POWERPLANT ENGINEERING

School Year 2019-2020 | Second Semester

Prepared by:
CHRISTIAN M. MORTEL  | Mechanical Engineering Department
 Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

POWERPLANT DESIGN GUIDE 101

DESIGN PROBLEM
A Diesel Power Plant will be constructed to save the community of Brgy. San Felipe, Naga City.
The Power Plant will supply power to be available for 24hrs.
Assumption:
1. Plant Capacity Factor = 60%
2. Fuel Supply in the area = 45 days
3. Electrical connection including distribution will be consulted by a Electrical Engineer
Requirements:
1. Determine the no. of customers in the community.
2. Identify the kind and no. residential, commercial and shops.
3. Identify the customers by zone.
4. Determine the time of usage of customers per 24hrs.
5. Determine the total power requirements for the area.
6. Draw the map of the area and indicated the customers in its zone.
7. Design the Power Plant including its auxiliaries.
8. Design the foundation of the engine.
9. Specify the required diesel power units.
10. Provide for space for expansion.
11. Design the Power house building.
12. Prepare the working schedule of the project.

1
 Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

DESIGN SOLUTION
1. Number of customers in Brgy. San Felipe, Naga City.

Number of population: 14098

Number of Households: 3873

2. Identifying the kind and no. of residential, commercial and shops.

Households: 3873 Satellite market: 6

Business offices and establishments: 13 School: 6
Park & Recreational center: 4 Water Pumping station: 3

3. Identifying the number of customers per zone.

Zone No. of Population No. of households

1 722 155
2 5246 1212
3 1200 365
4 643 130
5 3009 618
6 4933 852
7 2013 456

4. Time usage of the customers per 24 hours.

 Households

2
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

No. of Schedule of Schedule

Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
electric fan 500 80 6pm-6am 12hrs 40000 480
6am-9am &
oven toaster 30 1200 5hrs 36000 180
2pm-4pm
refrigerator 95 850 daily 24hrs 76000 1824
fluorescent
357 40 6pm-6am 12hrs 14280 171.36
lamp
bulb 285 50 6pm-6am 12hrs 14250 171
water
12 300 daily 24hrs 3600 86.4
dispenser
5am-6am &
rice cooker 75 320 2hrs 24000 48
6pm-7pm
vacuum 6am-8am &
10 630 4hrs 6300 25.2
cleaner 2pm-4pm
air
6pm-12am &
conditioning 45 3358 12hrs 151110 1813.32
10am-5pm
unit
10am-12nn &
dvd player 90 13 4hrs 1170 4.68
7pm-9pm
laptop 79 250 8am-1pm 5hrs 19750 98.75
computers 36 350 9am-2pm 5hrs 12600 63
printers 15 18 8am-10pm 2hrs 270 0.54
electric stove 24 1800 9am-11am 2hrs 43200 86.4
coffee maker 3 1200 6am-8am 2hrs 3600 7.2
10am-12nn &
charger 300 65 4hrs 19500 78
5pm-7pm
water pumps 30 2238 8am-8pm 12hrs 67140 805.68
television sets 198 110 9am-9pm 12hrs 10780 129.36
washing
78 20 9am-11am 2hrs 1560 3.12
machines
5am-7am &
flat iron 100 1000 4hrs 100000 400
8pm-10pm
8am-10am &
ceiling fan 50 60 5hrs 3000 15
2pm-5pm
karaoke 180 180 9pm-2am 5 900 4.5
stereo 50 40 1pm-6pm 5hrs 2000 10
TOTAL 6505.51
 Sari- sari stores
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
electric fan 84 80 8am-8pm 12hrs 6720 80.64
fluorescent
32 40 6pm-12mn 6hrs 1280 7.68
lamp
bulb 75 18 6pm-6am 12hrs 1350 16.2
refrigerator 36 850 daily 24hrs 30600 734.4
television sets 20 110 9am-5pm 8hrs 2200 17.6
8am-10am &
radio/karaoke 12 180 5hrs 2160 10.8
1pm-4pm
Air conditioning
3 3358 2pm-7pm 5hrs 10074 50.37
unit
11am-1pm &
dvd player 3 10 5hrs 30 0.15
2pm-5pm
ceiling fan 40 60 daily 24hrs 2400 5706
TOTAL 6623.84
 Resorts

3
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

No. of Schedule of Schedule

Appliances Wattage total Wattage kW-hr
Appliances Use hr/day
8am-11am &
electric fan 10 80 6hrs 800 4.8
2pm-5pm
fluorescent
10 40 6pm-6am 12hrs 400 4.8
lamp
bulb 10 18 daily 24hrs 180 4.32
television sets 3 110 9am-2pm 5hrs 330 1.65
8am-10am &
karaoke 2 180 5hrs 360 1.8
1pm-4pm
refrigerators 2 850 daily 24hrs 1700 40.8
10am-12nn
blender 4 750 4hrs 3000 12
&3pm-5pm
water
3 300 daily 24hrs 900 21.6
dispenser
Air conditioning
3 3358 1pm-6pm 5hrs 100721 503.6
unit
vacuum 8am-10am &
4 630 4hrs 2620 10.48
cleaner 3pm-5pm
ceiling fan 30 60 daily 24hrs 1800 43.2
freezer 4 1200 daily 24hrs 4800 115.2
TOTAL 764.25

 Hotel
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
Air conditioning
10 3358 6pm-11pm 5hrs 33580 167.9
unit
2pm-5pm &
ceiling fan 10 60 6hrs 600 3.6
8pm-11pm
8am-12nn &
computer 5 350 8hrs 1750 14
2pm-6pm
10pm-11pm &
printer 1 18 3hrs 18 0.054
3pm-4pm
6am-8am &
coffee maker 3 1200 3hrs 3600 10.8
3pm-4pm
television sets 20 110 8am-4pm 8hrs 2200 17.6
fluorescent
15 40 6pm-6am 12hrs 600 7.2
lamp
bulb 20 18 6pm-6am 12hrs 360 4.32
10am-11am &
rice cooker 2 320 3hrs 640 1.92
5pm-7pm
vacuum 9am-11am &
5 630 4hrs 3150 7.15
cleaner 3pm-5pm
8am-10am &
dvd player 1 13 4hrs 13 0.052
2pm-4pm
water pump 2 2238 daily 24hrs 4476 107.42
TOTAL 342.016
 Machine Shops
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
milling 9am-12nn &
1 2500 5hrs 2500 12.5
machines 1pm-3pm
welding 10am-12nn &
2 13000 5hrs 26000 130
machines 1pm-4pm
compressor 1 3000 9am-12nn 3hrs 3000 9

4
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

10am-12nn &
pumps 1 2238 6hrs 2238 13.428
1pm-5pm
fluorescent
1 40 6pm-6am 12hrs 40 0.48
lamp
bulbs 5 18 6pm-6am 12hrs 90 1.08
9am-12nn &
ceiling fan 2 60 6hrs 120 0.72
1pm-4pm
9am-12nn &
exhaust fan 1 60 6hrs 60 0.36
1pm-4pm
9am-11am &
drill press 1 750 3hrs 750 2.25
2pm-3pm
9am-12nn &
electric fan 3 80 12hrs 240 2.88
1pm-4pm
oven toaster 1 1200 9am-12nn 3hrs 1200 3.6
9am-12nn &
lathe machine 1 2700 12hrs 2700 32.4
1pm-10pm
TOTAL 208.698
 Vulcanizing Shops
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
9am-11am &
compressor 1 3000 4hrs 3000 12
1pm-3pm
fluorescent
3 40 6pm-6am 8hrs 120 0.96
lamp
bulbs 2 18 6pm-6am 12hrs 36 0.432
electric fan 3 80 8am-8pm 12hrs 240 2.88
9am-11am &
drill press 1 750 4hrs 380 1.52
1pm-3pm
refrigerator 1 380 daily 24hrs 540 12.96
9am-11am &
radio 1 180 4hrs 110 0.44
1pm-3pm
television sets 1 110 8am-1pm 5hrs 350 1.75
welding 9am-12nn &
1 13000 5hrs 13000 65
machines 1pm-3pm
9am-12nn &
ceiling fan 1 60 6hrs 60 0.36
1pm-4pm
TOTAL 98.302
 Hardware
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
electric fan 3 80 8am-8pm 12hrs 240 2.88
refrigerator 4 380 daily 24hrs 1520 36.48
radio/karaoke 1 180 8am-1pm 5hrs 180 0.9
computer 2 350 8am-5pm 8hrs 760 6.08
bulb 3 50 8am-8pm 12hrs 150 1.8
ceiling fan 15 60 8am-5pm 8hrs 900 7.2
exhaust fan 15 80 daily 24hrs 1200 2808
TOTAL 55.34
 Bodegas
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
fluorescent
20 40 6pm-6am 12hrs 800 9.6
lamp
radio/karaoke 3 180 8am-1pm 5hrs 540 2.7
air conditioning
6 3358 2pm-7pm 5hrs 20148 100.74
unit

5
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

television sets 2 110 9am-2pm 5hrs 220 1.1

Computer 6 350 9am-2pm 5hrs 2100 10.5
exhaust fan 15 60 9am-3pm 6hrs 900 5.4
10am-11am &
Printer 2 18 3hrs 36 0.108
2pm-4pm
Bulb 20 50 daily 24hrs 1000 24
coffee maker 2 1200 6am-8am 2hrs 2400 4.8
Christmas lights 4 25 6pm-6am 12hrs 100 1.2
TOTAL 160.148
 Bakeries
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
electric fan 2 80 8am-5pm 8hrs 160 1.28
oven toaster 2 1200 8am-2pm 6hrs 2400 14.4
Refrigerator 1 380 daily 24hrs 380 9.12
fluorescent
4 40 8am-5pm 8hrs 160 1.28
lamp
television sets 1 110 8am-1pm 5hrs 110 0.55
TOTAL 26.63
 Gasoline Stations
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
fluorescent
15 40 5pm-5am 12hrs 600 7.2
lamp
8am-11am &
radio/karaoke 2 100 6hrs 360 2.16
1pm-4pm
air conditioning
4 3358 8am-8pm 12hrs 13432 161.184
unit
8am-11am &
television sets 2 110 6hrs 270 1.32
1pm-4pm
Computer 4 350 8am-5pm 8hrs 1400 11.2
9am-11am &
Compressor 2 30000 4hrs 6000 4
1pm-3pm
Bulb 7 50 6pm-6am 12hrs 350 4.2
coffee maker 2 1200 5am-9am 4hrs 2400 9.6
christmas lights 4 25 6pm-6am 12hrs 100 1.2
TOTAL 202.064
 Barber Shops
No. of Schedule of Schedule
Appliances Wattage total Wattage kw-hr
Appliances Use hr/day
electric fan 7 80 8am-8pm 12hrs 560 6.72
8am-10am &
Karaoke 1 180 5hrs 180 6.9
1pm-4pm
television sets 1 110 8am-8pm 12hrs 110 1.32
10am-12nn &
Charger 3 65 5hrs 195 0.975
1pm-4pm
Razor 3 110 8am-6pm 10hrs 330 3.3
TOTAL 19.215

5. Determining the total power requirement for the area.

Kw-hr
TIME LOAD VALUE
CONSUMPTION
1 9544.212 397.6755

6
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

2 9544.212 397.6755
3 9539.712 397.488
4 9539.712 397.488
5 9997.312 416.5546667
6 10218.112 425.7546667
7 9296.08 387.3366667
8 10194.026 424.7510833
9 10619.416 442.4756667
10 12484.247 520.1769583
11 18106.285 754.4285417
12 18017.097 750.712375
13 18450.117 768.754875
14 13034.507 543.1044583
15 12984.341 541.0142083
16 11067.911 461.1629583
17 12577.582 524.0659167
18 13563.946 565.1644167
19 13208.726 550.3635833
20 13162.296 548.429
21 12103.692 504.3205
22 11969.706 498.73775
23 11536.766 480.6985833
24 11365.212 473.5505
Average Load 507.161849

With the table above, we can now tabulate the data to obtain the load curve which would obtain the
specific Diesel Engine type, the number of units and the operation time the engine would run to provide
power.

900

800

700

600

500

400

300

200
kW consumption
100

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

With the load curve above, we can now propose the type of Diesel Engine by choosing the appropriate
unit comparative to the operational peak load in providing power to the community

7
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

900

800

700

600

500

400

300

200
kW consumption
100

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

6. Drawing the map of the area and indicating the customers in its zone
(Refer to the drawing at the last page)

7. Designing the Power Plant including each auxiliary

A. Cooling Water System
1. Required Circulating Cooling Water:

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Cooling System; pages 177 to 178; we are to use a cooling (preferably a forced draft
cooling tower) as it is minimal upon consideration cost, bulk, and auxiliary power. This
would provide an immediate cooling for the Diesel Engine’s frame jackets in the heated
parts. To obtain the circulating cooling water requirements, we are to use the equation
provided by several references. Based from Power Plant Engineering (Adapted to MKS
Units) by Frederick T. Morse; Cooling System; page 178; using the equation below we are
to use the given equation to obtain the required circulating cooling water.

Rated Bhp
W = 674.58
(t 1−t 2)
Where: W – circulating cooling water; liter per hour

Rated Bhp – Rated Brake horsepower

t1 – inlet temperature; °C

t2 – outlet temperature; ° C

Accordingly, we must first obtain the rated brake horsepower as readily provided in the
Diesel Engine type F8-138 Specification. Deviating from the law of conservation of energy
(simply stated as Energy In = Energy Out) then the rated horsepower of the engine would

8
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

be equal to the generator output. Losses would be present so the net efficiency would be
used to offset the generator output. Based from Power Plant Engineering (Adapted to
MKS Units) by Frederick T. Morse; Table A – 16: Normal Efficiencies of Engine type
Synchronous Generators; page 675; at a kilowatt rating of 560 kW with 450 rpm, by
interpolation we have 94.46%. Deductions upon this efficiency are also given. Based from
Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 6 – 3:
Standard Deduction (Engine Generator Efficiency); page 185; at a generator efficiency of
94.1% to 95% with a full load operation we deduct 1.2 so we have a 93.26% Net
Generator Efficiency. Therefore the rated break horsepower is equal to the equation
below.

GeneratorOutput
Rated Bhp =
Net Generator Efficiency
560 kW
=
0.9326
1 hp
= 600.47 kW ( )
0.7457 kW
Rated Bhp = 805.24 hp

Assuming that the temperature range would be 10° C, as most of the cooling tower range
applied in the industry from the manufacturer ranges from 5.6° C to 16.7° C, then we use
an assumed values of 75° C & 65° C for the inlet water temperature and outlet water
temperature respectively, we can now obtain the required circulating cooling water for the
cooling tower. With the 2 units we have 1610.48 hp. So the required circulating cooling
water is...

Rated Bhp
Wc = 674.58
(t 1−t 2)
1610.48 hp
= 674.58
(75 ° C−65° C)
Wc = 108639.76 Liters/hr

Based from Mark’s Standard Handbook for Mechanical Engineers, 9th Edition; Section 6:
Materials of Engineering; 6.1 General Properties of Materials; Specific Gravity and
Density of Water at Atmospheric Pressure; page 6 – 10; at 75° C the density of water is
974.86 kg/m3…

= 108639.76 L/hr (1hr/60mins) (1m3/1000L) (974.86 kg/m3)

Wc = 1765.14 kg/min

Therefore, we need 108639.76 Liters/hour or 1765.14 kg/min for the circulating cooling
water for the 2 Diesel Engine Genset units.

2. Water Jacket Circulating Pump:

9
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Based from Mark’s Standard Handbook for Mechanical Engineers, 9th Edition; Section 8:
Machine Elements; 8.7 Pipe, Pipe Fittings and Valves; Table 8.7.3 Properties of
Commercial Steel Pipes; page 8 – 149; assuming we are to use a nominal pipe size of 3
in outside diameter schedule 40 for the suction line pipe and a nominal pipe size of 2 ½ in
outside diameter schedule 40 for the discharge line pipe, the following data is given as
follows…

Suction line pipe:

Schedule 40
Outside diameter 3 in (3.5 in)
Inside diameter 3.068in (0.0779 m)

Discharge line pipe:

Schedule 40
Outside diameter 2.5 in (2.875 in)
Inside diameter 2.469 in (0.0627 m)

Computing for the specific velocity rate at both the suction and discharge we simply use
the given equation below…

Q = AV

Where: Q – volume flow rate; m3/min

A – Cross-sectional area; m2

V – Velocity of fluid; m/min

Also given for the area and deviating from the equation we have…

A = π d2/4

Where: A – Cross-sectional area; m2

d – Internal diameter; m

Thus,

4Q
V=
π d2
Computing now for the velocity at the suction we have…

4Q
Vs =
π d2

4 (1.811 m 3 /min)
=
π (0.0779m)2
Vs = 379.97 m/min (1min/60secs)

Vs = 6.33 m/sec

10
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Computing now for the velocity at the discharge we have…

4Q
Vd =
π d2

4 (1.811 m 3 /min)
=
π (0.0627 m)2
Vd = 586.53 m/min (1min/60secs)

Vd = 9.78 m/sec

Assuming that the pump is in the datum line, the height of delivery is 2.302 meters, the
storage is placed 4.5 meters below, a friction loss of 0.75; then with the given & computing
now for the discharge head…

Discharge head = FL+ZD+V

V 2D
Discharge head = FL+ZD+
2g
Where: FL – Friction losses for discharge; 0.75
ZD – Elevation from datum to discharge; 2.302 m
VD – Velocity head at discharge; 9.78 m/sec

V 2D
Discharge head = FL+ZD+
2g
m 2
(9.78 )
sec
Discharge head = 0.75 + 2.302 m +
m
2(9.81 )
sec 2
Discharge head = 3.052 m

Computing now for the suction head…

Suction head = FL + ZS + V
V 2S
Suction head = FL + ZS +
2g
Where: FL – Friction losses for suction; 0.75
ZS – Elevation from datum to suction; 4.5m (negative due to location)
VS – Velocity head at suction; 6.33 m/sec

V 2S
Suction head = FL + ZS +
2g

m 2
(6.33)
sec
Suction head = 0.75 – 4.5m +
m
2(9.81 )
sec 2

11
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Suction head = -1.71 m

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Chapter 13: The Gas Loop; 13 – 10 Water Pumps; pages 545 to 546; we use the
equations provided to obtain the required pump. As both the suction and discharge heads
are given, we can now obtain the pump operating head. With the given, the pump
operating head is…

Pump operating head = Discharge head – Suction head

Pump operating head = 3.052 m + 1.71 m

Pump operating head = 4.762 m

Assuming that the pump efficiency is 70 %, and then we have…

Q dw H
Pump supply power =
4500000 η p

Where: Q – Volume flow rate; 1811 liters/min

dw – Density of water; 1000 kg/m3

H – Pump operating head; 4.762 m

ηp – Pump efficiency; 70%

Q dw H
Pump supply power =
4500000 η p

1000 kg
1811 L /min( )( 4.762m)
Pump supply power = m3
4500000(0.70)
Pump supply power = 2.74 hp (2.75 hp)

Therefore, we are to use 2 ¾ hp water pumps for the water jacket transfer for each Diesel
Genset units.

3. Required Raw Water for the Cooling Tower:

Since most heat exchangers experience a steady state equation and deviating from the
energy balance equation [mC (hC1 – hC2) = mR (hR1 – hR2)] assuming that the
continuous flow would nullify the offsetting effects of density and enthalpy, and assuming
that temperature difference with 6° C of 34° C at inlet and 28° C at outlet, then we can
use the equation below for simplicity…

QC (tC1 – tC2) = QR (tR1 – tR2)

12
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Where: QR - Quantity of Raw Water circulating the cooling tower, Liter/min

QC - Quantity of Circulating Cooling Water; Liter/min

tR1 - temperature of raw water at outlet; 34° C

tR2 - temperature of raw water at inlet; 28° C

tC1 - temperature of jacket cooling water at inlet; 75° C

tC2 - temperature of jacket cooling water at outlet; 65° C

Using the equation, the quantity of raw water is…

QC (t C 1−t C 2 )
QR =
(t R 1−t R 2)

1811 L /min ⁡(75 °C−65 ° C)

=
(34 ° C−28 ° C )
= 3018.33 L/min

Based from Mark’s Standard Handbook for Mechanical Engineers, 9th Edition; Section 6:
Materials of Engineering; 6.1 General Properties of Materials; Specific Gravity and
Density of Water at Atmospheric Pressure; page 6 – 10; at 28° C the density of water is
996.242 kg/m3…

= 3018.33 L/min (1m3/1000L) (996.242 kg/m3)

WR = 3007 kg/min

4. Raw Water Pump:

Assuming that the parameters for the circulating water jacket pumps are the same with
the raw water pump, together with the assumptions, and then the requirements would be
close and be useful for the raw water pump computation…

Computing now for the velocity at the suction we have…

4Q
VS =
π d2

m3
4 (3.01833 )
VS = min
π (0.0779 m)2
VS = 633.29 m/min (1min/60 secs)

VS = 10.55 m/sec

Computing now for the velocity at the discharge we have…

13
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

4Q
VD =
π d2

m3
4 (3.01833 )
VD = min
π (0.0627 m)2
VD = 977.56 m/min (1 min/60 secs)

VD = 16.29 m/sec

Assuming that the pump is in the datum line, the height of delivery is 5 meters, the
storage is placed 4.5 meters below, a friction loss of 0.75; then with the given & computing
now for the discharge head…

Discharge Head = FL + ZD + V

V 2D
Discharge Head = FL + ZD +
2g
Where: FL = Friction Losses for Discharge; 0.75

ZD = Elevation from Datum to Discharge; 5 m

VD = Velocity Head at Discharge; 16.29 m/sec

V 2D
Discharge Head = FL + ZD +
2g

m 2
(16.29 )
sec
Discharge Head = 0.75 + 5m +
9.81 m
2( )
sec 2
Discharge Head = 19.28 m

Computing now for the suction head…

Suction Head = FL + ZS + VS

V 2S
Suction Head = FL +ZS +
2g
Where: FL = Friction Losses at Suction; 0.75

ZS = Elevation from Datum to Suction; 4.5 m (- due to location)

VS = Velocity Head at Suction; 10.55 m/sec

14
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

V 2S
Suction Head = FL +ZS +
2g

m 2
(10.55)
sec
Suction Head = 0.75 – 4.5 m +
9.81 m
2( )
sec 2
Suction Head = 1.92 m

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Chapter 13: The Gas Loop; 13 – 10 Water Pumps; pages 545 to 546; we use the
equations provided to obtain the required pump. As both the suction and discharge heads
are given, we can now obtain the pump operating head. With the given, the pump
operating head is…

Pump Operating Head = Discharge Head – Suction head

= 19.28 m - 1.92 m

Pump Operating Head = 17.36 m

Assuming that the pump efficiency is 70 %, and then we have…

Q dw H
Pump supply power =
4500000 η p

Where: Q – Volume flow rate; 3018.33 L/min

dw – Density of water; 1000 kg/m3

H – Pump operating head; 17.36 m

ηp – Pump efficiency; 70%

Q dw H
Pump supply power =
4500000 η p

1000 kg
3018.33 L/min( )(17.36 m)
Pump supply power = m3
4500000(0.70)
Pump supply power = 16.63 hp (16.75 hp)

Therefore, we are to use 16 ¾ hp water pump for the raw water transfer.

5. Required Quantity of Make-up Water:

15
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Chapter 6: Internal Combustion Engine Power Plant; 6-7 Evaporative Cooling; page 181;
using the given mass balance and heat balance equations we can obtain the required
make up water for the cooling tower.
For mass balance we use…
1 kg air + SH1 + WW + ΔW = 1 kg air + SH2 + WW

Deviating for simplicity we have…

ΔW = SH2 – SH1

For heat balance we use…

h1 + WWhfa + ΔWhf = h2 + WWhfb

Deviating for simplicity we have…

(h ¿ ¿ 1−h 2)
WW = −ΔW hf + ¿
h fa −hfb

Where: SH1 = Humidity Ratio of Entering Air; kg moisture/kg dry air

SH2 = Humidity Ratio of Leaving Air; kg moisture/kg dry air

WW = Water Circulating per kg of dry air; kg

ΔW = Make-up Water per kg of dry air; kg

h1 = Enthalpy of Moist Air Leaving; kJ/kg of dry air

h2 = Enthalpy of Moist Air Entering; kJ/kg of dry air
hfa = Enthalpy of Water in the Spraying Nozzles; kJ/kg
hfb = Enthalpy of Water in the Basin; kJ/kg
hf = Enthalpy of Make-up Water; kJ/kg
Assuming we are given the following relative humidity and temperatures…

Relative Humidity:

Entering Air = 60%

Leaving Air = 90%

Temperature:

Entering = 28° C DB

Leaving = 34° C DB

WBT = 21° C

16
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Based from Mark’s Standard Handbook for Mechanical Engineers; 9th Edition; Figure
12.4.13: Psychometric Chart in SI Units; page 12 – 97; the following are given and
obtained so we have..

At a R.H. 60% and dry bulb temperature of 28° C at entering point…

SH1 = 0.01425 kg moisture/kg dry air

At a R.H. 90% and dry bulb temperature of 34° C at leaving point…

SH2 = 0.031 kg moisture/kg dry air

Based from Refrigeration & Air Conditioning by W. F. Stoecker & J. W. Jones; Table A-2:
Moist Air; pages 418 to 419, with the assumed temperatures the enthalpy are as follows…
At 28° C, h1 = 89.952 KJ/kg
At 34° C, h2 = 122.968 KJ/Kg

Using the equation of mass balance we use…

ΔW = SH2 – SH1

= (0.031 – 0.01425) kg moisture/kg dry air

ΔW = 0.01675 kg moisture/kg dry air

Based from Refrigeration & Air Conditioning by W. F. Stoecker & J. W. Jones; Table A-1:
Water: Properties of Liquid and Saturated Vapor; pages 416 to 417, with the assumed
temperatures the enthalpy are as follows…

At 34° C, hfa = 142.38 KJ/Kg

At 28° C, hfb = 117.31 KJ/kg

Assuming we have a make-up water temperature of 18° C; based from Refrigeration & Air
Conditioning by W. F. Stoecker & J. W. Jones; Table A-1: Water : Properties of Liquid and
Saturated Vapor; pages 416 to 417; with the assumed temperature the enthalpy and
pressure is…

hf = 75.50 KJ/kg, p = 2.062 kPa

Using the equation of energy balance we have…

(h ¿ ¿ 1−h 2)
WW = −ΔW hf + ¿
h fa −hfb

−(0.01675 x 75.50)+122.968 – 89.952

=
142.38 – 117.31
WW = 1.27 kJ/kg dry air
Since 3007 kg/min of raw water is given, the air flow is…

3007 kg / min
Air flow =
1.27 kg moisture /kg dry air

17
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Air flow = 2367.72 kg/min

Based from Mark’s Standard Handbook for Mechanical Engineers; 9th Edition; Figure
12.4.13: Psychometric Chart in SI Units; page 12 – 97; the following are given and
obtained so we have…

DB temperature = 28° C

WB temperature = 21° C

The specific volume, v, is 0.87 m3/kg dry air…

Then the air flow would be…

Air Flow = 2367.72 kg/min (0.87 m3/kg)

Air Flow = 2059.92 m3/min

The required make-up water then is…

Make-up Water = 2367.72 kg/min x 0.01675

39.66 kg/min(1000liters /m3 )

Make-up Water =
(999.706 kg /m3 )
Make-up Water = 39.67 L/min

6. Forced Draft Fan:

Based from [Link]

%[Link], we are to choose a fan that would provide a capacity of air flow of
2059.92m3/min or 72745.39ft3/min.

We select a fan with the following size…

Fan Size: 60 TA Direct Drive Tubeaxial

Motor hp: 20 hp
Rpm: 870
Capacity: 73948ft3/min
Static Pressure: 1/4 in SP
7. Size of Cooling Tower:

For the total cooling requirements we must first obtain the total cooling water
requirements…

Water Requirements = Circulating Jacket Water + Raw Water

= 1811 Liters/min + 3018.33 Liters/min

= 4829.33 Liters/min x (1 gallon/3.7854 Liters)

Water Requirements = 1275.78 gpm

18
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Assuming we have water concentration of 3.0 gpm per ft2, then the area of the cooling
tower is…

Area of Cooling Tower = 1275.78 gpm / (3.0 gpm/ft2)

= 425.26 ft2

Assuming we have a square sized cooling tower, then the size of the cooling tower would
be…

Side of the Cooling Tower = √ 425.26 ft 2

Side of the Cooling Tower = 20.62 ft

So the dimensions of the cooling tower that would service the diesel engines are 20.62 ft
x 20.62 ft or 6.28 m x 6.28 m.

B. Fuel System

1. Fuel Oil Consumption:

Our design requires 3 units of F8-138 Diesel Engines with 560 kW generator rating; 1 unit
is continuous in operation; another unit for 10 am to 3 pm shift; another unit as a reserve;
all of which are capable of continuous operation at least for a limited duration of time
assuming that maintenance to either one of them is required. A future expansion is also
provided. Our plant capacity factor is given at 60%.

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Table A – 16: Normal Efficiencies of Engine type Synchronous Generators; page 675 ; at a
kilowatt rating of 560 kW with 450 rpm, by interpolation we have 94.46 %. Deductions
upon this efficiency are also given.
Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Table 6 – 3: Standard Deduction (Engine Generator Efficiency); page 185 ; at a generator
efficiency of 94.1 % to 95 % with a full load operation we deduct 1.2 so we have a 93.26
% Net Generator Efficiency.

From the statement above we can now obtain the fuel consumption for the plant. Based
from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Figure 6 –
15: Range of Variable Load Performance of Diesel Plants; page 164 ; at 60% rated load
the fuel consumption is about 0.1625 kg/kW-hr. With such the maximum rate of fuel usage
would be as follows…

560 kW (2)
Maximum Rate of Fuel =
0.9326
= 1200.94 kW (0.1625 kg/kW-hr)
Maximum Rate of Fuel = 195.15 kg/hr

For a 24 hours operation of the 2 units, then maximum rate of fuel usage would be given
as follows…

Maximum Rate of Fuel Use = 195.15 kg/hr x 24 hr/day

Maximum Rate of Fuel Use = 4683.6 kg/day

19
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Based from Mark’s Standard Handbook for Mechanical Engineers, 9th Edition, Section 7:
Fuels & Furnaces; Table 7.1.9 Analyses and High Heat Values of Crude Petroleum,
Typical Distillates, and Fuel Oils; page 7 – 13; assuming we are using a California grade
fuel oil, with a specific gravity of 0.9554 at 60° F, then the fuel consumption in terms of
mass would be..

Fuel Consumption = (4683.6 kg/day) / 0.9554

Fuel Consumption = 4902.24 kg/day

Based from Mark’s Standard Handbook for Mechanical Engineers, 9th Edition; Section 6:
Materials of Engineering; 6.1 General Properties of Materials; Approximate Specific
gravities & Densities; page 6 – 8; as most industrial oils have an average density of 914
kg/m3 and obtaining for its specific volume then we have 1.094 x 10-3 m3/kg then the fuel
consumption in terms of volume would be..

Fuel Consumption = (4902.24 kg/day) (1.094 x 10-3 m3/kg)

= (5.363m3/day) (1000 Liters/m3)

Fuel Consumption = 5363 Liters/day

2. Required Storage of Fuel Oil:

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Figure 6 – 15: Range of Variable Load Performance of Diesel Plants; page 164; at 60%
plant capacity the kilowatt-hour per liter oil ranges from 2.5 to 3.49 liters. One (1) Diesel
Genset unit will operate continuously while another for 5 hours each per day at peak
loads. For fuel consumption for within a 45 day supply we have…

Required Storage = 45 days (5363 Liters/day)

Required Storage = 241335 Liters

3. Dimensions of the Fuel Oil Storage Tank:

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Table 12 – 4: Dimension of the Bulk Storage Tank; page 459 ; with a required storage of
241335 liters then we are to use 3 tanks with a capacity of 109715 liters each, the
dimensions of a cylindrical bulk tank is given as follows…

Diameter: 3.05 m
Length: 15.04 m
Plate Thickness: 7.94 mm
Weight: 10399 kg

4. Required Storage of Day Tank:

As the operation in motion, the greatest consumption of each diesel engine will occur at its
full load rating. Let the day tank volume be good for a 1 day (24 hours) operation. At full
load rating, maximum full load consumption would be…

195.15 kg/hr x 24 hrs = 4683.6 kg

20
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

For a 1 day operation, assume that the day tank will charge 4683.6 kg per day. Since the
fuel oil is cooled during the transfer & operation we must obtain the value to compute the
volume. Assuming we are using a California grade fuel oil, based from Mark’s Standard
Handbook for Mechanical Engineers, 9th Edition, Section 7: Fuels & Furnaces; Table 7.1.9
Analyses and High Heat Values of Crude Petroleum, Typical Distillates, and Fuel Oils;
page 7 – 13; at 60° F (15.6° C) the specific gravity of it would be 0.9554. Based from
Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 5: Fuels
& Combustion; Internal Combustion Engine Fuel; pages117 to 119; Using API (American
Petroleum Institute) standard, assuming an oil temperature of 6° C and the equations 5 –
3, the °API would be…

141.5
°API = - 131.5
S . G . at 15.6/15.6 °
141.5
= – 131.5
0.9554
°API = 16.61° API or 17° API

The density of oil at 15.6°C (60° F) would be equal to the specific gravity at such
temperature. Based from Power Plant Engineering (Adapted to MKS Units) by Frederick
T. Morse; Chapter 5: Fuels & Combustion; Internal Combustion Engine Fuel; pages117 to
119; the volumetric coefficient of expansion of oil is 0.0007 per °C. The contractions of oil
at 6° C we have…

Contraction from a 6° C cooling = 0.0007 x 6

= 0.0042

The density of fuel oil at 6° C would be…

Density at 6° C = 0.9554 / 0.9958

= 0.9981 kg/liter

The volume would now be equal to…

V = 4683.6 kg / 0.9981 kg/liter

= 4692.52 liters (1m3/1000 Liters)

V = 4.69 m3

Assuming a 15 minute charging for the day tank, the volume flow rate would be…

Q = 4.69 m3 / 15 min

= 0.3127 m3/min (1000 Liters/m3)

Q = 312.7 Liters/min

21
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

5. Dimensions of the Fuel Oil Day Tank:

Given a volume of 4.69 m3 and assuming we have a cylindrical day tank, then using the
following equation below we can obtain the dimension required for the day tank…

π d2
V= h
4

Where: V = Volume of the cylinder; m3

d = Diameter of the cylinder; m
h = Height or Length of the cylinder; m

Assuming we have a 2.5 m length of the day tank, deviating from the dimension and
computing for the diameter we have…

4V
d2 =
πh

4 (4.69 m 3)
d =
2

π (2.5 m)

18.76 m 3
d2 =
π (2.5 m)
d2 = 2.39 m2

d = 1.55 m

Therefore, the dimension of the day tank is 1.55 m diameter by 2.5 m length cylindrical
tank per Diesel Engine.

6. Fuel Oil Transfer Pump:

Based from Mark’s Standard Handbook for Mechanical Engineers, 9th Edition; Section 8:
Machine Elements; 8.7 Pipe, Pipe Fittings and Valves; Table 8.7.3 Properties of
Commercial Steel Pipes; page 8 – 148; assuming we are to use a nominal pipe size of 1
½ in outside diameter schedule 40 for the suction line pipe and a nominal pipe size of 1 ¼
in outside diameter schedule 40 for the discharge line pipe, the following data is given as
follows…

Suction Line Pipe:

Schedule 40
Outside Diameter 1 ½ in (true size of 1.9 in)
Inside Diameter 1.610 in (or 0.0409 m)
Discharge Line Pipe:
Schedule 40
Outside Diameter 1 ¼ in (true size of 1.660 in)
Inside Diameter 1.380 in (or 0.0351 m)

22
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Computing for the specific velocity rate at both the suction and discharge we simply use
the given equation below…

Q = AV

Where: Q = Volume Flow Rate; m3/min

A = Cross-Sectional Area; m2

V = Velocity of Fluid; m/min

Also given for the area and deviating from the equation we have…

A = π d2/4

Where: A = Cross-sectional Area; m2

d = Internal Diameter; m

4Q
V=
π d2
Computing now for the velocity at the suction we have…

4Q
VS =
π d2

0.313 m3
4( )
= min
π (0.0409 m)2
VS = 238.24 m/min (1min/60secs)
VS = 3.97 m/sec
Computing now for the velocity at the discharge we have…

4Q
VD =
π d2

0.313 m3
4( )
= min
π (0.0351m)2
VD = 323.47 m/min (1min/60secs)
VD = 5.39 m/sec
Assuming that the pump is in the datum line, the height of delivery is 4.5 meters, the
storage is placed 2.5 meters below, a friction loss of 0.75; then with the given & computing
now for the discharge head…

23
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Discharge Head = FL + ZD + V

V 2D
Discharge Head = FL + ZD +
2g
Where: FL = Friction Losses for Discharge; 0.75

ZD = Elevation from Datum to Discharge; 4.5 m

VD = Velocity Head at Discharge; 5.39 m/sec

V 2D
Discharge Head = FL + ZD +
2g

5.39 m 2
()
sec
Discharge Head = 0.75 + 4.5 +
m
2(9.81 )
sec 2
Discharge Head = 6.73 m

Computing now for the suction head…

Suction Head = FL + ZS + V

V 2S
Suction Head = FL + ZS +
2g
Where: FL = Friction Losses at Suction; 0.75

ZS = Elevation from Datum to Suction; 2.5 m (- due to location)

VS = Velocity Head at Suction; 3.97 m/sec

V 2S
Suction Head = FL + ZS +
2g

3.97 m 2
( )
sec
Suction Head = 0.75 – 2.5 +
m
2(9.81 )
sec 2
Suction Head = -0.95 m

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Chapter 13: The Gas Loop; 13 – 10 Water Pumps; pages 545 to 546; we use the
equations provided to obtain the required pump. As both the suction and discharge heads
are given, we can now obtain the pump operating head. With the given, the pump
operating head is…

24
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Pump Operating Head = Discharge Head – Suction head

= 6.73 m + 0.95 m

Pump Operating Head = 7.68 m

Assuming that the pump efficiency is 70 %, and then we have…

Q do H
Pump supply power =
4500000 η p

Where: Q = Volume Flow Rate; 312.7 Liters/min

dO = Density of oil; 914 kg/m3 (or 0.914 kg/liters)

H = Pump Operating Head; 7.68 m

ηP = Pump Efficiency; 70 %

Q do H
Pump supply power =
4500000 η p

kg
312.7 Liters /min( 914 )(7.68 m)
= m3
4500000(0.70)
Pump supply power = 0.70 hp

Therefore, we are to use 3/4 hp oil pump for the fuel oil transfer.

C. Air System

1. Air Intake System:

The air intake system usually consists of air intake duct or pipe appropriately supported, a
silencer, an air cleaner, and flexible connections as required. This arrangement permits
location of area of air intake beyond the immediate vicinity of the engine, provides for the
reduction of noise from intake air flow, and protects vital engine parts against airborne
impurities. The air intake will be designed to be short and direct and economically sized
for minimum friction loss. The air filter will be designed for the expected dust loading,
simple maintenance, and low pressure drop. Oil bath or dry filter element air cleaners will
be provided. The air filter and silencer may be combined.

Based from Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T.
Morse; Chapter 6: Internal Combustion Engine Power Plant; 6 – 6: Auxiliary Systems;
Intake & Exhaust Passages; pages 174; an engine needs from 0.056 to 0.084 m3 of air
per min per hp developed.

Assuming we have maximum intake of 0.084 m3/min of air per hp developed during
operation, with 560 kW (or 750.97 hp) then the flow rate of the discharge would be…

Q = (0.084 m3/min-hp) / (750.97 hp)

25
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Q = 63.08m3/min

Assuming we have a flow velocity of 800 m/min, then the dimensions of the intake pipe
would be…

A = (63.08 m3/min) / (800 m/min)

A = 0.07885 m2

Thus, the area of the pipe is…

A = πd2/4

Where: A – Area

d – Diameter

d = (4A/π)1/2

d = (4*0.07885 m2/π)1/2

d = 0.32 m

The diameter of the intake pipe would be 0.32 meter or 320 mm. Therefore, we are to use
a pipe with such diameter.

2. Exhaust System:

The exhaust system consists of a muffler and connecting piping to the atmosphere with
suitable expansion joints, insulation, and supports. In cogeneration plants, it also provides
for utilization of exhaust heat energy by incorporating a waste heat boiler which can be
used for space heating, absorption refrigeration, or other useful purpose. This boiler
produces steam in parallel with the vapor phase cooling system. The exhaust silencer
attenuates exhaust gas pulsations (noise), arrests sparks, and in some cases recovers
waste heat. The muffler design will provide the required sound attenuation with minimum
pressure loss.

Based from Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T.
Morse; Chapter 6: Internal Combustion Engine Power Plant; 6 – 6: Auxiliary Systems;
Intake & Exhaust Passages; pages 175 to 76 ; the exhaust system must carry
approximately 0.168 – 0.224 m3/min of gases per hp developed.

Assuming we have a maximum discharge of 0.224 m3/min of gases per hp developed on

an average exhaust temperature, with 560 kW (or 750.97 hp) then the flow rate of the
discharge would be…

Q = (0.224 m3/min) (750.97 hp)

Q = 168.22 m3/min

Assuming we have a flow velocity of 1500 m/min, then the dimensions of the exhaust pipe
would be…

A = (168.22 m3/min) / (1500 m/min)

26
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

A = 0.112 m2

Thus the area of the pipe is…

A = πd2/4

Where: A – Area

d – Diameter

d = (4A/π)1/2

d = (4*0.112 m2/π)1/2

d = 0.38 m

The diameter of the exhaust pipe would be 0.38 meter or 380 mm. Therefore, we are to
use a pipe with such diameter.

3. Air Starting System:

The vast majority of diesel engines installed in power plants are started with compressed
air. Compressed air is directed by a distributor directly into the combustion chamber or is
provided to an air motor which rotates the engine. Dedicated compressors typically
provide starting air at 250 psig. The system must provide adequate storage to allow
multiple attempts to start the engines. The compressed air start system will included two
air compressor units, each with diesel engine-electric motor drive, and two main air
storage tanks. The compressors will be rated at 250 psig operating pressure, and each
will have a capacity capable of restoring any single storage receiver from 150 psig to 250
psig in 30 minutes or less. Each main storage tank will provide adequate air to the
individual air start tanks at each diesel engine, supply air to the utility shop air outlets, and
provide a second source to air to the instrument air system. Each air start tank will be
sized to provide two 30 - second start sequences without recharging and will be rated at
300 psig working pressure. Each main storage tank will have a volume equal to three air
start tanks plus a volume equal to one instrument air receiver, and an additional volume to
supply the utility shop air requirement.

Therefore, we need 4 units of Air Compressors for the 2 Diesel Engines. Both Air
Compressors must have a 250 psig operating pressure. This working pressure is uniform
regardless of the diesel engine size.

4. Required Capacity Air Storage Tank:

Assuming we are using a two stage air compressor with a 250 psig working pressure and
a compressor power of 200 hp. Based from
[Link] with the topic
Compressed Air Receivers and using the provided tables…

Recommended Receiver Volume per HP

Compressor Power Recommended Receiver Volume

27
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

(hp) kW Ft3 Gal m3

125 93.3 67 500 1.9
200 149.2 107 800 3.0
350 261.1 188 1400 5.3

For the storage tank, assuming the storage volume is twice that of the air receiver and the
utility shop requirements consumes half of the receiver, then the air storage volume would
be…

Total Volume = 3 m3 + (3 m3 *2) + (3 m3 *0.5)

Total Volume = 10.5 m3 = 370.8 ft3

5. Dimensions of the Air Storage Tank:

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Table 12 – 4: Dimension of the Bulk Storage Tank; page 459 ; with a required storage of
10.5 m3 or 10500 liters then we are to use a tank of the next closest value of 11860 liters,
the dimensions of a cylindrical bulk tank is given as follows…
Diameter 2.44 m
Length 2.54 m
Plate Thickness 6.35 mm
Weight 1844 kg

D. LUBRICATION SYSTEM

1. Daily Lubricating Oil Consumption:

Lubrication is essential to any machine element; this includes the diesel engines as well
as its auxiliaries. Our design requires 3 units of F8-138 Diesel Engines with 560 kW
generator rating; 1 unit is continuous in operation; another unit for 10 am to 3 pm shift;
another unit as a reserve; all of which are capable of continuous operation at least for a
limited duration of time assuming that maintenance to either one of them is required. A
future expansion is also provided. Our plant capacity factor is given at 60%.

From the discussion above we have a 93.26 % Net Generator Efficiency for each engine
during the operation. The brake horsepower would then be the same as the obtained.
Therefore, the brake horsepower is equal to…

GeneratorOutput
Rated Bhp =
Net Generator Efficiency
560 kW
=
0.9326
= 600.47 kW

28
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

For a continuous operation, the generated power would be…

Generated Power = 600.47 kW * 24 hours

Generated Power = 14411.28 kW-hour

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse;
Chapter 6: Internal Combustion Engine Power Plant; 6 – 6: Auxiliary Systems;
Lubrication; page 174; most diesel power plants have an average consumption of 1 gallon
of Lubricating oil per 1600 kW-Hour generated at full load rating. For both the diesel
engines that operates continuously, then the total generated power would be..

Generated Power = 14411.28 kW-hour + (600.47kW *6 hours)

Generated Power = 18014.1 kW-hour

Since 1 gallon of Lubricating oil per 1600 kW-Hour generated at full load rating is give as
an average consumption for lubrication, for one day consumption, we have…

Oil Consumption = (18014.1 Kw-Hr) x (1 gallons / 1600 kW-Hr)

= 11.26 gallons/day

Similarly with the fuel oil, assuming that the delivery of lube oil is every 45 days, the oil
consumption…

Oil Consumption = 11.26 gallons/day * 45 days

= 506.7 gallons

2. Dimensions of the Lube Oil Storage Tank:

By conversion…
Volume = 506.7 gallons*(3.7854 Liters/gallons)*(1 x 10-3 m3/1 Liters) Volume =
1.92 m3

Assuming that the tank is filled within 5 minutes as compared for the fuel oil, then…

Volume Flow Rate = 1.92 m3 / 5 min

= 0.384 m3/min

Volume Flow Rate = 384 Liters/min

Using a cylindrical drum for storage with a 1 meter diameter, the length could be obtained
and so is the dimension…

Volume = (π x d2 / 4) x L

Length = (1.92 m3 x 4) / (π x 1 m2)

Length = 2.44 m

The dimensions of the lube oil tank would be in 1 m diameter by 2.44 m length.

29
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

3. Lube Oil Transfer Pump:

Assuming that the fuel oil and the lube oil storage tanks and discharge settings are the
same, together with the assumptions, then the requirements would be close and be useful
for the lube oil transfer pump computation…

Computing now for the velocity at the suction we have…

4Q
VS =
π d2

0.384 m3
4( )
= min
π (0.0409 m)2
VS = 292.28 m/min (1min/60secs)
VS = 4.87 m/sec
Computing now for the velocity at the discharge we have…

4Q
VD =
π d2

0.384 m3
4( )
= min
π (0.0351m)2
VD = 396.85 m/min (1min/60secs)
VD = 6.61 m/sec
Assuming that the pump is in the datum line, the height of delivery is 4.5 meters, the
storage is placed 2.5 meters below, a friction loss of 0.75; then with the given & computing
now for the discharge head…

6.61m 2
( )
sec
Discharge Head = 0.75 + 4.5 +
m
2(9.81 )
sec 2
Discharge Head = 7.48 m

Computing now for the suction head…

4.87 m 2
( )
sec
Suction Head = 0.75 – 2.5 +
m
2(9.81 )
sec 2

30
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Suction Head = -0.54 m

As both the suction and discharge heads are given, we can now obtain the pump
operating head. With the given, the pump operating head is…

Pump Operating Head = Discharge Head – Suction head

= 7.48 m + 0.54 m

Pump Operating Head = 8.02 m

Assuming that the pump efficiency is 70 %, and then we have…

Q do H
Pump supply power =
4500000 η p

Where: Q = Volume Flow Rate; 384 Liters/min

dO = Density of oil; 914 kg/m3 (or 0.914 kg/liters)

H = Pump Operating Head; 8.02 m

ηP = Pump Efficiency; 70 %

Q do H
Pump supply power =
4500000 η p

kg
384 Liters /min (914 )(8.02 m)
= m3
4500000(0.70)
Pump supply power = 0.89 hp

Therefore, we are to use 1 hp oil pump for the lube oil transfer.

8. Designing the foundation of the engine

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Chapter 4: The Power
Plant Building; Foundation; pages 105 to 113; & The PSME Code; we are to use the following equations to
design the Diesel Engine Foundations…

A. Given in the Diesel Engine Specifications:

Engine Length: 7.468 m

Engine Width: 2.299 m
Engine Weight: 29484 kg
B. For the Length of the Machine Foundation, LF:

LF = LB + 2c

Where: LF = Length of the Machine Foundation; m or ft

LB = Length of the Bed plate (given in Machine Specs); m or ft

31
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

c = Clearance; 1 foot or 10% of the length of the bed plate

LF = LB + 2c
LF = 7.468 m + (2*0.7468 m)
= 7.468 m + 1.494
LF = 8.962 m
C. For the Width of the Machine Foundation, a:

a = w + 2c

Where: a = Width of the Machine Foundation; m or ft

w = Width of the Bed plate (given in Machine Specs); m or ft
c = Clearance; 1 foot or 10% of the length of the bed plate

a = w + 2c
a = 2.299 m + (2 x 0.2299 m)
= 2.299 m + 0.4598 m
a = 2.759 m
D. For the Weight of the Machine Foundation, WF:

Based from The PSME Code of 1993, Chapter 2; Commercial and Industrial Building; Article 2.4
Machinery & Equipment; Section 4.4.1-2, p. 9, the weight of foundation should be 3 to 5 times the
weight of the machinery. Using 5 times to maximize the design…

WF = mass of the machine x desired multiplier

= 29484 kg x 5
WF = 147420 kg
E. For the Base Width of the Machine Foundation, b:

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 4-4.
Safe Bearing Power of Soils, page 105 & Mark’s Standard Handbook for Mechanical Engineers,
9th Edition, Revised by Eugene Avallone & Theodore Baumester III, Design of Structural
Members, Table 12.2.6 Safe Bearing of Soils, p. 12 - 21 , we must use at least best brick masonry
or higher for the safe bearing for our Diesel Engines, Using the Best Brick Masonry with a safe
bearing capacity of 145 to 195 Tons/m2 and using the given equation we have…

SB W M+ W F
=
N b Lf

Where: SB = Safe Soil Bearing Capacity; tons/m2 (195 tons/m2 or 195000 kg/m2)

WM = Weight of the Machine; kg

WF = Weight of the Machine Foundation; kg

b = Base Width of the Machine Foundation; m

LF = Length of the Machine Foundation; m

N = Safety Factor; usually a value of 2

32
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Deviating from the equation & computing we have…

N (W M + W F )
b=
S B LF

2(29484 kg+ 147420 kg)

b=
195000 kg /m 2 (8.962m)
b = 0.20 m

Since the lower width is less than the width of the machine foundation, then let the lower width be
equal to the width. Therefore, b = 2.759 m.

F. For the Volume of the Machine Foundation, VF:

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 4-2:
Approximate Weights of Building Material; page 90; using reinforced concrete as our base material
and using its approximate density we have ρ = 2406 kg/m³…

VF = WF / ρ

147420 kg
VF =
2406 kg/m ³
VF = 61.27 m3

G. For the Depth of the Machine Foundation, HF:

Since the width and the lower width are equal, then we have a rectangular block as for our
foundation. The width, WF, would be equal to the width of the foundation.

VF = LF * WF * HF

VF
HF =
LF W F

61.27 m3
=
8.962m(2.759 m)

HF = 2.48 m

H. Materials for the Machine Foundation:

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Table 4-1:
Data on Concrete Mixes to Yield 1 cu. m Concrete; page 90 ; using a mixture of [Link] as it is often
used for foundations we have the following data…

Using a Mixture of [Link] (1 part of cement, 3 parts of sand, and 5 parts of stone) to produced 1 cu.
meter of concrete using [Link] mixtures, the ff. are needed:

33
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

6.2 sacks of cement

0.52 m3 of sand
0.86 m3 of stone

We are given 6.2 sacks of cement per m3 & 3 units of Diesel Engines and computing for the
quantity or required numbers of sacks we have…

= 6.2 sacks x 3 x 61.27 m3

= 1139.62 or 1140 sacks

Computing for the quantity or volume of sand for the mixture we have…

= 0.52 m3 x 1140 sacks

= 592.8 m3

Computing for the quantity or volume of gravel or stone for the mixture we have…

= 0.86 m3 x 1140 sacks

= 980.4 m3

I. Anchor Bolts:

Based from The PSME Code of 1993, Anchor Bolts should be embedded in the concrete at least
30 times to the Bolt Diameter. Assuming a diameter of 25 mm of the Anchor Bolts then the length
of the Anchor Bolts is…

LAB = 25 mm x 30
LAB = 750 mm or 0.75 m
J. Length of Sleeves, LS:

Based from The PSME Code of 1993, Chapter 2; Commercial and Industrial Building; Article 2.4
Machinery & Equipment; Section [Link], page 9; the length of the sleeve should be 18 times that
of the bolt diameter. Therefore we have…

LS = Bolt Diameter x 18
= 25 mm x 18
LS = 450 mm or 0.45 m
K. Internal Diameter of Sleeves, DS:

Based from The PSME Code of 1993, Chapter 2; Commercial and Industrial Building; Article 2.4
Machinery & Equipment; Section [Link], page 9; the internal diameter of the sleeve should be 3
times that of the bolt diameter. Therefore we have…

Ds = Bolt Diameter x 3

= 25 x 3

Ds = 75 mm or 0.075 m
L. Number of Steel Bars, NSB:

34
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Number of Steel Bars, NSB: Based from Mark’s Standard Handbook for Mechanical Engineers; 9th
Edition; Section 6: Materials of Engineering; 6.2 Iron & Steel; Weights of Square & Round Bars;
page 6-46; with a 1 in (25.4 mm) round steel bar for our foundation it is given that it has 2.670 lb/in.
Converting we have 3.97 kg/m as for its weight. Using the given formula we have…

NSB = WF x m%/ WSB

Where: NSB = Number of Steel Bars

WF = Weight of the Machine Foundation
m% = percent multiplier; ½ % to 1%
WSB = Weight of the Steel Bars; kg

Computing for the required number of steel bars as obtained from the data above, we have…

NSB = WF x m% / WSB

= 147420 kg x 0.01 / 3.97 kg

NSB = 371.34 or 372 pieces

M. Total Length of the Steel Bars, LSB:

Since most of the manufactured steel bars in the market have a standard length of 6.1 m, then we
simply have…

LSB = NSB x 6.1 m

= 372 x 6.1 m
LSB = 2269.2 m

9. Specifying the required diesel power units

Diesel Engines are preferable as an internal combustion component in all internal combustion
engine type power plants. They are good and reliable substitute as power plants in places where
the supply of coal and water is not available in a desired quantity and for operations where it
requires continuity and for standby and emergency purposes. Based from Power Plant
Engineering by A. J. Raka, A. P. Srivastava, M. Dwivedi; Chapter 8: Diesel Power Plant; 8.4
Advantage of Diesel Power Plant & 8.5 Disadvantage of Diesel Power Plant; the advantages &
disadvantages for using Diesel Engines includes the following..

Advantages:
1. Limited cooling water requirement.
2. Standby losses are less as compared to other Power plants.
3. Low fuel cost.
4. Quickly started and put on load.
5. Smaller storage is needed for the fuel.
6. Layout of power plant is quite simple.
7. There is no problem of ash handling.
8. Less supervision required.
9. For small capacity, diesel power plant is more efficient as compared to steam
power plant.

35
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

10. They can respond to varying loads without any difficulty.

Disadvantages:
1. High maintenance and operating cost.
2. The plant cost per kW is comparatively more.
3. The life of diesel power plant is small due to high maintenance.
4. Noise is a serious problem in diesel power plant.
5. Diesel power plant cannot be constructed for large scale.

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T. Morse; Fig. 6-33;
Dimensions of Nordberg 4-cycle Unsupercharged & Supercharged Engines; page 186; we are to
use 3 units of F8-135 Diesel Engines (1 unit is continuous in operation; another unit for 7 am to 8
pm shift; another unit as a reserve; all of which must be capable of continuous operation at least for
a limited duration of time) as based from our load curve.

Diesel Engine Specifications:

Engine Type: F8-138 Diesel Engine

Engine Height: 2.302 m
Engine Length: 7.468 m
Engine Width: 2.299 m
Engine Weight: 29484 kg
Generator kW Rating at 450 RPM: 560 kW Units: 3 Units (1 unit operating continuously; 1
unit that operates at 7 am to 8 pm shift; 1 unit
reserve; all are capable of continuous
operation)
10. Providing space for future expansion
(See the drawing)

11. Design the Power house building

12. Prepare the working schedule of the project

PROPOSED SCHEDULE OF WORK & ESTIMATE TIME OF COMPLETION

Assuming we start the project at the month of January of 2020, then we are to follow the proposed
schedule given below…

36
Romblon State University |Department of Agricultural Engineering
BS Mechanical Engineering
POWERPLANT ENGINEERING| Second Semester | School Year 2019-2020

Time & Month Target Work Output Relevance

Load Survey for the consumer Initial work frame for the
kilowatt consumption; project; idealization for the
Gathering & surveying of the project’s continuity
January to March 2020 environment within the
location; Planning & securing
necessary permits

Computation for the required Initial work frame for the

plant operation which includes plant’s construction &
the following: Selection of operation; Idealization for the
Diesel Engine type, plant layout, operation &
Design of the Generator Set, maintenance
Design of its Fuel Oil System,
Design for its Cooling Water
System,
Design for its Lubricating
April to June 2020 System,
Design for its Air Handling
System,
Design for the Engine
Dimension, others; Thorough
reevaluation of the plant
design; Obtaining contracts &
advice from various
engineering firms

Construction of the plant site; Idealization of the plant site

Purchase of equipments;
Construction of Administration
July to February 2021
Building & Others; Installation
of the equipments

Initial operation; Recalibration Testing phase of the project;

March to April 2021 of equipments Checking for flaws & defects

Turnover of Plant operation to Final project phase

May 2021 the owner/firm

37