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INTRODUCTION
Electricity generation is the process of harnessing electrical power from
other sources of energy. Electricity transmission, distribution and electrical power
storage and recovery using pumped-storage methods are other processes
normally carried out by the electric power industry.
Power
plants
or
power
stations
generate
electricity
by
using
In a diesel electric power plant, diesel engine is used as the prime mover.
The diesel fuel burns inside the engine and the products of this combustion act
as the working fluid to produce the mechanical energy. The diesel engine then
drives the alternator to convert the mechanical energy into electrical energy.
Such power stations are only used to produce small power, because of the
considerably high price of diesel.
Existing diesel power stations here in the Philippines offers a good
reference for this study. The 225 MW Bauang medium-speed bunker-fired diesel
power plant is one of the largest bunker-fired diesel power generation facilities in
the world. It has the highest capacity among all the diesel electric power plants
here in the Philippines operating under a 15 year Build-Operate-Transfer (BOT)
agreement. It is located approximately 255 kilometers north of Manila in
Payocpoc Sur, Bauang La Union. Other notable DEPPs in the Philippines are the
11 MW Bohol Diesel Power Plant in Tagbilaran, Bohol and the 75 MW Panay
Diesel Power Plant located in Iloilo City.
The researchers propose of establishing a Diesel Electric Power Plant
(DEPP) at Brgy. Locloc, Bauan, Batangas that will supply electricity to Bauan and
other nearby municipalities. The province of Batangas is located at the southern
tip of Luzon. It is one-hundred twenty kilometers away from Metro Manila through
a modernized expressway. A lot of large scale industries and modernized
commercial establishments can be found in the province.
Since the proposed location is near the coastal area, the water supply and
the cooling system of the plant will not be a problem. Other factors like fuel
transportation and the like will also not be much of an issue. The main objective
of the construction of the power plant in Locloc, Bauan, Batangas is to provide
and generate enough electricity to cope up with the increasing demands of the
people for a better way of living and economic advancements.
After a comprehensive survey of the load demands of Bauan and 10 other
nearby municipalities, namely, Agoncillo, Alitagtag, Calaca, Cuenca, Lemery,
Mabini, San Luis, San Nicolas, Sta. Teresita and Taal, the following load
demands for the year 2009 to 2013 was obtained:
2009
2010
2011
2012
2013
Agoncillo
7,281,081
7,731,959
8,182,837
8,633,715
7,957,398
Alitagtag
60,859,471.82
69,988,392.59
80,486,651.48
92,559,649.20
Bauan
37,914,721
37,908,337
43,081,375
46,204,496.76
26,244,091
27,734,124
29,224,157
30,714,190
122,868,953.73
141,299,296.79
162,494,191.30
186,868,320.00
33,398,348
31,531,465
32,643,483
31,713,286.25
151,147,129
173,819,199
199,892,079
229,875,890.40
Calaca
24,754,058
Cuenca
Lemery
29,279,849
Mabini
San Luis
7,565,409
8,985,330
8,677,323
8,970,158
8,549,555
San Nicolas
4,373,104
5,065,873
4,930,757
4,537,849
4,726,895.75
Sta. Teresita
3,820,507
4,380,060
4,173,034
4,207,120
4,145,180.25
Taal
15,537,074
17,854,530
17,144,951
17,713,587
17,062,535.50
To obtain the capacity of the diesel electric power plant, an assumption of 13% annual load increase was made. Using a 10
year load projection the following data were obtained:
Load (kW)
2014
85186.18
2015
96260.3834
2016
108774.2332
2017
122914.8836
2018
138893.8184
2019
156950.0148
2020
177353.5167
2021
200409.4739
2022
226462.7055
2023
255902.8573
2024
289170.2287
2025
326762.3584
CAPACITY
330 MW
1. Design a 330MW diesel electric power plant with properly defined overall
plant capacity and component specifications such as:
1.1 Diesel Engine
1.2 Fuel Supply System
1.3 Air intake System
1.4 Exhaust System
1.5 Cooling System
1.6 Lubricating System
1.7 Engine Starting System
2. Provide a comprehensive system diagram, flow of operations, and the
necessary plant layout of the 330MW Diesel Electric Power Plant together
with the calculations essential for the design stage.
3.
CHAPTER III
DATA AND ASSUMPTIONS
This chapter presents all the data and information acquired including the
load demand profile of the chosen municipalities and the basic assumptions
which will be used and considered in the design calculation to pursue the
designing process of the 330 MW diesel electric power plant.
Load Demand Profile of the chosen Municipalities
Table 3. Survey of Load Demands of the Proposed Location for 2013
Municipality
Load (kW)
Agoncillo
908
Alitagtag
10566.17
Bauan
5,274
Calaca
3,506
Cuenca
21332
Lemery
3,620
Mabini
26241.54
San Luis
976
San Nicolas
540
Sta. Teresita
473
Taal
1,948
Economic Assumptions
The following assumptions will be considered for a comprehensive
economic analysis of the design project.
The estimate land cost in Barangay Locloc, Bauan Batangas is Php 2100
is 21 Php/l.
The proposed energy sale of the 330MW diesel electric power plant is
$5.777/kW-hr.
The cost of fuel has an annual increase of 1.25%
The labor cost is assumed to be 7% of the total running cost.
The supplies, maintenance cost and operating taxes is 5% of the total
running cost.
9
CHAPTER IV
TECHNICAL DESIGN
This chapter highlights the discussion of how the different parts of a diesel
engine power plant together with the necessary computation works gathered
from the internet, books and other reference materials. This will serve as basis
and additional knowledge in pursuing the plant design.
I.
Diesel Engine
drawn into the cylinder and compressed by the rising piston. At the top of the
piston stroke, diesel fuel is injected into the combustion chamber at a high
pressure, through an atomizing nozzle, mixing with hot, high pressure air. This
phenomenon will make the mixture ignite and burn very rapidly. The explosion
causes gas in the chamber to expand, driving the piston down with considerable
force and creating power in vertical direction. The connecting rod transmits this
motion into the crankshaft which is forced to turn, delivering rotary power at the
output end of the crankshaft. Scavenging of the engine is done either by ports or
valves. Usage of the turbocharger to compress the intake air will fully realize the
capabilities of the diesel engine. An intercooler/after cooler used to cool the
intake air after compression by the turbocharger will increase the efficiency.
11
stiffness to transmit the variable thrust from the thrust collar to engine
seating.
2. Frame box
The frame box is equipped on the exhaust side with a relief valve and
on the camshaft side with large door for each cylinder providing access
to the crankshaft components.
3. Cylinder Frame
The cat iron cylinder frames from the top of the frame box make
another significant contribution to the rigidity of the overall engine
structure. The frame include the scavenge boxes which are
dimensioned to ensure that scavenge air is admitted uniformly to the
cylinders. Staybolts are tightened hydraulically to connect the bedplate,
the frame box and the cylinder frames and form a very rigid unit.
4. Crankshaft
The conventional semi-built, shrink-fitted type crankshaft is provided
with a thrust collar. The sprocket rim for the camshaft chain drive is
fitted on the outer circumference of the thrust collar in order to reduce
the overall length of the engine except for the high cylinder numbers.
5. Connecting Rod
In order to limit the height of the engines a relatively short connecting
rod, comprising few principal parts is specified. The large area of the
lower half of the crosshead bearing allows the use of white metal or
thin aluminum on the small bore engine models
6. Cylinder Liner
The liner is bore cooled on the larger engine models and available on
two different configurations with or without insulation of the cooling
water jet pipes to match the cooling intensity closely to the different
engine ratings.
7. Cylinder Cover
13
It consists of storage tank, strainers, fuel transfer pump and all day fuel
tanks. The fuel oil is supplied at the plant by rail or road. The oil is stored in the
storage tank. From the storage tank, oil is pumped to smaller all day at daily or
short intervals. From this tank, fuel oil is passed through strainers to remove
suspended impurities.
14
This system supplies necessary air to the engine for fuel combustion. It
consists of pipes for the supply of fresh air to the engine manifold. Filters are
provided to remove dust particles from air which may act as abrasive in the
engine cylinder.
The air entering the engine must be clean, free from debris, and as cool
as possible because a diesel engine requires close tolerances to achieve its
compression ratio. To improve a turbocharged or supercharged engines
efficiency, the compressed air must be cooled after being compressed. Air intake
systems are classified into wet or dry types. In a wet filter intake system, the air is
sucked or bubbled through a housing that holds a bath of oil such that the dirt in
15
the air is removed by the oil in the filter. The air then flows through a screen-type
material to ensure any entrained oil is removed from the air. In a dry filter system,
paper, cloth, or a metal screen material is used to catch and trap dirt before it
enters the engine. In addition to cleaning the air, the intake system is usually
designed to intake fresh air from as far away from the engine as practicable,
usually just outside of the engines building or enclosure. This provides the
engine with a supply of air that has not been heated by the engines own waste
heat. The reason for ensuring that an engine's air supply is as cool as possible is
that cool air is denser than hot air. This means that, per unit volume, cool air has
more oxygen than hot air.
Exhaust System
16
This system leads the engine exhaust gas outside the building and
discharges it into the atmosphere. To reduce the noise level of this process; a
silencer is usually incorporated in the system.
The exhaust system of a diesel engine performs three major functions.
First, the exhaust system routes the spent combustion gases away from the
engine, where they are diluted by the atmosphere. This keeps the area around
the engine habitable. Second, the exhaust system confines and routes the gases
to the turbocharger if used. Lastly, the exhaust system allows mufflers to be used
to reduce the engine noise.
V.
Cooling System
The heat released by the burning of fuel in the engine cylinder is partially
converted into work. The remaining amount of heat passes through the cylinder
wall, piston, rings and other parts may cause damage to the system. Cooling is
provided in order to keep the temperature of the engine parts within safe
operating limits. It consists of a water source, pump and cooling towers. The
pump circulates water through cylinder and head jacket. The water takes away
heat from the engine and becomes hot. The hot water is cooled by cooling
towers and then re-circulated for cooling.
17
VI.
Lubricating System
18
An internal combustion engine could not run for even a few minutes if the
moving parts were allowed to have metal to metal contact. This contact
generates heat due to tremendous amount of friction leading to the engines
destruction. To prevent this, all moving parts of the engine ride on a thin film of
oil. The oils function is to lubricate the bearings surfaces and to cool the bearings
by absorbing the friction generated heat. The flow of oil to the moving parts is
accomplished by the engines internal lubricating system.
19
20
into the block. This is accomplished by either internal or external oil cooler. The
lubrication system also supplies oil to the engines governor.
VII.
21
22
23
24
500mm
Stroke
580mm
Piston Displacement
113.9L/cycle
Number of Valves
Cylinder Configuration
V-angle
45 degrees
Direction of rotation
Clockwise
Speed
Process 1-2
Process 2-3
26
Process 3-4
Energy Balance
27
Cooling Loss
For water
For oil
28
Generator
KWe= Generator Efficiency x Ec
= 0.965 x 0.48 x 35587.5 kW
29
Plant Efficiency
Plant Efficiency= KWe/Ec x 100%
= 16484.13/35587.5 x 100%
Plant Efficiency= 46.32%
20
7890 KW
1.4m/s
12m
70%
Equipment Specifications:
Cooling Tower
Type:
Capacity:
8MW
20
16 kW
Speed:
up to 1000 rpm
Max Head:
up to 12m
31
CHAPTER V
ECONOMIC ANALYSIS
This chapter presents the power plant economics of the designed 330 MW
Diesel Electric Power Plant.
Plant Economics
A power stations function is to deliver power at the lowest possible cost
per kilo watt hour. The charges must include the of interest on the capital, taxes,
insurance, depreciation and salary of managerial staff, the operating expenses
such as cost of fuels, water, oil, labor, repairs and maintenance.
The power production can be minimized by:
1. Reducing the amount of investment in the plant.
2. The plant must be operated by fewer worker
3. The plant must be uniformly designed
4. Selecting the station as to reduce cost of fuel, labor, etc.
All the electrical energy generated in a power station must be consumed
immediately as it cannot be stored. So the electrical energy generated in a power
station must be regulated according to the demand. The demand of electrical
32
energy or load will also vary with the time and a power station must be capable of
meeting the maximum load at any time.
In order to predict power plant costs given the desired output power, a
model to relate the unit cost of a new power plant varying with installed capacity
was developed. The resulting data points were plotted from the total unit costs to
build a diesel electric plant. The total unit costs are a function of equipment costs,
labor costs, balance-of-plant costs, indirect costs, engineering costs and
contingencies. These unit costs were estimated in accordance with the power
plant cost estimate basis.
.
Table 5. Equipment Cost for the Set Up
Equipment Cost for the Set Up
Investments
Diesel- Generator(20 units)
Price ($)
40,950,000
972,003
Main Transformers
1,217,173.241
18,912,963.54
Total
62,052,141
Land Cost
33
cost
of
the
building,
electrical
excavation
and
foundation,
Cost (Php)
Building
30%
115,707,155.1
Electrical
20%
77,138,103.39
Excavation and
Foundation
Instrumentation and
Control
Other
15%
20%
15%
57,853,577.54
77,138,103.39
57,853,577.54
Total
385,690,516.94
Economic Aspect
34
A. Land Cost
Land Cost = 50, 000 m2 (P2100 / 1 m2)
Land Cost = 105, 000, 000.00 Php.
C. Capital Cost, CC
CC = Equipment Cost + Total Miscellaneous Cost
CC = (62,052,141 $) (42 / 1$) + 490, 690, 516.90
CC = 2,606,189,903 Php.
%increase/year = 1.25%
The cost of fuel per kg is 28 Pesos, and the annual fuel cost is:
msfc = 0.178 kg/kW-hr
Price = msfc x 51 Pesos/kg
= 0.178 kg/kW-hr x 28 Php/kg
= 4.984 Php/kW-hr
Table 7. Fuel Cost
Year
Projected Load
(MW)
Price(Php/kw-hr)
Cost (Php)
2014
85186.18
4.984
424567921.1
2015
96260.3834
5.0463
485758772.8
2016
108774.2332
5.10937875
555768755.7
2017
122914.8836
5.173245984
635868928
2018
138893.8184
5.237911559
727513536.9
2019
156950.0148
5.303385454
832366425.4
2020
177353.5167
5.369677772
952331236.4
2021
200409.4739
5.436798744
1089585976
2022
226462.7055
5.504758728
1246622555
2023
255902.8573
5.573568212
1426292031
36
2024
289170.2287
5.643237815
1631856370
2025
326762.3584
5.713778288
1867047669
Total
11875580176
Projected Load
(MW)
Price(Php/kw-hr)
Cost (Php)
2014
85186.18
0.00321
273.4476378
2015
96260.3834
0.00321
308.9958307
2016
108774.2332
0.00321
349.1652886
2017
122914.8836
0.00321
394.5567764
2018
138893.8184
0.00321
445.8491571
2019
156950.0148
0.00321
503.8095475
2020
177353.5167
0.00321
569.3047886
2021
200409.4739
0.00321
643.3144112
2022
226462.7055
0.00321
726.9452847
2023
255902.8573
0.00321
821.4481719
2024
289170.2287
0.00321
928.2364341
2025
326762.3584
0.00321
1048.90717
Total
7013.980499
37
The cost of oil per liter is 21 Pesos, and the annual fuel cost is:
Average Annual Oil Cost = total cost for 12 years/ 12 years
= 7013.980499/12 Php
= 584.4983749 Php
Average Annual Fuel and Oil Cost = 989,631,681.3 Php + 584.4983749 Php
= 989,632,265.8 Php
LC = 0.07 1,237,040,332
LC = 86,592,823.26 Php
Operating Taxes, OT
Considering OT is 5% of the total running cost,
OT = 0.05 1,237,040,332
OT = 61,852,016.62 Php
Supplies, S
Considering S is 5 % of the total running cost,
S = 0.05 1,237,040,332
S = 61,852,016.62 Php
Supervision Taxes, ST
Considering ST is 1.5% of the total running cost,
ST = 0.015 1,237,040,332
ST = 18,555,604.98 Php
39
Item
Cost (Php)
989,632,265.8 Php
Labor
86,592,823.26 Php
Maintenance and
Material
61,852,016.62 Php
Supplies
61,852,016.62 Php
Operating Taxes
61,852,016.62 Php
Supervision
18,555,604.98 Php
Total
1,323,633,155.54 Php
Projected Load
(MW)
Power Generation
Price(Php/kw-hr)
Revenue (Php)
2016
108774.2332
6.8636537
6540116733
2017
122914.8836
7.481382533
8055461786
2018
138893.8184
8.154706961
9921912277
2019
156950.0148
8.888630587
12220819351
2020
177353.5167
9.68860734
15052383193
40
2021
200409.4739
10.560582
18540020380
2022
226462.7055
11.51103438
22835743102
2023
255902.8573
12.54702748
28126784801
2024
289170.2287
13.67625995
34643760825
2025
326762.3584
14.90712334
42670720189
Table 14 shows the projected power generation price and revenue for 10
years of operation of the plant from the year 2014 to 2025.
From Power Plant System Design, typical values of rate of return is 8 to
12%, consider 10%.
Profit Element = 0.10 x revenue
Table 11. Profit Element
Year
Revenue (Php)
Profit Element(Php)
2016
6540116733
654011673.3
2017
8055461786
805546178.6
2018
9921912277
992191227.7
2019
12220819351
1222081935
2020
15052383193
1505238319
2021
18540020380
1854002038
2022
22835743102
2283574310
2023
28126784801
2812678480
2024
34643760825
3464376083
2025
42670720189
4267072019
41
Profit Element(Php)
2014
2,606,189,903
431097612.2
2,175,092,291
2015
2,175,092,291
530982928.9
1,644,109,362
2016
1,644,109,362
654011673.3
990,097,689
42
2017
990,097,689
805546178.6
184,551,510
2018
184,551,510
992191227.7
-807,639,718
CHAPTER VI
ENVIRONMENTAL MANAGEMENT
This chapter incorporates the environmental standards for the design
policies related to the Diesel Electric Power Plant.
Environmental Aspect
Environmental Management Plan
Environmental conditions shall provide dust control of all excavations,
material sites, roads, disposal areas within its assigned areas of responsibility
and shall provide suitable equipment, facilities and precautions limit, the
discharge of contaminants and noise level. The ambient air quality impact
resulting from the emission of pollutants shall not exceed the National Ambient
Air Quality Standards for Source Specific Air Pollutants. Noise generated during
power plant operation shall conform to Noise Standards stipulated in NPCC
43
memorandum. The waste water discharges from the power plant complex shall
not cause the water quality of bodies around the power plant to exceed the
standards set by DENR.
One of the important first steps in establishing an environmental
management system is to understand the range and diversity of environmental
issues to be addressed.
The list of issues is no longer than many managers at first believe. The
relationship between issues is also an important factor, for action on one issue
can easily affect the estates performance on another.
The preparation of a comprehensive environmental assessment report is
thus an important first step.
Some of the specific management elements, which contribute to improving
environmental performance, are described below.
Elements of an Environmental Program
1. Sound policies and clear objectives, which define environmental issues and
identify the states approach, such as emphasis on prevention rather than
treatment.
2. Well-defined operating standards and realistic targets for discharges and site
safety.
3. Visible and effective management commitment to environmental protection.
44
45
46
CHAPTER VII
PROJECTION CONSTRUCTION EXECUTION PLAN
This chapter addresses the planning problem of a 330 MW Diesel Electric
Power Plant by optimal allocation of diesel fuel portfolios in long term fixed
contracts and short term market. It includes the method of the design policies
related to the project management of the entire operation of the plant.
I. Construction Strategy and Management
The construction of buildings and engine layout are similar in many
respects to the steam power plants, although on a much smaller scale. A steel
frame with brick panels and asbestos sheet roof is quite satisfactory. Good
natural lighting can be provided by including large vertical or horizontal windows
in the side walls and rows of skylights in the engine house roof. Quick deliveries,
simplicity of operation and ability to start quickly are in the favor of diesel plants.
However, the direct numerical comparison is meaningless unless
accompanied by a detailed analysis of each plant in respect to the construction
difficulties encountered during erection, special foundation needs equipment,
47
48
49
Program monitoring.
51
CHAPTER VIII
SUMMARY OF FINDINGS, CONCLUSION AND RECOMMENDATIONS
The key environmental issues associated with the power plant are as follows:
Emission of carbon dioxide to the air;
Generation and disposal of liquid effluents including cooling water;
and
52
Emission of noise.
The potential impacts of the carbon dioxide emissions to the air,
generation and disposal of liquid effluents including cooling water; and the
emissions of noise have been assessed using sophisticated modeling
techniques, which include consideration of the ambient background environment
and the characteristics of the releases or emissions, and predicts the potential
impacts which may occur. The assessment indicates that no significant
environmental impacts will occur as a result of the construction or operation of
the power plant and, when taken together, the overall environmental and social
impact will not be significant.
Conclusion
This final section briefly reviews findings of the study across the various
environmental factors. It notes the potential impacts and indicates whether
mitigation measures can alleviate all concerns, and if they cannot, it identifies the
residual impacts. This section follows the sequence of environmental factors
presented in the last two chapters. In essence, it is an overall summation of the
environmental soundness of the proposed project.
Recommendations
The findings in this work can be used for training and also serve as an
important handbook for Diesel Electric Power Plants. The outcome of the
research may also serve as an information source for Mechanical Engineering
students.
53
54