(CHAPTER V DESIGN FRAMEWORK Design Philosophy "Heat engines wherein the produts of combustion form the working uid of thal elec gece Aap eigeeses O are meeting stationary power needs, an important exception is where the mechanical power is employed to drive generators originating the supply of electrical power. This application has the following variations: > Portable generating units which maybe moved from site to site where electrical power is required temporarily. Standby units, normaly idle, which can be activated when there is a failure of cert station power where an inteuption would mean financiel loss or danger. (Tunnel lighting, operating rooms, key industrial processes, ete) Engine generator unis installed in powerplants where they are the normal Primary source of electrical power generated for public, industrial or institutional consumption. Internal combustion engines are built around a variety of thermodynamic ‘eyeles. One type may vary from another in characteristics such as flexibility, fuel used, ease of starting, weight, cos, etc, but all have many features in common such a v Use of the piston and the cylinder to create a variable volume chamber in Which to work out the eyele. > Gaseous working medium. > Open thermal cycles, meaning a flow of ar as well as fuel into engine and discharge of gaseous products of combustion ftom it > ‘Two orfour stroke mechanical cycles, > Cyclic rather than uniform power output, necessitating multiple cylinders andlor heavy flywheels for steady delivery. Design concept Form/mass; Diesel engine power plants consist mainly of several parts that are important on its operation. The engine itself and its auxiliaries are the main features of a diesel power plant The auxiliaries may be grouped into. the following systems: the fuel supply, cooling, intake and exhaust, lubrication andthe starting system. The int sufficient amount of pre scnteton ofthese important pars can produce & and electricity. Function ‘The main purpose of a diesel 7 diesel electric powerplant is to produce electricity sr Power. Most diesel engines use @ feursvoke cycle: the pistons fist ward stoke draws in sr, the second, upward stroke compresses it the third, lownward stroke, following combustion, delvers power, and the fourth, upward Stroke expels waste gases At the end ofa piston’s compression toe, a fuel injector spray fel into the combustion chamber. Ar temperatr ise the chamber a that poi is about 540° C (about 1000°F), The fel ignites, causing a rapid expansion of hot air that forcefully pushes the piston downward. Tha downward power suoke tums the crankshaft. Sine the engine is directly coupled othe generator, asthe crankshaft turns the generator tums and produce current. Power is produced through this process. Economy Economics of diese! power includes the convenience of use of the diesel engine and its ability to meet the needs ofa given power problem as well as the ‘cost of operation. In fact, some economic advantages are not reducible to cost data, Costs themselves are relative and stould be compared with competing sources of power suitable forthe same application, After the plant has been placed in operation, good management, careful operation, and competent maintenance have important effet on costs. Conditions and cost for a5 to 10 hp plant are quite different from those for 14 5000 to 10000 hp plant. Smaller sizes have as competition the gas or gasoline engine, or electric power, Larger sizes compete with steam or electric power. if fuel gas of any sort is available, there is competition against fuel oil on a full, partial, or seasonal basis. For any industrial power applcaion where a mechanical drive is employed, the diesel has a better pulling power throughout the speed range: the torque holds up better at reduced speeds. In many applications, the diesel uses less fuel than any other prime mover: hence in any application where the fuel is Carried (eg transportation) or where fuel must be transported to an isolated Tocation, the diese! usually hs a distinct advantage on this point alone. ‘The diesel engine uses a safe fuel, free from ordinary fire hazards, and shows excellent economy over its whole load range-better than a gasoline engine,ee DIESEL POWER PLANT UNIT SPECIFICATIONS: Unit 1,2, 9.and 1 stand by unit (4 units inclding stand by unit) Mode! v26/a2H - | Capacity 3760 kw. a No. of Cylinders Ty ~ 286 mm 320 mm - ‘Set Weight (Dry) |'Set Weight (Wet) Weight of Foundation We x VN Wr= Where: ‘We= Weight of the Foundation ‘empirical coefficient 0.11 for mutiple cylinder W. = Weiaht of Engine + Weight of Generators & Exciter N= Engine Speed Generator & Exciter From Power Plant Engineering by Morse, P. 109. Generator Exciter weight is probably one half of the weight ofthe engine. Generator & Exciter weight = wo/2 = 63321.164 ka 2 = 31660.582 kg Weight of Foundation We=exW, x VN We = 0.11 x 94981.746 kg kg x V750”= 286130.0486 kg Eccentric Load From Power Plant Engineering by Morse, Eccentric Load is one third the weight ofthe mactine. Eocentric Load = 94981.746 ka, 3 = 31660,582 kg Total Weight of Units and Foundation Machine weight + Eccentric load + Foundation weight 194981.748 kg + 31660.582 kg + 286130.0466 ko = 412772.3746 kg Base Area of the Foundation From PSME Code P.9 Article 2.4.1.3, the weight of the machine plus the weight ofthe foundation should be distrbuted over a sufficient sol area which is large enough to cause a bearing stress within the safe bearing capacity ofthe soil wla factor of safety of five (6) Where: allowable unit sol stress = 64 tonnes/m? = 58059.52 kgim? ul Foundation ‘Allowable Unit Soil Stress/5 = 412772.3746 kc '58059.62 ions = 35.55 m? Volume of concrete foundation (Va) Va WL of Foundation Density of concrete ‘Where density of concrete = 2403 kg/m’, from table 4-2 approximate weight of building materials P.90 P.P-E. by Morse. Vea 286130,0486 ka 2403 kg/m = 119.072 m* Depth of Foundation From PSME Code P.10, Foundation depth maybe taken as a good practice, to be 3.2 to 42 times the engine stroke, the lower factor for well balance multi cylinder and higher factor for engine with fewer cylinders.D=32(STROKE) stroke D=3.2(0.320 m) D=1.024m 320 mm = 0.320 m, ‘Anchor Bolt Design Tom ICE by Maleey, P. 472, States ead , P- 472, States that a good practical rule is to cratne POH diameter equal to one twelth the cylinder oF 1OW 8 Frere, and one eight for high speed, also to prevent puling out of the bolt eam tiahtening of the mute embedded length snouid be bent to form a hook or ring and atleast 30 bot diameter Bot diameter = Enaine Bore 8 =280mm é = 36mm (1.3779 in) Embedded Length of Bolt, L, L.= 30 x Bolt diameter 30x 35 mm = 1050 mm Hook Length, Ly Hook length should be 3 to 10 times the bolt diameter Ly= 6.5 x Bolt diameter 5x35 mm 227.5 mm. Pipe Sleeve For a clearance of % in. all around the bolt use a pipe diameter of 2 in. oF 50.8 mm with a length of 500 mm. Length of Bolt above the Foundation Ls Le beige + Height crower + 2Height vontng* Allowance oo ese nm + 2(90 mm) + 30 mm =150 mm Quantity of Bolt Foundation try on me Master Can Coy. Catalog 90, the ro. of anchor bois ‘approximately equal to twice the no. of engine cylinders, Anchor Bolt = 2x18= 36 bolts for 3760 kw capacity Weight of Reinforcing Steel From PSME code, Artic y , Article 2.4.1.6 wei be from % % to 1 % of the weight of weight of rarforcing sae showit Wt of Foundation 01 x 286130.0466 kg x 4 unit = 11445 20180K9 For Total Stee! Bar Required From Kent's M.E. handbook P. 188 use 5/8 in. round bar wt. of steel in Ib/ft is 1.043 Ibvft or 0.47: eee en at 3 kgf, length of steel bar commercially Steel bar required = 11445.20186 ka = 24197.04 fi. 0.473kg/ft. 20 fibar = 1209.85 bars say 1210 bars Concrete Foundation From PSME Code, Article 8.4.1.5 concrete foundations are ly built in 1: 2: 4 proportions of cement, sand, stone. From PPE by Morse table 4-1; data on concrete mixes,to yield 1 Cu. M concrete has the values; 7.8 cement (sacks), 0.44 sand (rm), 0.88 stone (m°) for 1: 2: 4 mixtures. Ver = 119.072 m? Cement (sacks) = 7.8 x 119.072 m® x4 units = 3715.05 m° say 3716 m 44 x 119.072 m? x4 units Sand (m°) ‘ 109.57 m° say 210 m 2 Stone (m*) = 0.88 x 119.072 x4 units ‘ ye i913 m? say 420mCOOLING TOWER Design conditions. Brake Thermal Efficiency 30% Jacket Water Loss 32% ‘Temperature of water entering the cooling tower 40°C ‘Temperature of water leaving the cooling tower 28°C. ‘Temperature of make up water arc Condition of entering air 30°C, 55% RH Condition of entering air 36°C sat Temperature of water leaving the heat exchanger 37.8°C ‘Temperature of water entering the heat exchanger 656°C Amount of cooling H20. My From Power Plant Engineering by Morse P.178 W= 674.58 bho | per hour tet Where: W= cooling water ty = inlet temp. in * tz = outlet temp. in °C For 3960 Kw engine (5310.45 hp) 674.58 (5310.45) 65.6 -37.8 = 128860.5 Vr Let My be the water flow in the cooling tower (40°C - 28°C) My = (65.6°C ~ 37.8°C) 128860.55 Ur M, = 298526.94 Uhr 2.92 kg/s For three units = (e292 ko!) bed = Sie 76 kg/sAir Properties from psychrometrics chart at 30°C, 55% RH y= 68 KJIKg; AL 35°C sat, From table A 2(ret, aac) OOM? Kaa it hee 12 9.411 KJIKg; HR, = 0.03671 kg/kg air Heat balance on the cooling tower MuCow(ts ~ ta) + MveCpnts = Ma (hy - hs) My = Ma = My, My = My = My ‘Aur out (4) H20 in(1)—> roe ,__Airin(3) H,0 in(5) | H20 out(2) Mys= Ma (hy = hs) = MuConlts = t Cmts = Ma (129.411 - 68) Kika ~ (248.76kais)(4.187KJ/ka"K)(40 ~ 28)°K (4.187KJikg?K) (27 + 273)°K Mys= 0.0489 My - 9.9504 kos Mass balance by water Mars + Mys + Ma (HRs) = Me + Ma (HR4) Mys = Ma (HRs ~ HRa) Mz (0.03671 — 0.0148) My = 0.02191 My Equating 1 & 2 0.0489 M, — 9.9504 ka/s 368.67 kg /s 0.02191 Ma M. For mass of make up water My = 0.02191 Ma= 0,02191(368.67 ka/s) = 8 Cooling towerarea, A nae From refrigeration engineering by ¥y Mc Intire P. sectional are of forced dra cooing tower fs foun by allowing 3.0 gpriea For the ave. temp. T=40+28 2 =34°C From kent’s Mechanical Engr.’s Hand Density of water at 34°C, (83.2°F) book P.5-08 60°F — 1.938 slugs/f 93.2°F -p 100°F - 1.927 By interpotation = 1.92887 slugsitt? x 14.694 kglslugs x 35.31 f/m? = 993.97 kg/m’ Vow = Mw _Om = 248.76 ka/s ~ 993: 97 kg/m? = 0.250269122 mi/s x 1000L/m? x 1 ga/3.786 L x 60 sec/min = 3966.859 gpm = __Vw ___ So gomieat “3 a jf = 3966.859 f 13.28 = 403.14 m? Cooling tower dimension Let L = 1.6W .5(16.39M) 4.60 mCooling tower specification Cooling tower range Cre that = 40°C - 28°C = 126 Cooling tower approach, Cra Cra te ts @ 30°C & 55% RH; toes = 228°C Cooling tower efficiency; ex fo= tite we | = 40°C 28°C 40°C -22.8°C = 69.76% For the no. of nozzles required From refrigeration and air conditioning by Jordan and Priester P. 276, nozzles are 80 spaced to deliver 0.10 to 0.40 gpmit* of pool surface ‘and about 7 to10 gpm capacity per nozzle. Using 10 gpm capacities per nozzle; No. of nozzle = Capacityinozzie = 9968,859 am TOgprnnozzie ‘= 396.6859 nozzles say 397 nozzles Nozzle arrangement No. of rows = 20 No of nozzle per row = 20 Header dimension For headers, economical water velocity is 1.5 to 2.1 m/sec Use: 1.8 mis Volumetric flow = area x velocity 0,250269122 m*/s = "is (1D) “1.8 mis) Q=AV 0.250260122 m/s = "Ue (1D) *(70)(1.8 ms) 1D? = 0.00253m"Use 150 HP motor or the nearest hi standard pump capacity igher commercially jiable ‘Makeup water pump ‘Assume 5 m total dynamic head 11.75 ka/s ‘oo0Kp = 0.01175 mis WHP = 0.01175 m’/s x 9.81 knim? x 5 m = 0.57634 kw x_HP_ O748 ew = 0.726 HP Pump motor rated power = 0.7726HP 0.80 = 0,966 HP Use 1 HP motor Forced Draft Fan From Kent's mech' engr.’s handbook, for commercial axial flow fans (P. 1-34), wheel diameter ranges from 15 to 72 in. its rated capacty ranges up to 150 rpm of air against a static pressure of less than 12 of water. User whee! diameter — 48 in. = 4 ft Mech.’ efficiency ~ 85% Static pressure - 3 in H:0 Fan capacity ‘At 30°C and 55% RH, Psat = 2.2402 kpa tH (Psat) '55(2.2402 kpa) 23211 kpa Py=mRT (Pe — Pi)Ve= ms Ra Ts (101.325 - 1.23211) Vo Vq = 29.536 m/s, +34,016(0.2871) (30 + 213) Velocity of air me 4 (328f) Velocity of air = 25.31 ™/STotal head, Hi» His = hva(for fan wd a epee ischarge duct only) y 29 B= (3 in Hao) fV12in}imn/3.26n)(1 oH 4.2kg)m" 63.5126 m = (25.31 mis* 25 2@.81ms*) =3265m [sx < Hy = 63.5162 m + 32.65 m = 96.17m Fan power Fan power Ha (368.67kglsec) (96.17 m) (0.0088 kr/Kg) = 347.81 HP use 510 HP Area of discharge duct Aoo= Q v = 729563 mls 25.31 mis, 46604 m= Azmb2 4 D=V4A a = VaCit680407) a = 132m Heat exchanger Shell and tube heat exchanger (horizontal) = jacket water on shell side = cooling water on tube side = material (steel) Parameters “Temperature of cooling water entering the condenser - 28°C ‘Temperature of cooling water leaving the condenser - 40°C ‘Temperature of jacket water entering tne condenser - 37.8°CTemperature of jacket water ent condenser Economic water velocity - 5 t0.6 rpg” Tee Use: 5.5 f. per sec. (1.68mis) From Shoove and Tuve, Mech: ‘nical Engineering Pract Water veloty Us (lume) 225 55 vu, : a U, = 253.125 Btu/hr-f-°F (1.4365 knee) Mass of cooling / condensing water, M, = 361.84 kg/sec. Steel Tube Diameter For shell and tube heat exchanger, steel tube diameter ranges from 16mm to 50 mm Use: 40 mm Nps, S-40 From Stoeker Tab. 7 -2 (dimension of steel pipe) OD = 48.16 mm 1D = 40.90 mm Cooling surface area, Ao, Ay For LMTD ©, = 37.8 - 28 = 9.8°C ©2 = 65.6 — 40 = 25.6°C umTl = Q)-@ ir ee = 98-256 Ino.8 258 = 16.455°C Q=U,A, LMTD Total jacket water loss, Qwur ‘Qyur = 3(8960 kew) + 2(2700 kw) = 17280 kw Q=UA, LMTD 47280 kw = 1.4365 KNim?*C (Ac)(16:455°C) Ao = 731.04m? tubes Length of condenser 18 ceptable range of condenser tubes falls within 1 to 6.5 m_ Let: L = 5.36 mNumber of Tubes per pass Conaldenng a single pees from PRE by Mors, P 20 al ipasses) Winere ‘A. = extemal tube area ‘8, = surface per linear meter of tube No. of tubes ibe lenght 731,04 m? (©.04826m)(5.36m) = 2826.11 tubes/pass ‘Say 2827 tubes/pass Diameter of shell, Ds ‘According to Kent's M.E. Handbook P. 9-10, cross sectional area of tube should occupy 20% to 25% of shell cross sectional area. Use: 24% ‘OD = 0.04826 m n of tubes per pass ‘Ay. = shell crogs sectional area Aa = 1/40. 2 0.24 21.55 m? As= TLDs 4 D2 = 4(21.55 m?) 7 = 27.44? D,=5.24m Piping for the cooling system ae 7 according to refrigeration and For water used as a cooling rredium air conditioning by Jordan and Priester, economic water velocity is 5 to 6 Fps with pumping unit, using 6 Fps (1.82983 misec) further Tore it mentioned that return pipes usually have the same length and arrangement as the supply pipes. Hence, designs may be done considering only the supply pipes. From fluid mechanics Q=AV Q = volumetric flow in mils by Dugherty Where:Flow in Pipings = Mw (Vw @ 27°C) = 8.08 kg/s (1.0046 x 10m . 1.0046 x 10°%m'ng) cone 0.00812 m/sec = mE (1.8289 mvs) 0? = 4 (0.00812 m/s) TF (1.8293 m/sec) = 0.00565 m* D= 0.07518 m 5.18 mm Use 76.8 Nps, S-40 Pioing orn cooling tower pool to heat exchanger inlet 4 0.250269122 m/s = 1 D°V 4 D? = 4(0.250269122 m/s) ‘tr (1.8293 mis) 0.1742 m> 4174m =417.4mm Use Nps 50.8 mm D, S- 40 Piping from heat exchanger outlet to engine outlet For units 1, 2 & 3 (3960 kw) —_* Pw at 37.6°C = _82.92 ki see oko = 0.0836 m/s Q=nDV D?=40 ™ = 4(0.0836 m/s) 11(1.8293 m/s) = 0,05819 m* ai D=0.24122m = 241.22 mm ‘Use 254mm OD Nps, S “Design of Air Tank From P.P.E. Morse P. 42 kgim? by 7 Starting pressure = 28 kg/m? Starting Pressure Ranges from14 Material for air tank (AISI No. C1015") Cold drawn wrought steel Corrosion allowance = 1/8 m = 3.715 in, Welding efficiency = 0.75 From P.P.E. by Morse, in starting internal combustion engine, two ‘or more compressed air storage tanks or “bottles” should be Also from ICE by Malev, the volume of air tank necessary to start an engine may be taken as 7 to 10 times the piston displacement for large engines. Use: 10 For 3960 kw capacity engine: units 1,2 & 3 Vo = 1 (Bore}*(Stroke) vort (0.280 m)?(0.320 m) =. 0197 m? For 3 engines having 18 cylinder arrangement each 0197 m* (3) 1.0638 m* Ve = 10VD a 10x 1.0638 m? Je 2 units having this same air volume Use 13 im? air tank Capa ET ree sano Ean Dimension of air storage «Assuming L.= 2D Proportion ; ou apna 0 2 43m) A= 8.2761 m? = 2.02275 m = 2(2.02275 m) = 4.0455 m > ° L For the thickness of the cyii rom cylindric From DME. by Fares ere ay gM ; Material; AISI C1015" Su = (461821.43)(0.92)(0, = 108218 99 kpa Pressure conversion P= 28 kafem'x 101.528 koa, 1.033 kgl = 2746.47 kpa For thickness of plate; t = _PD _+C 28s(e) (2942.64 klm?\(2.02275N)(1000 mm/min, gam) + 18 in 2(106218.93 kn/m?)(0.7) ~ 2748.47 knit 7327 in. Use: 1 3/4 in thick plate Design of air compressor ‘Considering a single stage reciprocating compressor Receiver Pressure = 2746.47 kpa (26 kg/cm’) Considering atmospheric pressure as pressure of supply ar. dbook by Kent's P 1-54, the volume of supply air of the recites for good practice on 100 psi (689. :286 kpa) should be such as to hold % min. discharge cape the connected compressor, thus the time Seamed ne ive parameter to the design condition wc has @ pressure of 2942.64 kp@. —%min = __t_—_— 689.286 kpa 2042.64 kp4 t= 2.13456 minFor 3960 kw (units 1,2 &3) For volume of ar atthe receiver, Vs 2.13456 min 13m? 2.13456 min 090248 m*/min. 1015 m/s For volume of free air delivered at the compressor, Vi Considering isentropic compression process Use: k= 1.4 Py Vik = Po Vo V4 = Va (Pal Pi) ™ 1015(2942.64) 101.325 2585 m°/s, in Ideal work of the compressor, We We =_k_P1 Vi (Pal Pi)" <1] k = 4.4 (101.325)( 1.2585)[(2942.64) enna ay 14-1 101.325 We = 646.104 kw ‘Actual work (Power) of compressor From steam, air & gasses power by Saverns. Miles & Degler, compressor efficiency range is 75% to 80% as standard. Use 80% as compressor Rated compressor power = 646.104 kw x —_HP 0.80 0.746 kw = 1082.61 Use the nearest higher standard commercially available Hp capacity. Desi tem oCelvery Sythe fuel is arranged on @ monthly basis, vendor is expect the supply by truck trailers. From ore by Seep. 170, truck trailers can usually drop 11300 - 19900 liters at a delivery:For plant capacty 23760 kw) = 11280 kw The average output at one Since we have 5 units Average kw = 6669.208 kw 3 = 223.069 kw ‘week operation equals 6669 208 kw. Plant Capacity Factor = 11280kw = 19.71% From P.P.E. by Morse fig. 6 -15 P. 164, the greatest fuel ‘consumption to expect at 19.71% load factor is 1.25 kw Hr per iter ol, the lowest 1.80 kw Hr per liter oil For required storage, from P.P.E. by Morse P. 171 Required storage =____Average output at plant capacity factor ‘Average fuel consumption at plant capacity factor = 2223,069 kw _x 24x 30 7.25 + 1.80) kwHrlLi 2 = 1049580.118 liters Say 1049581 liters For volume of storage tank Considering a 15% allowan: oil evel .ce for upper volume space above fuel = 104958tlters(1.15) Volume of Storage Tank = 1207017.136 ites say 1207018 liters For storage tank dimension ‘Assume L =20 eno? Volume rans = 11D® b= mz go) =p 4 D> = 2VrMaximum rate of fuel At full rated load, the fuel consumption to be about 0.18 kg BHp Hr (fig. 6-15 P.P.E. by Morse P. e1) 11280 goneraon kw is 15126.73 engine Hp. If a generator efficiency of 94% is assumed Max. Rate of fuel usage = 15126.73 x 0.18 = 2722.82 kg/hr For transfer pump capacity Where: fuel density = 0.8401kg/L Transfer pump capacity = (1: 0.8401 kg/t = 54.02 Umin. Say 14.27 galimin ‘Transfer pumps and piping should have at least this capacity me capacity of day tank For Considering ‘transfer pump capacity x 2 hours equals the capacity of day tank. youre ‘of Day Tank =3241.07 UHrx 21H = 6842.14 say 6643 Liters Vor= mD? L = nD? (20) = D- 4 4 2 D? = 2Vpr 1 216843 Liters) T = 4126.658Liters x !m"/1000 | 12666 m° D=1.60m L=2D = 2(1.60m) = 3.2mAnti Pollution System. From PSME code, P.11 in article 2.5, Anti pollution for industrial building that all machines/ equipment w/c characteristically generates noise shall be provided w/ appropriate enclosure to control emissions. So as not to cause ambient noise level higher than the quality standard act by the government agency concerned. If impractical, the buildings housing, the same should be at appropriate design, or should be provided w/ means to achieve compliance w/ standards.