Date post: | 03-Apr-2018 |
Category: |
Documents |
Upload: | karthi-keyan |
View: | 218 times |
Download: | 0 times |
of 40
7/29/2019 52049510 Power Plant Design PART III
1/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Location
Guinsiliban, Camiguin
Camiguin, the smallest province in Northern Mindanao (Region X), had a total population of74,232 persons based on the results of the 2000 Census of Population and Housing. It wasthe second to the smallest in the Philippines in terms of population. It registered an annualgrowth rate of 1.88 percent from 1995 to 2000, higher than the 1.08 percent growth rateduring the 1990 to 1995 period. If the current rate continues, the population of Camiguin was
expected to double in 37 years.
The number of households rose to 14,826, higher by 1,352 households from the 1995 figure.The average household size was 5.0 persons (same as the national average), which waslower than the 1995 average of 5.04 persons.
Of the five municipalities in Camiguin, its capital Mambajao, which comprised 42 percent ofthe total provincial population, was the largest in terms of population size. Catarman,Mahinog, and Sagay followed with 21 percent, 17 percent and 14 percent, respectively. Of thetotal population, Guinsiliban had the least share (seven percent).
Camiguin had the least population in Northern Mindanao (Region X), contributing only 2.70
percent to the 2.7 million population of the region. At the national level, Camiguin shared 0.10percent to the total Philippine population of 76.5 million as recorded in the Census 2000.
Of the total household population five years old and over, about two out of five persons hadattended or completed elementary education. Thirty one percent had either attended orfinished high school while 12 percent had attended college. Only four percent were academicdegree holders. More than half of those who had attended or finished elementary education(53.1 percent) and post secondary (54.7 percent) were males. On the other hand, those whohad attended or finished college, academic degree holders and post baccalaureate werepredominantly females.
About 45 percent of the total population in Camiguin classified themselves as Cebuano.
Kamigin/Kinamiging followed with 36 percent and the Boholanos, with 11 percent. Theremaining three percent were either Binisaya or belonged to other ethnic groups.
There were 15,449 housing units in Camiguin, of which 14,735 were occupied. This registeredan increase of 23.3 percentage points from 1990, a ratio of 1.01 household per occupiedhousing unit, and 5.03 persons per occupied housing unit. Almost all (98.6 percent) occupiedhousing units were single houses, an increase of 22 percentage points from the 1990 figure.
7/29/2019 52049510 Power Plant Design PART III
2/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Guinsiliban is 6.9% of total population of Camiguin therefore we can assume that out of
14,735 Occupied Housing Unit there are 1002 single houses which represents the majority of
the building structures on Guinsiliban and a household population of 1023.
Demographic Data:
Total No. of Population: 5,092
Household Population: 1023
Structures:
(Group A)
Single House: 1002
Duplex: 6
(Group B)
Multi-Unit Residential: 3
Commercial/Industrial/Agricultural: 1
7/29/2019 52049510 Power Plant Design PART III
3/40
0
500
1000
1500
2000
2500
LoadinkW
Load Per Hour
Load Per Hour
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Graphical Representation of Load
7/29/2019 52049510 Power Plant Design PART III
4/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Load Table (GROUP A)
Load Table (GROUP B)
7/29/2019 52049510 Power Plant Design PART III
5/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Total Power Consumption Table
25449.08kW-hr/day
Design Overview
Peak Load = 2357.16 kW, 2.35716mW
Plant Capacity: 3200 kW, 3.2mW
No. of Engines: 5
7/29/2019 52049510 Power Plant Design PART III
6/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Engine Capacity Number of Hours of Operation/day
Unit 1 800 kW 18 hours/day
Unit 2 800 kW 18 hours/day
Unit 3 800 kW 18 hours/day
Unit 4 800 kW 18 hours/day
Unit 5 800 kW Reserve
Schedule of Engine Operation
Time ofOperation
EngineOperating
TimeInterval
12AM - 6AM UNIT 1,2 & 3 6 hours
6AM -12NN UNIT 2,3 & 4 6 hours
12NN - 6PM UNIT 4,1 & 2 6 hours6PM - 12AM UNIT 3,4 & 1 6 hours
Each Unit has a 6 straight hours break.
Design for Machine Foundation
For 800 kW Generator Set (Per Unit 1,2,3,4 and 5)
Mixture for Concrete Foundation:
Use 1:3:5 concrete mixture ratio (from PPE by F.T. Morse, Table 4-1 p.90)
7/29/2019 52049510 Power Plant Design PART III
7/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Soil Bearing Pressure:
Use 50-98 tones/m2 for compact clay (from PPE by F.T. Morse, Table 4-4 p.105)
Soil Bearing Pressure (Sb)
Weight of foundation
Where:
Wf= weight of the foundation, kgs
We = weight of the engine, kgs
e = empirical coefficient
n = engine speed, RPM
Use e = 0.11 (from PSME code, Table 2.4.2.3 (4), p.11)
Volume of foundation
Where:
Vf= volume of foundation [m3]
c = density of concrete = 2406 kg/m3
Depth of Foundation
Where:
hf= depth of foundation [m]
7/29/2019 52049510 Power Plant Design PART III
8/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Lf= length of foundation [m]
wf= width of the foundation [m]
Length of the foundation:
Where:
Lb
= length of bedplate [m]Le = length of engine [m]
Width of the foundation:
Where:
wb = width of bedplate [m]
we = width of the engine [m]
7/29/2019 52049510 Power Plant Design PART III
9/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Soil Stress
Soil Stress
Soil Stress
Foundation Materials:
Concrete Mixture Ratio = 1: 3: 5
X + 3x + 5x = 15.32 m3
9x = 15.32 m3
X = 15.32 m3/ 9
X = 1.70 m3
For cement:1 x 6.2 x 1.70 m3 = 10.54 m3
For sand:
7/29/2019 52049510 Power Plant Design PART III
10/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
3 x 0.52 x 1.70 m3 = 2.65 m3
For gravel:
5 x 0.86 x 1.70 m3 = 7.31 m3
For Reinforcing Bar:
Using 14 mm diam. rebars
7/29/2019 52049510 Power Plant Design PART III
11/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Flexure formula
Eccentricity from mid-base
Y1 = 1/2h = (1.25m) = 0.625m
Y2 = 1/3h = 1/3(1.25m) = 0.42m
A1 = Lf x h = (5 m)(1.25 m) = 6.25 m2
A2 = Lfx b
Where:
b
if b < wf, then wf= b; use b = wf= 2.5 m
A2 = Lfx b = (5 m)(2.5 m) = 6.25 m2
A = A1 + A2 = (6.25 + 6.25) m2 = 12.5 m2
AY = A1Y1 + A2Y2 = [(6.25)(0.625) + (6.25)(0.42)] m3 = 6.53 m3
C
m =
7/29/2019 52049510 Power Plant Design PART III
12/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
For Bolts:
Diameter = 1/8 x (bore) = 1/8 x (150mm) = 18.75 mm
Length = 7/8 x (stroke) = 7/8 x (160 mm) = 140 mm
Use L = 30D (from ASME code)
L = 30 (18.75 mm) = 562.5 mm
No. of boltsWhere:
Tbolts
From Table AT 7 DME by V.M. Faires
Material: AISI 8630 (for connecting rods, bolts, shapes)
Sy = 100 ksi = 100, 000 psi; Fy = 7 (max. for shock)
Tbolts
No. of bolts
7/29/2019 52049510 Power Plant Design PART III
13/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Design for Fuel Tank
For 800 kW Generator Set (Per Unit 1, 2, 3, 4 and 5 )
Type of Oil: Diesel Fuel Oil
Specific Gravity = 0.917 @ 60F
(From Power Plant Theory and Design by P.J. Potter, Table 5-4, and p.187)
Generator Output (EP) = 800 kW
Specific Fuel Consumption
Where:
BP
(For 1800 rpm & 494.73 kW Ave. Load)
(From Power Plant Theory and Design by P.J. Potter, Figure 9-27, p.445)
BP
Specific Fuel Consumption
Plant Operation = 24 hrs/day
Engine Operating Hours/day = 18 hrs/day
Expected Fuel Delivery Schedule = every 15 days
% Rated Capacity
7/29/2019 52049510 Power Plant Design PART III
14/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
From PPE by F.T. Morse, Fig 6-15, p.164
Max. fuel consumption = 0.25 kg/kW-hr
Min. fuel consumption = 0.21 kg/kW-hr
Volume of Day Tank
Where:
mF = daily fuel consumption [kg/day]F = density of fuel = 917 kg/m
3
mF = max. fuel consumption x BP x engine operating hours/day
= (0.25 kg/kW-hr) (818 kW) (18 hrs/day)
= 3681 kg / day
Dimension of Day Tank
(From the above equation)
Assume:
HDT = 2DDT = 2 (1.37 m) = 2.74 m
Thickness of Fuel Day Tank
Where:
PT = pressure inside tank
7/29/2019 52049510 Power Plant Design PART III
15/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Where:
fuel = 8.996 kN/m3
PT = 2.74 m x 8.996 kN/m3 = 24.65 kN/m2 or kPa
Sy = Tensile Yield = 35,000 psi (from DME by V.M. Faires, Table AT 4, p.568)
F.S.y = Design factor of safety
F.S.y = 3 (for stainless steel from DME by V.M. Faires Table 1.1, p.20)
n = 75%
Storage Tank for 30 days operation
Dimension of Storage Tank
(From the above equation)
Assume:
HST = 2DST = 2 (4.25 m) = 8.5 m
Material for Fuel Tank: AISI No. 321 (stainless steel)
Thickness of Fuel Storage Tank
Where:
PT = pressure inside tank
Where:
fuel = 8.996 kN/m3
PT = 8.5 m x 8.996 kN/m3 = 76.46 kN/m2 or kPa
7/29/2019 52049510 Power Plant Design PART III
16/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Sy = Tensile Yield = 48,000 psi (from DME by V.M. Faires, Table AT 7, p.576)
F.S.y = Design factor of safety
F.S.y = 2 (for stainless steel from DME by V.M. Faires Table 1.1, p.20)
n = 75%
Transfer Pump from Fuel Storage Pump to Day Tank
Assumption:
Desired Operating Time for Fuel Pump = 1 hr/day
p = 72%
Power input for Unit 1, 2, 3, 4 and 5
Where:
EPi = electrical power input [kW] or [hp]
fuel = 8.996 kN/m3
TDH = total dynamic head [m]
Q = volume flow rate [m3/s
Where:
VDT = volume of fuel at day tank [m3/s]t = time of pump operation [sec]
= 0.00111 m3/s
7/29/2019 52049510 Power Plant Design PART III
17/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
1 hp is used for unit 1 transfer pump
Design for Heat Exchanger
For 800 kW Generator Set (Per Unit 1, 2, 3, 4 & 5)
Theoretical and Actual Limits of Cooling Water and Jacket Water
(From PPE by F.T. Morse, p.178)
tji = jacket water inlet temperature = 37.8 C
tjo = jacket water outlet temperature = 65.6 C
tcwi = cooling water inlet temperature = 32.2C
tcwo = cooling water outlet temperature = 54.4 C
LMTD
tmax = (65.6 54.4) C = 11.2 C
tmin = (37.8 32.2) C = 5.6 C
LMTD
Qj = mj x cpj x tj
Where:
Qj = heat rejected from jacket water = 358.9 kW (from catalog)
mj = mass of jacket watertj = temp. Difference of jacket water= (65.6 37.8) C = 27.8 C
Cpj = 4.187 kJ / kg-K (for water)
7/29/2019 52049510 Power Plant Design PART III
18/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
A
Where:
A = surface area of heat exchanger
U = overall coefficient of heat transfer
LMTD = log mean temp. Difference
Solving for U (from PPT & D by P.J. Potter, Fig. 8-9, p.351 and p. 352)
Where:
= coefficient of heat transfer
Ft = temp. Correction factor
Fm = tube material and thickness correction factor
Fc = cleanliness factor
Fp = prime mover factor
Tube Specifications:
Material: Aluminum Brass 18 BWG
Water Velocity = 9 ft/s
Ft = 1.08
Fm = 0.96
Fc = 0.85
Fp = 1.0
C = 270
7/29/2019 52049510 Power Plant Design PART III
19/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Where:
mcw = mj = 11,088 kg/hr
= specific volume of circulating water @ t
From steam table @ 51.7 C (by interpolation)
= 1.01295 L/kg
From PPT & D by P.J. Potter, p. 357
For each No. 18 BWG tube will pass 1.042 GPM/1 fps
7/29/2019 52049510 Power Plant Design PART III
20/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Where:
0.1963 ft2/lin. ft = outside surface area of tube (18 BWG)
(From PPT & D by P.J. Potter, Table 8-1, p.353)
Design for Cooling Tower
For 800 kW Generator (Per Unit 1, 2, 3, 4 and 5)
BP = 818 kW = 1,096.51 hp
Installation Data:
t2 = engine water into heat exchanger (in) = 65.6 C
t1 = engine water into heat exchanger (out) = 37.8 C
tb = cooling water to heat exchanger = 32.2 C
ta = cooling water to heat exchanger = 48.9 C (max. state of humidified air)
Make-up water = 15.6 C ; 29.4 C DB & 21.1 C WB (@ atmospheric condition)
7/29/2019 52049510 Power Plant Design PART III
21/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Using the formula (from PPE by F.T Morse, eq. 6-16, p. 178)
Where:
W = cooling water [1 / hr)
Bhp = rated brake horsepower
t1 & t2 = inlet & outlet water temperatures [C]
Let ww = water flow in the cooling tower circuit
From PPE by F.T. Morse, p. 181
The theoretical maximum humidified state of the air leaving is 48.9 C at 100 % humidity.
Assume 5.5 C differential and 90% RH
From Psychometric Chart @ 29.4 C DB & 21.1 C WB:
SH1 = 0.0123 kg
h1 = 79.088 kJ/kg
Using the formula (from PPE by F.T Morse, eq. 6-19 & 6-20, p. 182)
Where:
Td = dry bulb temperature [C] = (48.9 5.5) C = 43.4 C
RH = percent relative humidity
Ps = saturation pressure of water vapor @ td
7/29/2019 52049510 Power Plant Design PART III
22/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Pa = atmospheric pressure [kg/cm2]
hg = enthalpy at td, dry and saturated [J/kg]
From Steam Table @ 43.4 C:
Ps = 0.0895 kg/cm2 (converted value)
Hg = 2,580,140 J/kg
Using the formula (from PPE by F.T Morse, eq. 6-17 & 6-18, p. 177)
Mass balance for cooling tower:
Heat balance for cooling tower
Ww = 1.7 kg water / kg dry air (from above equation)
From Psychometric Chart
Since air@ 29.4 C & 21.1 C = 0.862 m3/kg
7/29/2019 52049510 Power Plant Design PART III
23/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
= 60 %
From PPE by F.T. Morse, p. 182Recommended Type: Natural Draft Cooling Tower
Cooling Tower Pipe
; QCTP = mcw (f @ 32.2 C)
From Steam Table (by interpolation)
f= 1.00506 L/kg = 0.0010506 m3/kg
Velocity of water @ HX = Velocity of water at cooling tower
9 ft/s = 2.74 m/s
;
Material Specification (from PSME code, p.200)
7/29/2019 52049510 Power Plant Design PART III
24/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Size: 1 in. Inside Dia.: 1.5 in Wall thickness: 0.2 in
Schedule: 80x Outside Dia.: 1.9 in
Cooling Tower Pump
PCT = (QCTP)(water)(TDH)
Assume z = 2 m ; TDH = 2 m
PCT = (0.00324 m3/s)(9.807 kN/m3)(2 m) = 0.064 kW = 0.085 hp
Assume p = 75 %
Fan Power of Cooling Tower
Fan Capacity
QA = mAA
Where:
mA = mass of air = 1.59 kg/sA = specific vol. of air
A = density of air @ standard condition = 1.2 kg/m3
7/29/2019 52049510 Power Plant Design PART III
25/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Cooling Tower Floor Area
Concentration of Water = 80 L/min-m2
;
Variable Load Calculations
(We use 3200kW from catalog 800kw X 4 genset)
7/29/2019 52049510 Power Plant Design PART III
26/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
7/29/2019 52049510 Power Plant Design PART III
27/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Catalogue
7/29/2019 52049510 Power Plant Design PART III
28/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
7/29/2019 52049510 Power Plant Design PART III
29/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
7/29/2019 52049510 Power Plant Design PART III
30/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Perspective View
7/29/2019 52049510 Power Plant Design PART III
31/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
7/29/2019 52049510 Power Plant Design PART III
32/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
7/29/2019 52049510 Power Plant Design PART III
33/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Side View
7/29/2019 52049510 Power Plant Design PART III
34/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Top View
List of Materials
7/29/2019 52049510 Power Plant Design PART III
35/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Materials Quantity
Cement 3675
Gravel 435
Anchor Bolts 1/8 x 7/8 3315
Renforcing Bars 14mm x 20ft 65
Aluminum Brass Tube 3/4" 120
List of Equipments
Equipment Quantity
800kW Diesel Genset (IDLC 800-2M) 5
Fuel Transfer Pump 1hp 5
Cooling Tower Pump 0.11hp 10Cooling Water Fan 0.27hp 10
Heat Exchanger
7/29/2019 52049510 Power Plant Design PART III
36/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
7/29/2019 52049510 Power Plant Design PART III
37/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Cooling Tower
Fuel Tank
7/29/2019 52049510 Power Plant Design PART III
38/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Machine Foundation
7/29/2019 52049510 Power Plant Design PART III
39/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
Rizal Technological University
Boni Ave., Mandaluyong City
7/29/2019 52049510 Power Plant Design PART III
40/40
RIZAL TECHNOLOGICAL UNIVERSITY
College of Engineering and Industrial Technology
College of Engineering and Industrial Technology
Mechanical Engineering Department
In partial fulfillment
Of the course requirements on
ME 54L - Power Plant Design Lab
Submitted by:
Submitted to:
Engr. Gerry Cabrera
Submitted on:
March 14, 2011