item Cost Sub-Total P 3,131,000.00 PROJECT OVER-ALL COST P 5,713,200.00

Project A over-all cost = Php. 5,713,200.00

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Cost Estimate A: O & M Costs
OPERATION COST MAINTENANCE COST
(Displayed cost for 3 units) (Displayed cost for 3 units)
Monthly
Description Frequency Yearly Cost Description Frequency Monthly Cost Yearly Cost
Cost
Electric Consumption of AC oil 4 hours every Preventive Maintenance: Electric
pump (30kW) per Unit year (5 mins Motor –checking & inspection or Every 10,000
(Monthly: Php. 7.10/kw-hr x 30 test run every replacing integrated components running hours or Php. 100,000.00
Php. 213.00 Php. 10,224.00 (i.e. bearings, seals, terminals, every 6 months
kw x 3 x 20/60 hrs. = Php. 213.00) week) + 12
(Yearly: Php. 7.10/kw-hr x 30 kw hours per year cables, instruments)
x 3 x 16 hrs. = Php. 10,224.00) every start-up Preventive Maintenance: Pump –
Manpower for Operating and checking & inspection or replacing Every 10,000
Cleaning of the unit and its Every Month integrated components (i.e. running hours or Php. 50,000.00
Php. 1,050.00 Php. 12,600.00 Impeller, bearings, bolts and nuts, every 6 months
accessories and instruments
Lubrication (Greasing and oil gaskets and seals, shafts, etc.)
Every week Php. 200.00 Php. 9,600.00
system) Instruments such as local pressure
Weekly Php. 3,000.00 Php. 36,000.00
Sub-Total O Php. 32,424.00 gauge, cables, transmitter
Vibration Test Monthly Php. 1,000.00 Php. 12,000.00
Sub-Total M Php. 198,000.00

Total O&M project cost every year Php. 230,424.00

Project A over-all O & M cost in a year = Php. 230,424.00

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Cost Estimate B: Items and Services Costs
Total Cost Equipment Cost Per Unit Qty
Total Cost
Equipment Cost Per Unit Quantity (3 Units)
(3 Units)
PROJECT ESTIMATED SERVICE COST
PROJECT ESTIMATED ITEM COST Electrical Works Php. 5,000.00 Php. 5,000.00
Manvac’s Hot Air Blowers (60 Instrumentation Works Php. 2000.00 Php. 2000.00
hertz, 12.6 kW, three-phase, Php. 70,000.00 3 Php. 210,000.00 Mechanical Works Php. 5,000.00 Php. 5,000.00
480V) Delivery (freight, Taxes,
Php. 500,000.00 Php. 500,000.00
High-Temp Flexible Customs)
Ducts/Clips (300mm Php. 10,000.00 3 Php. 30,000.00 Spare Parts:
diameter) Intake Filter
Reducer Pipes (DN300- Switches/Lamps
Php. 5,000.00 3 Php. 15,000.00
DN150) Hose/Hose Clamps Php. 40,000.00 3 Php. 120,000.00
Diffuser/Reducer
Project Estimated Item Cost Sub-Total Php. 255,000.00 Motor
Impeller
Miscellaneous charges
(troubleshooting, Php. 50,000.00 Php. 50,000.00
diagnostic, training)
Project Estimated Service Cost Sub-Total Php. 679,000.00
Project B over-all cost = Php. 1,120,800.00 Sum of Item & Service Cost Php. 934,000.00
Mark-Up (20%) Php. 186,800.00
PROJECT TOTAL COST Php. 1,120,800.00

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Cost Estimate B: O & M Costs
OPERATIONS COST MAINTENANCE COST
(Displayed cost for 3 units) Preventive Maintenance: Electric Motor
Every 10,000
–checking & inspection or replacing
running hours or Php. 10,000.00
Description Frequency Monthly Cost Yearly Cost integrated components (i.e. bearings,
every 6 months
seals, terminals, cables, instruments)
Electric Consumption of Hot Air
Preventive Maintenance: Blower –
Blower (12.6kW) per Unit 1 hour every year
checking & inspection or replacing Every 10,000
a. (Monthly Routine: Php. 7.10/kw-hr x (5 mins test run
integrated components (i.e. Impeller, running hours or Php. 10,000.00
12.6 kw x 3 x 5/60 hrs. = Php. 22.365) every week) + 60
bearings, bolts and nuts, gaskets and every 6 months
b. (Yearly PMS: Php. 7.10/kw-hr x 12.6 hours per year
Php. 22.36 Php. 67,900.14 seals, shafts, etc.)
kw x 3 x 60 hrs. = Php. 16,102.80) every PMS + Ave. Instruments such as local pressure
c. (Yearly 3 Force-Outages: Php. force outages of 3x gauge, heater panels, circuit breakers, Weekly Php. 5,000.00
7.10/kw-hr x 12.6 kw x 3 units x 3 x 64 per unit per year hose
hrs. = Php. 51,528.96)
Vibration Test Monthly Php. 5,000.00
Manpower for Operating and
Cleaning of the unit and its Monthly Php. 500.00 Php. 6,000.00 Sub-Total M Php. 30,000.00
accessories and instruments
Php.
Lubrication (Greasing and oil system) Weekly Php. 200.00 Php. 9,600.00 TOTAL COST O & M in a year
113,500.14
Php.
Sub-Total O
83,500.14

Project A over-all O & M cost in a year = Php. 113,500.14

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
FDC-MPC: Gross Income
Scenarios Electric Peso No. of Hours Total Gross Income
Operating hour Rate per kWh running Running per Year (Php)
(7,872 (2023) units Based from actual operating regime of 3 units
hours/unit) running from the year 2022 data, the Scenario
Scenario 1:
2 is the more accurate to predict the gross
Based from Full
Load Capacity of
P 7.100/kWh 3 7,872 hrs. Php. 20,707,689,600.00 income due to revisions/changes in actual
123.5 MW loads every hour in a day.
Scenario 2:
Based on Average
P 7.100/kWh 3 7,872 hrs. Php. 15,593,644.800.00
Load Demand of 93
MW 𝑃ℎ𝑝
= 𝐴𝑣𝑒. 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑘𝑊ℎ 𝑥 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑅𝑎𝑡𝑒 𝑥 𝑅𝑢𝑛𝑛𝑖𝑛𝑔 𝐻𝑜𝑢𝑟𝑠
Scenario 3: 𝑘𝑊ℎ𝑟
𝑃ℎ𝑝
At minimum Load of P 7.100/kWh 3 7,872 hrs. Php. 10,311,926,400.00 = 93,000 𝑘𝑊 𝑥 7.10 𝑥 7,872 ℎ𝑟𝑠 𝑥 3 𝑢𝑛𝑖𝑡𝑠
𝑘𝑊ℎ𝑟
61.5 MW
Base also on the data provided by Performance Engineers of FDC-MPC, the average outage per year (2017-2021):
= Php. 15,593,644,800.00 FDC-MPC average gross income every year
= Php. 15,593,644,800.00 (1 day/24 hours)
Outages Per Unit/year Natural Cooling
600 hours
Planned Outage/s (25-day PMS)
Php. 649,735,200.00 FDC-MPC
Forced Outage/s
504 hours
(3 times a year due to tripping)
average gross income daily

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
FDC-MPC: O & M Expenditures
The FDC-MPC operational, maintenance and other cost should be calculated Monthly
prior to calculate the net income of the plant. The cost necessary for the plant to Expenses Yearly Costs
run productively are shown in Table 3.4. The operating costs/expenses were Costs
A. Consumables
presented based on monthly and yearly actual average consumption for the
➢ Coal (P5,160/ton) - 70,000 MT/month Php. 36,120,000.00 Php. 8,820,000,000.00
three (3) plant units.
➢ Diesel (liters) Note: Php. 55.00/liter
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 = 𝐺𝑟𝑜𝑠𝑠 𝐼𝑛𝑐𝑜𝑚𝑒 − 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 & 𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐸𝑥𝑝𝑒𝑛𝑑𝑖𝑡𝑢𝑟𝑒𝑠 a. Operations- 960,000 liters/yr. Php. 52,800,000.00
b. Iso tank (light and heavy tank)- Php. 55,011,000.00
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 = Php. 15,593,644,800.00 – Php. 9,611,861,000.00 1,000,200 liters/yr.
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 = Php. 5,981,783,800.00 per year ➢ Limestone(tons) - Note: Php. 3,250/ton x
Php. 42,250,000.00
13,000 tons/yr.
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 = Php. 5,981,783,800.00 / 7872 hours B. Chemicals Php. 8,333,333.33 Php. 100,000,000.00
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 = Php. 759,881.08 per hour (24 hours/day) C. Wages, salaries, and fringe benefits Php. 7,000,000.00 Php. 84,000,000.00

D. Trainings, Seminars, Conferences Php. 750,000.00 Php. 9,000,000.00

E. 3rd Party Agency Php. 3,600,000.00 Php. 43,200,000.00
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 F. Supplies, Communication, Utilities Php. 4,000,000.00 Php. 48,000,000.00
G. Transportation Php. 2,000,000.00 Php. 24,000,000.00
Php. 18,237,145.73 per day H. Maintenance Php. 17,000,000.00 Php. 204,000,000.00
I. Preventive Maintenance Schedule Php. 81,600,000.00
J. Spare Parts Php. 4,000,000.00 Php. 48,000,000.00

TOTAL Php. 9,611,861,000.00

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Return of Investment (ROI): Project A - Cost Saving Method

𝑪𝒐𝒔𝒕 𝑺𝒂𝒗𝒊𝒏𝒈𝒔 − 𝑪𝒐𝒔𝒕 𝒐𝒇 𝑰𝒏𝒗𝒆𝒔𝒕𝒎𝒆𝒏𝒕 𝒐𝒓 𝑷𝒓𝒐𝒋𝒆𝒄𝒕

Whereby, 𝑹𝑶𝑰 = 𝒙 𝟏𝟎𝟎%
𝑪𝒐𝒔𝒕 𝒐𝒇 𝑰𝒏𝒗𝒆𝒔𝒕𝒎𝒆𝒏𝒕 𝒐𝒓 𝑷𝒓𝒐𝒋𝒆𝒄𝒕
1. Cost of Spare Rotor (replacement due to damage (𝐶 𝑅𝑂𝑇𝑂𝑅 + 𝐶𝑆𝑇 + 𝐶𝐵 + 𝐶𝐿 ൯ − 𝐶𝑜𝑠𝑡 𝑜𝑓 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 𝑜𝑟 𝑃𝑟𝑜𝑗𝑒𝑐𝑡
𝑅𝑂𝐼 = 𝑥 100%
blade) (Php. 200,000,000.00 for set of rotor & 𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑗𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + 25 𝑦𝑒𝑎𝑟𝑠 𝑥 𝑂&𝑀 𝑐𝑜𝑠𝑡 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟
carriers), CROTOR
2. Cost for maintenance of the steam turbine (Php. Where, Cost of Investment or Project = Total Project Cost + (25 years x O&M cost per year)

40,000,000.00), CST
200,000,000 + 40,000,000 + 7,000,000 + 1,000,000 − 11,473,800
3. Cost of damage bearings - Radial and Thrust 𝑅𝑂𝐼 =
5,713,200 + 25 𝑦𝑒𝑎𝑟𝑠 𝑥 230,424
𝑥 100%
bearings (Php. 7,000,000.00), CB
4. Cost of damage labyrinth seals due to deformation
(Php. 1,000,000.00), CL
ROI = 2061%

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Payback Period (PP): Project A
𝑻𝒐𝒕𝒂𝒍 𝑷𝒓𝒐𝒋𝒆𝒄𝒕 𝑪𝒐𝒔𝒕
𝑷𝒂𝒚𝒃𝒂𝒄𝒌 𝑷𝒆𝒓𝒊𝒐𝒅 𝑨 =
𝑪𝒐𝒔𝒕 𝒐𝒇 𝑺𝒂𝒗𝒊𝒏𝒈𝒔 𝒊𝒏 𝟐𝟓 𝒚𝒆𝒂𝒓𝒔

11,473,800 𝑥 25
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑃𝑒𝑟𝑖𝑜𝑑 𝐴 =
200,000,000 + 40,000,000 + 7,000,000 + 1,000,000

365 𝑑𝑎𝑦𝑠
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑃𝑒𝑟𝑖𝑜𝑑 𝐴 = 0.575 years x 1 𝑦𝑒𝑎𝑟

Payback Period (A) = 210 days or 7 months

• The computation for payback period showed the time it will need to take to recover the initial costs of
around 210 days with 2061x ROI.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Return of Investment (ROI): Project B - Cost Saving Method
Per Unit/year With Forced 3 Units time
Natural Cooling Cooling saved/year
The daily average income of FDC-MPC is about Php. Planned 600 hours 600 – 27.5 = 27.5 hours x 3 units
18,237,145.73, and by using the proposed Project B, Outage/s (25-day PMS) 572.5 hours = 82.5 hours
the company could gain around Php. 223,405,035.21 504 hours
per year since it could start-up early than the target Forced 504 – 23.5(3) = 23.5 hours x 3 Units
(3 times a year due
schedule. Outage/s 433.5 hours x 3 = 211.5 hours
to tripping)

294 hours or
Total Saved Hours 12.25 days per
year

𝑺𝒂𝒗𝒊𝒏𝒈𝒔 𝑮𝒂𝒊𝒏 𝒂 𝒚𝒆𝒂𝒓 − 𝑪𝒐𝒔𝒕 𝒐𝒇 𝑰𝒏𝒗𝒆𝒔𝒕𝒎𝒆𝒏𝒕 𝒐𝒓 𝑷𝒓𝒐𝒋𝒆𝒄𝒕

ROI = 17800 % 𝑹𝑶𝑰 =
𝑪𝒐𝒔𝒕 𝒐𝒇 𝑰𝒏𝒗𝒆𝒔𝒕𝒎𝒆𝒏𝒕 𝒐𝒓 𝑷𝒓𝒐𝒋𝒆𝒄𝒕
𝒙 𝟏𝟎𝟎%

223,405,035.21 − 1,120,800.00 + 113,500.14

𝑅𝑂𝐼 = 𝑥 100%
1,120,800.00 + 113,500.14

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Payback Period (PP): Project B

𝑻𝒐𝒕𝒂𝒍 𝑷𝒓𝒐𝒋𝒆𝒄𝒕 𝑪𝒐𝒔𝒕 As seen in the result, the data shows

𝑷𝒂𝒚𝒃𝒂𝒄𝒌 𝑷𝒆𝒓𝒊𝒐𝒅 𝑩 = aggressive, lucrative, and convincing in terms
𝑪𝒐𝒔𝒕 𝒐𝒇 𝑺𝒂𝒗𝒊𝒏𝒈𝒔 𝒊𝒏 𝐚 𝐲𝐞𝐚𝐫 of payback period. This is because of the high
risk it takes on plant operation. Any
1,234,300.14 Unscheduled plant shutdown due equipment’s
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑃𝑒𝑟𝑖𝑜𝑑 𝐵 = downtime and failure to mitigate these huge
223,405,035.21
issues would greatly affect plant financial
status.
12 𝑚𝑜𝑛𝑡ℎ𝑠
Payback Period (B) = 0.006 years x 1 𝑦𝑒𝑎𝑟 In addition, this project is highly beneficial to
the plant operation, not only does it resolve the
problem but take advantage on the financial
Payback Period (B) = 0.07 month side.

• The computation for payback period showed the time it will need to take to recover the initial costs of
around 2 days with 17800x ROI.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 3: ENGINEERING ECONOMY
Cost-Benefit Analysis (CBA)
Parameters Value (Php)
BENEFITS
Save from Spares such as rotor and turbine blades
Php. 200,000,000.00
(Strategic and Critical Spares)
Save from maintenance of the steam turbine (Major
overhaul of Steam Turbine)
Php. 40,000,000.00 The CBA from Table 3.10 has showed a
Cost of damage bearings - Radial and Thrust bearings Php. 7,000,000.00 cost-benefit factor 607 which means that
Cost of damage labyrinth seals due to deformation Php. 1,000,000.00 the proposal is projecting a 607x return
Gain from early start-ups in 25 years Php. 5,585,125,880.00
from the total overall cost of investment it
COSTS would need for 25 years.
Total Project A initial cost Php. 5,713,200.00

Total Project A O&M cost for 25 years (Php. 230,424 x 25) Php. 5,760,000.00

Total Project B initial cost Php. 1,120,800.00

Total Project B O&M cost for 25 years (Php. 113,500.14 x
Php. 2,837,503.5
25)

Cost-Benefit Ratio 609.93

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

CHAPTER 4 : Evaluation, Conclusion
And Recommendation

1 Evaluation

2 Conclusion

3 Recommendation

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 4: EVALUATION, CONCLUSION, AND RECOMMENDATION
Evaluation
BACK-UP AC AUXILIARY OIL PUMP MOBILE FORCED-AIR COOLING SYSTEM FOR STEAM TURBINE
Reliability Critical Function Redundancy: The backup AC auxiliary oil pump serves as a redundant system in case the Heat Preventing Thermal Stress: Forced-air cooling helps dissipate residual heat in the turbine
and primary pump fails. This redundancy is critical for ensuring continuous and reliable operation, preventing Dissipation components after shutdown. This is crucial for preventing thermal stress and ensuring that the
Redundancy disruptions in the lubrication and cooling of essential machinery. turbine components cool down uniformly, which can extend the lifespan of the equipment.
Prevention Continuous Lubrication: The auxiliary oil pump ensures a continuous supply of oil for lubrication. This is crucial for Reduced Cool Faster Cool Down: Forced-air cooling accelerates the cooling process compared to natural
of preventing wear and tear on rotating machinery components, such as turbines and generators. Continuous Down Time convection. This can reduce the overall downtime during shutdowns, allowing the turbine to be
Equipment lubrication helps extend the lifespan of equipment. brought back into service more quickly when needed.
Damage
Prevention of Uniform Cooling: Forced-air cooling ensures more uniform cooling across various turbine
Emergency Quick Response to Failures: The backup system provides a quick response in the event of a primary pump failure. Hot Streaks components, preventing the formation of hot streaks or uneven temperature distribution. This is
Response This rapid response is essential for preventing damage to equipment and minimizing downtime. important for avoiding thermal gradients that could lead to mechanical stresses.
Maintenance Scheduled Maintenance: The presence of a backup AC auxiliary oil pump allows for scheduled maintenance on Preservation Minimizing Corrosion: Forced-air cooling can help minimize the risk of corrosion on turbine
Flexibility the primary pump without interrupting operations. During maintenance periods, the backup pump can take over to of components during shutdown periods. By maintaining a controlled environment with reduced
ensure continuous lubrication. Components humidity, the potential for corrosion is lowered, preserving the integrity of critical parts.
Enhanced Risk Mitigation: The backup pump contributes to the overall resilience of the system by reducing the risk of Enhanced Reduced Wear and Tear: Efficient cooling during shutdowns can reduce wear and tear on turbine
System prolonged downtime due to pump failures. This is particularly important in critical applications where uninterrupted Equipment components, contributing to overall equipment reliability. Components subjected to thermal stress
Resilience operation is essential. Reliability during shutdowns may experience accelerated deterioration, and forced-air cooling helps mitigate
this.
Improved Optimized Performance: The backup pump helps maintain optimal operating conditions by ensuring a consistent
Operational supply of oil for lubrication. This contributes to the overall efficiency and performance of the machinery, leading to Operational Quick Restart Capability: With forced-air cooling, the turbine is in a more favorable condition for a
Efficiency improved energy output and reduced operational costs. Flexibility quicker and smoother restart. This is particularly beneficial in situations where rapid response to
changes in power demand is required.
Compliance Regulatory Compliance: In many industrial sectors, having backup systems, including auxiliary pumps, is a
and Safety requirement to comply with safety and reliability standards. Compliance ensures the facility operates within Energy Reduced Standby Energy Consumption: Forced-air cooling systems can be designed for energy
established safety guidelines. Efficiency efficiency, consuming less power compared to continuous operation of other cooling systems
during shutdowns. This can contribute to overall energy conservation and operational cost savings
Cost Prevention of Downtime Costs: The backup pump helps prevent unscheduled downtime, which can be costly in
Savings: terms of lost production and potential equipment damage. Investing in a backup system can result in long-term Improved Facilitates Inspection and Maintenance: Forced-air cooling can create a more controlled
cost savings by minimizing the impact of pump failures Maintenance environment during shutdowns, facilitating inspection and maintenance activities. This is
Practices particularly valuable for ensuring the integrity of turbine components and identifying potential
Adaptability Variable Load Conditions: In power stations or industrial facilities with variable load conditions, having a backup
issues early.
to Changing pump ensures adaptability to changes in demand. The backup system can handle increased loads or provide
Conditions support during peak operating periods Cost-Effective Improve duration of shut down and in return early start-ups which the days saved converted into
profits.
 CHAPTER 4: EVALUATION, CONCLUSION, AND RECOMMENDATION
Conclusion
In conclusion, adapting forced-air cooling for a steam turbine during shutdown offers advantages such as
enhanced heat dissipation, reduced cool down time, prevention of hot streaks, preservation of components,
improved reliability, operational flexibility, energy efficiency, environmental considerations, and improved
maintenance practices. These benefits contribute to the overall performance and longevity of the steam turbine
system. However, the specific design, implementation, and operational considerations.

The backup AC auxiliary oil pump, on the other hand, provides critical redundancy, prevents equipment damage,
facilitates quick emergency response, allows for maintenance flexibility, enhances system resilience, improves
operational efficiency, ensures regulatory compliance, contributes to cost savings, and adapts to changing
conditions. The presence of such a backup system is an integral part of a comprehensive risk management and
reliability strategy in industrial applications should be carefully evaluated based on the characteristics of the turbine
and the requirements of the power generation facility.
Having the two projects have a significant impact to the power station. These projects bring a huge profit to the
table and could give ease to operations and maintenance.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

 CHAPTER 4: EVALUATION, CONCLUSION, AND RECOMMENDATION
Recommendation
The study of these two (2) projects are very feasible and has been showed and justified in previous chapters.
Based from the evaluation up to the conclusion of the study, a few points are to consider and finalize. To further
develop and finalize the study, the following recommendations are to consider:

The implementation of the back-up AC Auxiliary Oil pump and Forced-Air Cooling System will need considerations on cost,
downtime, storage conditions, effectiveness, and regulatory compliance. Thus, consideration for these items should be
accepted and identified during implementation or upgrading the systems.

The Forced-Air Cooling System for the steam turbine is dependent on the steam turbine layup or shutdown durations and
programs. Thus, the system may mostly be not used all throughout the year. In this case, maintaining the equipment is as always
necessary in order to prevent deterioration of the equipment. Regular operation without connecting to the turbine system should
be considered in order to replenish the system functions. Thus, maintain its readiness and availability anytime. On the other
hand, the back-up AC auxiliary oil pump is fully integrated to the system, and should be included in weekly routine as discussed
in the previous chapters, including the schedule of cleaning and preventive maintenance.

Lastly, the emerging new technology to preserve the turbine life is already available in the market. It is just to apply these
technologies and spend a penny now in exchange for longer profitability. The steam turbine is the heart of the power plant, a
single day of downtime could cause a huge loss to the company.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.

HARNESSING ENERGY. EMPOWERING COMMUNITIES.