Buok Chapter 3

CHAPTER 3
FUEL OIL SYSTEM
3.0 Design of Fuel Storage Tank

Design Parameters:
Generator set capacity 2,708 kW
Percent Plant Capacity Factor 55.06 %
Installed Capacity 10,832 kW
Daily Energy Produced 143,137.50 kW-hr
Consider that the fuel is consumed at 25°C (from the
catalogue).
3.1 Calculation Procedure:

3.1.1 Specific Gravity of Fuel
141.5
𝑆𝐺15.6 = 131.5+𝐴𝑃𝐼
Where:
API=35 from catalogue
Substituting,
141.5
𝑆𝐺15.6 = 131.5+35
𝑆𝐺15.6=0.85
Since fuel is consumed at 25°, we have,
SGt = SG15.6[1-0.0007 (t-15)]
SGt = 0.85 [1-0.0007 (25-15)]
SGt = 0.844
3.1.2 Density of Fuel “𝝆f” and Specific Weight of Fuel “𝜹f”:
For density of fuel, 𝜌f:
Power Plant Engineering – Design of Diesel Power Plant 23

𝜌𝑓
𝑆𝐺𝑡 =
𝜌𝑤
Where:
𝜌f = density of fuel
𝑘𝑔⁄
𝜌w = density of water, 1000 𝑚3
Substituting,
𝜌f = SGt x 𝜌w
𝜌f = 0.844x 1000 kg/m3

𝝆f= 844 kg/m3
3.1.3 Specific Weight of Fuel, 𝜹f:

δf
SGf =
δw
Where:
𝛿𝑓 = specific weight of fuel
𝛿𝑤 = specific weight of water, 9.81 𝑘𝑁⁄𝑚3
Substituting,
δf = 0.844 x 9.81 kN⁄m3
δf = 8.28 kN⁄m3
3.1.4 For Brake Power, PB:
PB =2850 kW from catalogue

3.1.5 Fuel Consumption @ 65.54%, mf:
From Catalogue:
Fuel consumption Prime rating
100% Load 179 g/kWhr
75% Load 185 g/kWhr
65.54% Load mf
50% Load 193 g/kWhr

3.1.6 Specific Fuel Mass Consumption of 65.54% Load by the
Use of Interpolation, mfc:
0.6554 − 0.75 𝑚𝑓 − 185
=
0.50 − 0.75 193 − 185
𝒎𝒇𝒄 = 𝟏𝟖𝟖. 𝟎𝟐𝟕𝟐 𝒈/𝒌𝑾𝒉𝒓
Therefore:
𝑔 1𝑘𝑔
𝒎𝒇𝒄 = 188.0272 𝑘𝑤ℎ𝑟 × 1000𝑔
𝑘𝑔
𝒎𝒇𝒄 = 0.188 𝑘𝑤ℎ𝑟 × 2850𝑘𝑤
mfc = 535.88 kg/hr

3.1.7 Volume Flow Rate of Fuel, Vf
mf
vf =
ρf
Where:
𝜌f= Density of fuel = 844 kg/m3

Substituting,
535.88 kg/hr
vf =
844 kg/m3
3
vf = 0.6349 m ⁄hr
3.1.8 Monthly Energy Produced, MEP:
MEP
Plant Capacity factor= 24 hr
IC x day x 30 days
Where:
MEP = Monthly energy produced
IC = Installed capacity, 10,832kW
PCF = Plant Capacity Factor, 55.06 %
3.1.9 Energy Produced for 3 months:

24 hr
MEP= PCF x IC x x 90 days
day

24 hr
MEP = 0.5506x 10,832 kW x x 90 days
day
MEP = 12,882,454.27 kW-hr

3.1.10 Mass of Fuel Consumption, mf:
mf = MEP x SFC
Where:
mf = mass of fuel consumption
MEP = Monthly energy produced
SFC = Specific Fuel Consumption
Therefore,
mf = 12,882,454.27kW-hr x 0.188kg/kW-hr
mf = 2,421,901.4kg
3.1.11 Volume of Fuel Consumption for 3 months, Vf:
mf
Vf = ρf
Where:
ρf =density of fuel
Therefore,
𝟐,𝟒𝟐𝟏,𝟗𝟎𝟏.𝟒kg
Vf = kg
844
m3
Vf = 2869.55 m3
3.1.12 Allowable Volume Capacity/ Tank, Va:
The designers believed that two (2) storage tanks should
be constructed, so that one may be cleaned or inspected while
the other is in operation.
Therefore,
Vf
Va = 2
Where:
Va = allowable volume capacity/tank

Substituting,
2869.55 m3
Va = 2
Va = 1434.775 m3
3.1.13 Volume of Storage Tank, VT:

Because of differences in production methods, it is
recommended to store several months’ supply of fuel and
provide contingency against delivery failures originating
from flood, storms, and the like.
Let the fuel oil delivery to be every three months of

storage and 25% contingency.
Therefore,
VT = Va + 0.25Va
VT = 1.25 Va
VT = 1.25(1434.775 m3)
VT = 1,793.47 m3
3.1.14 Dimensions of the Storage Tank,DT & H:

Note:
The most common shape for Fuel Oil Storage Tanks is
cylinders with a conical top then, let it also be the shape
of it in this design.
Therefore:
The volume of the tank is equal to the volume of cylinder
VT =Vc
π
Vc = DT 2 HT
4
Assume:
Height of the tank = 1.5 x Diameter of the tank
H = 1.5DT
Thus,
π
Vc = DT 2 (1.5DT )
4
Vc = 0.375πDT 3
Vc
DT 3 =
0.375π
3c V
DT =√0.375π
Substituting,
3 1,793.47 m3
DT = √ 0.375π
DT = 11.5 m
Therefore,
H = 1.5(11.5 m)
H = 17.25 m
And, since the fuel level should not reach the top of
the tank then we will use a conical top for the storage tank
in order that the rain water will not stock into it.
3.1.15 Total Height of the Fuel Storage
Tank,𝐇𝐓 :
HT = H + hc
Where:
Hc = Height of Cone
H = Height of Cylinder
Substituting,
HT = 17.25 m+1.0 m
HT = 18.25 m
3.1.16 Surface Area of the Cone, SAcone:
SAcone = π R √R2 +hc 2

Where:
𝑅= radius
hc = height of cone
Therefore:
SAcone = π (5.75 m) √(5.75 m)2 +(1.0m)2

SAcone = 106 m2
3.1.17 Surface Area of the Cylinder, SAc:

π
SAc = ( 4 D2 )+ π(DH)
π
SAc = (11.5 m)2 + π(11.5 m×17.25 m)
4
SAc = 727 m2
3.1.18 Total Surface Area of the Storage

Tank, SAT:
SAT = SAcone + SAcylinder
SAT = 106 m2 +727 m2

SAT = 833 m2
Dimension of the Storage Tank
D = 11.5 m
Hcyl = 17.25 m
Hcone = 1.0 m
HT = 18.25 m

Material Estimate for Storage Tank
3.2 Solving for the Thickness of the Storage Tank, tST
From A Textbook of Machine Design by Khurmi and Gupta,
p. 226. Therefore, the design of a pressure vessel must be
based on the maximum stress.
𝑝×𝑑
𝑡=
4𝜎2 ×𝜂𝑐
Where:
P = Maximum Allowable Internal Pressure
ri = Inside Diameter of the storage tank
𝜂𝑐 =efficiency of circumferential joint
𝜎2 =stress value of carbon steel SA-285
3.2.1 Pressure inside the Tank, P
P= δfuel ×hf + δair ×ha
3.2.2 Height of Fuel,hf

Va
hf = π
𝐷𝑇 2
4
Substituting the value,
𝟏,𝟒𝟑𝟒.𝟕𝟕𝟓 m3
hf = π
(11.5 m)2
4
hf =13.81 m
3.2.3 Height of Air, ha
ha =HT -hf
Substituting,
ha =(18.25 m – 13.81 m)
ha = 4.44 m
3.2.4 Specific Weight of Fuel, δf
δf =SGf xδw
Where:
SGf =0.844
kN
δw =9.81 m3
Substituting,
kN
δf =0.844 × 9.81 m3
kN
δf =8.28 m3
3.2.5 Density of Air
ρair =SGair × δwater
Where:
Pa =atmospheric pressure, 101.325 kPa

kJ
Ra =gas constant of air, 0.287 kg K
T = ambient temperature, 25 ℃
Substituting,
(101.325 kPa)
ρair = kJ
(0.287 )(25+273)K
kg K

𝒌𝒈
ρair = 1.1847 𝒎𝟑
3.2.6 Specific Weight of Air,𝛅𝐚𝐢𝐫
𝛾𝑎 = 𝜌𝑎 × 𝑔𝑎
Where:
𝜌𝑎 = density of air
m
𝑔𝑎 = acceleration due to gravity, 9.81 sec2
Substituting the values,
kg m
𝛾𝑎 = 1.1847 m3 × 9.81 sec2
𝑁
𝛾𝑎 = 11.62 𝑚3
𝒌𝑵
𝜸𝒂 = 𝟎. 𝟎𝟏𝟏𝟔𝟐 𝒎𝟑
From;
P= 𝛾fuel ×hf + 𝛾air ×ha
kN 𝑘𝑁
P= (8.28 m3 ×13.81 m+ 0.01162 𝑚3 ×4.44 m)
P =114.40 kPa
P =16.58 psi
Therefore,
Pa =Ps +Patm
Pa = 16.58 psi + 14.7 psi
Pa = 31.28 psi
3.2.6 Maximum Allowable Working Stress, S
Table 4. Design Equation Data for Pressure Vessel
Recommended Stress Values

Metal Temperature,  F S, Psi
Carbon Steel (SA-285, Gr. C) -20 to 650 13,700
From: Peters, M.S. and K.D. Timmerhaus. 1991. Plant
Design and Economics for Chemical Engineers 4thed. New York;
McGraw, Inc., Page 538
3.2.7 Welding Efficiency, EJ

From PME Code; p. 147; the efficiency of doubled but
weld for fusion weldjoints is 70%.
From,
𝑝×𝑑
𝑡=
4𝜎2 ×𝜂𝑐

lb 3.281𝑓𝑡 12𝑖𝑛
(31.28 2 )(11.5𝑚× × )
in 1𝑚 1𝑓𝑡
tST = 𝑙𝑏
4(13,700 2 )(0.70)
𝑖𝑛
tST = 0.369 inch
tST = 9.3726 mm
From PME Code, 2012 Edition, Page 418.

Table 2215.2.1.7 Shell Plate Thickness
Nominal Tank Diameter Nominal Thickness

m Ft mm in
< 15 <50 5 3/16
15 to <36 50 to <120 6 1/4
36 to 60 120 to 200 8 5/16
>60 >200 10 3/8

For fuel storage tank, standardized values from the PME code,
Therefore,
tST = 10 mm
3.3 DESIGN OF DAY TANK:
Note: The day tank should supply fuel oil in 8-hour operation
at full load (100%).
From Catalog: Fuel consumption
Diesel, Lph (gph) Prime Rating
at % load
100% 184 g/kWhr
85% 183 g/kWhr
75% 185 g/kWhr
50% 193 g/kWhr
3.3.1 Fuel Consumption of the Day Tank, mfD:

g 1kg
mfD =184 x x 2850 kw
kw-hr 1000g
kg
mfD =524.4
hr
Therefore,
kg
mfD =524.4 ×8 hrs
hr
mfD =4,195.2 kg of fuel oil per 8 hours operation

3.3.2 Volume of Fuel Consumption per 8 hours Operation, VfD:
mfD
VfD =
ρf
Substituting,
4,195.2 kg
VfD = kg
844 3
m

VfD =4.97 m3
3.3.3 Volume of the Day Tank, VDT:
Since the Fuel would occupy the Day tank, then the volume
of Day tank is equal to it.
VDT =VfD =4.97 m3

3.3.4 Dimensions of Day Tank:
Note:
For Day Tank, the most common shape is cylinder then let
it be also the shape of tank in this design.
Therefore:
The volume of the tank is equal to the volume of cylinder
VDT =VfD
π
VfD = DDT 2 hT
4
Assume:
Height of the tank = 1.5 x Diameter of the tank
hT = 1.5DDT
Thus,
π
VfD = DDT 2 (1.5DDT )
4
VfD = 0.375πDDT 3
VfD
DDT 3 = 0.375π
3 fD V
DDT = √0.375π
Substituting,
3 4.97 𝑚3
𝐷𝐷𝑇 = √ 0.375𝜋
DDT = 1.62 m
Therefore,
h = 1.5(1.62 m)

h = 2.43 m
To prevent overflow of fuel there should be an air gap
between the fuel and cover of the day tank. Then, assume an
air gap of 0.5 m. Therefore, the new height of the day tank
will be 2.93 m.
Therefore,
hT = 2.93m
Dimensions of the Day Tank

D = 1.62 m
Hcyl = 2.43 m
HT = 2.93 m
3.4 THICKNESS OF THE STORAGE TANK
From A Textbook of Machine Design by Khurmi and Gupta,
p. 226. Therefore, the design of a pressure vessel must be
based on the maximum stress.
𝑝×𝑑
𝑡=
4𝜎2 ×𝜂𝑐
Where:
P = Maximum Allowable Internal Pressure
d= Inside Diameter of the storage tank
𝜂𝑐 =efficiency of joint
𝜎2 =stress value of carbon steel SA-285
3.4.1 Pressure inside the tank, P
P= δfuel ×hf + δair ×ha
3.4.2 Height of the Fuel,Hf

VFD
hf = π
𝐷𝐷𝑇 2
4
4.97 m3
hf = π
(1.62 m)2
4
hf =2.4112 m
3.3.7 Height of Air, ha
ha =hT -hf
Substituting the value,
ha =(3.0 m–2.4112 m)
ha =0.5888 m
3.3.8 Specific Weight of Fuel, δf
𝛾f =SGf x𝛾w
Where:
SGf =0.844
kN
δw =9.81 m3
Substituting,
kN
𝛾f =0.844 × 9.81 m3
kN
𝛾f =8.28 m3
3.3.9 Specific Weight of Air,𝛅𝐚𝐢𝐫
𝛾𝑎 = 𝜌𝑎 × 𝑔𝑎
Where:
kg
𝜌𝑎 = density of air, 1.1847 m3

m
𝑔𝑎 = acceleration due to gravity, 9.81 sec2
kg m
𝛾𝑎 = 1.1847 m3 × 9.81 sec2
𝑁
𝛾𝑎 = 11.62 𝑚3
𝒌𝑵
𝜸𝒂 = 𝟎. 𝟎𝟏𝟏𝟔𝟐 𝒎𝟑
From;
P= 𝛾fuel ×hf + 𝛾air ×ha
kN 𝑘𝑁
P= (8.28 m3 ×2.4112 m+ 0.01162 𝑚3 ×0.5888 m)
P =20 kPa
P =2.9 psi
Therefore,
Pa =Ps +Patm
Pa = 2.9 psi + 14.7 psi
Pa = 17.60 psi
3.2.6 Maximum Allowable Working Stress, S
Table 4. Design Equation Data for Pressure Vessel
Recommended Stress Values
Metal Temperature,  F S, Psi
Carbon Steel (SA-285, Gr. C) -20 to 650 13,700
From: Peters, M.S. and K.D. Timmerhaus. 1991. Plant
Design and Economics for Chemical Engineers 4thed. New York;
McGraw, Inc., Page 538

3.2.7 Welding Efficiency, EJ
From PME Code; p. 147; the efficiency of doubled but
weld for fusion weldjoints is 70%.
From,
𝑝×𝑑
𝑡=
4𝜎2 ×𝜂𝑐

lb 3.281𝑓𝑡 12𝑖𝑛
(17.60 2 )(1.62𝑚× × )
in 1𝑚 1𝑓𝑡
tST = 𝑙𝑏
4(13,700 2 )(0.70)
𝑖𝑛
tST = 0.03 inch
tST = 0.762 mm
From PME Code, 2012 Edition, Page 418.

Table 2215.2.1.7 Shell Plate Thickness
Nominal Tank Diameter Nominal Thickness
m Ft mm in
< 15 <50 5 3/16
15 to <36 50 to <120 6 1/4
36 to 60 120 to 200 8 5/16
>60 >200 10 3/8
For fuel day tank, standardized values from the PME code, for
diameter less than 15 meters, use data as specified.
Therefore,
tST = 5.0 mm

3.5 DIMENSIONS OF RETURN FUEL TANK
DESIGN CONSIDERATIONs
As to the dimensions of return fuel tank, the designers
decided to have a diameter and height of about one half the
diameter and height of the diesel fuel day tank. And for the
thickness, it is equal to the thickness of fuel day tank.
Therefore,
Diameter of the Return Fuel Tank 0.810 m
Height of the Return Fuel Tank 1.465 m
Thickness of the Return Fuel Tank 5.0 mm
Specification of Fuel Oil Storage Tank

Material used Carbon steel (SA-285,Gr.C)
Height of Storage tank 17.25 m
Volume of storage tank 1,793.47 m3
Diameter of storage tank 11.5 m
No. of unit installed 2 units
Specification of Fuel Oil Day Tank

Height of day tank 2.93 m
Volume of day tank 4.97 m3

Diameter of day tank 1.62 m
No. of units installed 4 units

Specification of Return Fuel Oil Tank
Height of Return Fuel Tank 1.465 m
Diameter of day tank 0.81 m
No. of units installed 4 units
3.6 PIPING DESIGN AND SELECTION:

Pipelines from Storage Tank to Day Tank:
Volume Consumption for 8 hours 4.97 m3
Filling Time 5 minutes
From Power Plant Engineering by Morse, page. 603.
The parameters to be used in the determination of

appropriate specification for pipelines suited for this kind
of application are; the assumed filling time which is 5
minutes and the average velocities at pump’s suction and
discharge line which are 106.5 and 137 m/min respectively.
3.6.1 Volume Flow Rate of Fuel from Storage Tank to Day Tank,
Qs-d:
From:
𝑉𝐷𝑇
Qs-d = 𝑇𝑓
Where:
VDT = capacity of day tank
Tf = the assumed filling time
Substituting the values:
4.97𝑚3
𝑄𝑠−𝑑 =
5 𝑚𝑖𝑛
Qs-d= 0.994 m3/min
3.5.2 Diameter of Pipe at Suction Line, Ds:
From:
πDs 2 Vs
Qs−d =
4
4Qs−d
Ds 2 =
πVs
4Qs−d
Ds = √
πVs
Where:
Qs-d = volume flow rate of fuel from storage

tank to service tank or day tank
Vs = velocity of fuel at suction line
Substituting the values:
3
4 (0.994 m ⁄min)
Ds = √
π(106.5 m⁄min)
Ds = 0.109 m
Ds =109 mm
Say use 125 mm
Thus,
TABLE E.25 Principal Properties of Commercial Pipe (Metric

Data) page 2257 of PIPING HANDBOOK by Mohinder L. Nayyar

Nominal Schedule Outside Wall Inside
Diameter,mm Number Diameter Thickness(mm) Diameter(mm)
125 Std. 40 141.3 6.553 128.194
3.5.3 Diameter of Pipe at discharge line, Dd:
From:
πDd 2 Vd
Qs−d =
4
4Qs−d
Dd 2 =
πVd
4Qs−d
Dd = √
πVd
Where:
Qs-d = volume flow rate of fuel from

storage tank to service tank or day tank
Vd = velocity of fuel at discharge line
Substituting,
3
4 (0.994 𝑚 ⁄𝑚𝑖𝑛)
𝐷𝑑 = √
𝜋(137 𝑚⁄𝑚𝑖𝑛)
Dd = 0.096 m = 96 mm
Dd =96 mm
Say use 100mm
Thus,

From TABLE E2.1 Principal Properties of Commercial Pipe page
2257 of PIPING HANDBOOK by Mohinder L. Nayyar

100 Std. 40 114.3 6.02 102.26
3.5.4 Pipelines from Day Tank to Engine:
Design Data and Basic Assumptions
From Power Plant Theory and Design by Potter, page 72:
This item number presents the parameters needed in

determining the required specifications of pipelines to be
used in transporting fuel from service tank or day tank to
the engine.
Fluid Less than 8 in. Ø
Diesel Fuel Oil 200-300 ft/min
Let say take the average which is 250 ft/min (76.22

m/min). Assume also that the diameter at suction is equal to
that of the discharge line.
Discharge Flow Rate, Q:

Since the capacity of the day tank is for eight (8) hours
or 480 minutes of operation. The volume flow rate of fuel
from day tank to the engine will be,
4.97 𝑚3
𝑄 =
480 𝑚𝑖𝑛.
𝒎𝟑
𝑸 = 𝟎. 𝟎𝟏𝟎𝟑𝟓
𝒎𝒊𝒏

3.5.5 Diameter of Pipe at Pump’s Suction and Discharge Line,
Dde:
πDsd 2 Vsd
Qd−e =
4
4Qd−e
Dde 2 =
πVsd
4Qd−e
Dde = √
πVsd
Where:
Qd-e = volume flow rate of fuel from or day tank

to engine
Vsd = velocity of fuel at pump’s suction and

discharge line.
Substituting,
3
4 (0.01035 m ⁄min)
Dde = √
π(76.22 m⁄min)
Dde= 13.15 mm,
Say use 15 mm


15 Std. 40 21.336 2.769 15.798

3.5.6 Diameter of Pipe at Pump’s Suction and Discharge Line
of the Return Fuel Tank
The designers decided to have an equal diameters of

suction and discharge line of fuel day tank and return fuel
day tank.
Therefore, the diameters of suction and discharge line

is equal to 15 mm.


15 Std. 40 21.336 2.769 15.798

Pump System
Solving for pump for fuel storage to day tank:
1. FOR DYNAMIC DISCHARGE HEAD
A. Solving for the total dynamic head of fuel, TDH:
TDH = DDH – DSH →working equation.

Where:
DDH = dynamic discharge head at the pump’s
discharge side.
DSH = dynamic suction head at the pump’s
suction side.
For DDH:
𝑃𝐷 𝑉𝐷 2
DDH = + + 𝑍𝐷 +𝐻𝑓𝐷
𝑌𝐹 2𝑔
Where:
PD = pressure at the discharge side, 124.97
kPa
ZD = static head at the discharge side
𝐻𝑓𝐷 = friction head/loss at the discharge
side
B. Solving for the velocity of liquid inside the pipe:
Q = AV → Continuity equation.

V = Q / A
𝑚3
0.994
V = 𝜋
𝑚𝑖𝑛
(0.10226 𝑚)2
4
V = 121.027 m / min
V = 2.017 m/sec
C. Solving for the friction head at discharge side, 𝑯𝒇𝑫
𝐻𝑓𝐷 = 2fLV2 / gD
Where:
𝐻𝑓𝐷 = friction head / loss, m of fluid
f = friction coefficient of pipe.
L = total straight length of pipe, m
V= velocity of liquid, m/sec
g = acceleration due to gravity, 9.81 m/sec2
D = inside diameter of pipe, m
D. For coefficient of friction, f:
f = 0.0035 + 0.0007562 (z / DVS)0.424 → for Iron and

Steel
Where:
z = viscosity, centipoises
V = velocity of liquid, m/sec
S = SG of liquid = 0.844
For Absolute Viscosity, z:
Fuel oil is consumed at 25˚C
From PPE by Morse, page 606.
Temperature (˚C) Fuel Oil (Centipoises)
21.1 40
25 z
26.7 30
By Interpolation:
z = 33.04 centipoises
Identifying the flow characteristic of liquid inside the
pipe:
 (z / DVS) < 1163.5 → flow of liquid is

turbulent in clean pipe.
 (z / DVS) > 1163.5 → flow of liquid is

laminar in all pipes.
33.04
𝑧 / 𝐷𝑉𝑆 =
0.10226(2.017)(0.844)
z / DVS = 189.80
Therefore, the flow of liquid inside the tank is
turbulent.
Therefore,
f = 0.0035 + 0.0007562 (189.80)0.424
f = 0.0105
E. Solving for the total length of straight of pipe, L:

 Valves and Fittings used in the discharge side are as
follow:
 1 Gate valve
 4 (90° Standard elbow)
 4 Standard Tee
 2 Check Valve
From Table 7.4 Equivalent lengths in straight pipe of
several fittings, meters, from RAC by Stoecker and Jones,
page 139, we can get the equivalent length of straight pipe
of these fittings.
L = LS +LE
Where:

LS= straight length of pipe, meters
LE = equivalent length of all fittings, meters
F. Equivalent length of straight pipe of fitting:

For nominal diameter (DN) of standard pipe of 100 mm,
From TABLE C17.6 Equivalent Lengths for Various Sizes of
Valves and Fittings page C.850 of PIPING HANDBOOK by Mohinder
L. Nayyar
90° Standard Elbow = 1.98 m

Standard Tee = 1.07 m
From TABLE C9.10aM (SI) Valve Losses in Equivalent
Meters of Pipe page C.493 of PIPING HANDBOOK by Mohinder L.
Nayyar
Gate Valve = 1.4 meters
Check Valve = 37 meters
Length of Straight pipe (from drawing) = 47.50 m

For Gate valve: (Assume to be fully open)
L = 47.50 m+[(1)(1.4m)+(4)(1.07 m)+(4)(1.98 m)+ (2)
(37 m)]
L = 135.1 m
G. Solving for the friction head at discharge side, 𝑯𝒇𝑫
𝐻𝑓𝐷 = (2 x 0.0105 x 135.1 x 2.0172) / (9.81 x 0.10226)
𝐻𝑓𝐷 = 11.50 m
𝑽𝑫 𝟐
H. For the velocity head at discharge side, 𝟐𝒈

𝑉𝐷 2
HV = 2𝑔
( 1.2835𝑚⁄𝑠𝑒𝑐 )2
HV = 2𝑥 9.81𝑚/𝑠𝑒𝑐 2
HV = 0.0654 m
I. Solving for the Dynamic Discharge head, DDH:

Note:
ZD = 7.064 m
𝑃𝐷 𝑉 2
DDH = + 2𝑔𝐷 + 𝑍𝐷 +𝐻𝑓𝐷
𝑌𝐹
124.97 𝑘𝑃𝐴
𝐷𝐷𝐻 = ( + 0.195 + 7.064 + 9.9) 𝑚
9.81 𝑘𝑁⁄𝑚3
DDH = 29.9 meters
2. FOR DYNAMIC SUCTION HEAD

A. Solving for the Dynamic Suction Head, DSH:

𝑃𝑆 𝑉𝐷 2
DSH = + − 𝑍𝑆 - 𝐻𝑓𝑆
𝑌𝐹 2𝑔
Where:
ZS = static head at the suction side = 0.3644 m
𝐻𝑓𝑆 = friction head or loss at the suction side
Solving for the Pressure Drop on Suction Line
𝑃 = 𝛾𝐻
Where:
𝛾 =specific weight of fuel, 8.28 kN⁄m3
H = head on suction line, 0.3644 m

Substituting,
𝑃 = 8.28 kN⁄m3 (0.3644𝑚)
𝑷 = 𝟑. 𝟎𝟐 𝐤𝐏𝐚
V = Q / A
3
0.994 𝑚 ⁄𝑚𝑖𝑛
𝑉=𝜋
(0.128194 𝑚)2
4
V = 77.0125 m / min.
V = 1.2835 m/sec
C. Solving for the friction head at suction side, 𝑯𝒇𝑺
Where:
f = friction coefficient of pipe
B. For coefficient of friction, f:
f = 0.0035 + 0.0007562 (z / DVS)0.424 → for Iron and Steel

Where:
For absolute viscosity, z:

21.1 40
25 z
26.7 30
By Interpolation:
For identifying the flow characteristic of liquid inside the

pipe:


33.04
0.128194(1.2835)(0.844)
z / DVS = 237.92

turbulent.
Solving now for the coefficient of friction, f:

f = 0.0035 + 0.0007562 (237.922)0.424
f = 0.0112
C. Solving for the total length of straight of pipe, L:

 Valves and Fittings used in suction side are as
follow:
 1 Gate valve
L = LS +LE
Where:
LS = straight length of pipe, meter
LE = equivalent length of all fittings,meter
For nominal diameter (DN) of standard pipe of 125 mm,
From TABLE C17.6 Equivalent Lengths for Various Sizes of
Valves and Fittings page C.850 of PIPING HANDBOOK by Mohinder
L. Nayyar

From TABLE C9.10aM (SI) Valve Losses in Equivalent
Meters of Pipe page C.493 of PIPING HANDBOOK by Mohinder L.
Nayyar
Gate Valve = 1.8 meters

L = 1.7464 m +[(1 x 1.8 m ) + (2 x 2.74 m)
L = 9.0264 m
E. Solving for the friction head at suction side, 𝐻𝑓𝑆
𝐻𝑓𝑆 = 2fLV2 / gD
𝐻𝑓𝑆 = (2 x 0.0112 x 9.0264 x1.28352) / (9.81 x 0.128194)
𝑯𝒇𝑺 = 0.265
𝑽𝑫 𝟐
F. For the velocity head at suction side, 𝟐𝒈
𝑉𝐷 2
HV = 2𝑔
( 1.2835 𝑚⁄𝑠𝑒𝑐 )2
𝐻𝑉 =
2 (9.81 𝑚⁄𝑠𝑒𝑐 2 )
HV = 0.084 m
G. Solving for the Dynamic Suction head, DSH:

ZS = 0.769 m
𝑃𝑆
DSH = + 𝐻𝑣 − 𝑍𝑆 - 𝐻𝑓𝑆
𝑌𝐹
213.84 𝑘𝑃𝑎
𝐷𝑆𝐻 = + 0.0952 𝑚 − 0.769𝑚 − 0.373 𝑚
9.81 𝑘𝑁⁄𝑚3
𝐷𝑆𝐻 = 20.75 𝑚
3. Solving for the Total Dynamic Head, TDH:

TDH = DDH - DSH
TDH = 29.9 m – 20.75 m
TDH = 9.15 meters
4. Solving for the rated horsepower of pump to be used, HP:
HP = (Q x TDH x 𝛾F) / pump effy.

Where:
HP = net positive suction head available
Q = flow rate of fuel.
𝛾F = specific weight of fuel

For pump efficiency: (Assume pump efficiency of 80%)
Therefore,
Pump effy. = 80%
3 1 𝑚𝑖𝑛
[1.53 𝑚 ⁄𝑚𝑖𝑛 (60 𝑠𝑒𝑐 ) ] (9.15 m) (9.81 𝑘𝑁⁄𝑚3 )
HP=
(0.80)
1 𝐻𝑃
HP=(2.86 kW) ( )
0.746 𝑘𝑊
HP = 3.8 horsepower
For Standard Pump size,

Use, 4 Hp
4. Solving for the actual horsepower of pump to be used,

HPA:
From Catalog:
Day tank to engine

1. FOR DYNAMIC DISCHARGE HEAD
A. Solving for the total dynamic head of fuel, TDH:
TDH = DDH – DSH →working equation.

Where:
DDH = dynamic discharge head at the pump’s discharge side.
DSH = dynamic suction head at the pump’s suction side.
For DDH:
𝑃𝐷 𝑉𝐷 2
DDH = + + 𝑍𝐷 +𝐻𝑓𝐷
𝑌𝐹 2𝑔
Where:
PD = pressure at the discharge side, 124.97 kPa
ZD = static head at the discharge side
𝐻𝑓𝐷 = friction head/loss at the discharge side
V = Q / A
𝑚3
0.01035
V = 𝜋
𝑚𝑖𝑛
(0.015798 𝑚)2
4
V = 52.80 m / min
V = 0.88 m/sec
C. Solving for the friction head at discharge side, 𝑯𝒇𝑫
Where:
𝐻𝑓𝐷 = friction head / loss , m of fluid
f = friction coefficient of pipe.
D. For coefficient of friction, f:

Where:

21.1 40
25 z
26.7 30
By Interpolation:

pipe:


33.04
0.015798(0.88)(0.844)
z / DVS = 2,815.87
laminar.
Therefore,
f = 0.0035 + 0.0007562 (2,815.87)0.424
f = 0.0254
E. Solving for the total length of straight of pipe, L:

 Valves and Fittings used in the discharge side are as
follow:
 1 Gate valve
 1 Check Valve
From Table 7.4 Equivalent lengths in straight pipe of

several fittings, meters, from RAC by Stoecker and Jones,
page 139, we can get the equivalent length of straight pipe
of these fittings.
L = LS +LE
Where:
LS= straight length of pipe, feet
LE = equivalent length of all fittings, feet

For nominal diameter (DN) of standard pipe of 20 mm, we
have,
Gate Valve (fully open) = 0.0 m

Check valve = 6 m

L = 14.78 m +[(1)(0.0 m)+(6)(0.8 m)+(1)(6 m)]
L = 25.58 m
G. Solving for the friction head at discharge side, 𝑯𝒇𝑫
𝐻𝑓𝐷 = (2 x 0.00978 x 25.58 x 0.842) / (9.81 x 0.02093)
𝐻𝑓𝐷 = 1.72 m
𝑽𝑫 𝟐
H. For the velocity head at discharge side, 𝟐𝒈
𝑉𝐷 2
HV = 2𝑔
(0.88 𝑚⁄𝑠𝑒𝑐 )2
𝐻𝑣 =
2𝑥 9.81𝑚/𝑠𝑒𝑐 2
HV = 0.039 m
I. Solving now for the Dynamic Discharge head, DDH:

Note:
ZD = 7.00 m

𝑃𝐷 𝑉 2
DDH = + 2𝑔𝐷 + 𝑍𝐷 +𝐻𝑓𝐷
𝑌𝐹
124.97 𝑘𝑃𝐴
𝐷𝐷𝐻 = ( + 0.036 + 7.00 + 1.72) 𝑚
9.81 𝑘𝑁⁄𝑚3
DDH = 21.5 meters
2. FOR DYNAMIC SUCTION HEAD

A. Solving for the Dynamic Suction Head, DSH:
𝑃𝑆 𝑉𝐷 2
DSH = + + 𝑍𝑆 + 𝐻𝑓𝑆
𝑌𝐹 2𝑔
Where:
PS = pressure at the suction side = 120.83 kPa
ZS = static head at the suction side = 0.225 m
𝐻𝑓𝑆 = friction head or loss at the suction side

V = Q / A
𝑚3
0.01735
V = 𝜋
𝑚𝑖𝑛
(0.02093 𝑚)2
4
V = 50.43 m / min
V = 0.84 m/sec
C. Solving for the friction head at suction side, 𝑯𝒇𝑺
Where:
f = friction coefficient of pipe
B. For coefficient of friction, f:

Where:


21.1 40
25 z
26.7 30
By Interpolation:

pipe:


33.04
0.1541(1.367)(0.8937)
z / DVS = 175.5
turbulent.
Solving now for the coefficient of friction, f:

f = 0.0035 + 0.0007562 (175.5)0.424
f = 0.01026
C. Solving for the total length of straight of pipe, L:

 Valves and Fittings used in suction side are as
follow:
 1 Gate valves

L = LS +LE
Where:
LS = straight length of pipe, feet
LE = equivalent length of all fittings, feet
D. Equivalent length of straight pipe of fitting:
For nominal diameter (DN) of standard pipe of 20 mm, we
have,
Gate Valve (fully open) = 0.0 m


L = 2.3 m +[(1 x 0.0m ) + (2 x 0.8 m)]
L = 3.9 m
E. Solving for the friction head at suction side, 𝑯𝒇𝑺
𝐻𝑓𝑆 = 2fLV2 / gD
𝐻𝑓𝑆 = (2 x 0.01026 x 3.9 x 0.842) / (9.81 x 0.02093)
𝑯𝒇𝑺 = 0.275 m
𝑽𝑫 𝟐
F. For the velocity head at suction side, 𝟐𝒈
𝑉𝐷 2
HV =
2𝑔
(0.84 𝑚⁄𝑠𝑒𝑐 )2
𝐻𝑉 =
2 (9.81 𝑚⁄𝑠𝑒𝑐 2 )
HV = 0.036 m
G. Solving for the Dynamic Suction head, DSH:

ZS = -0.225 m
𝑃𝑆
DSH = + 𝐻𝑣 − 𝑍𝑆 - 𝐻𝑓𝑆
𝑌𝐹
120.83 𝑘𝑃𝑎
𝐷𝑆𝐻 = + 0.036 𝑚 + 0.225𝑚 − 0.275 𝑚
9.81 𝑘𝑁⁄𝑚3
𝐷𝑆𝐻 = 12.3 𝑚
3. Solving for the Total Dynamic Head, TDH:

TDH = DDH + DSH
TDH = 21.5 m + 12.3 m
TDH = 33.8 meters
4. Solving for the rated horsepower of pump to be used, HP:
HP = (Q x TDH x 𝛾F) / pump effy.

Where:
HP = net positive suction head available
Q = flow rate of fuel.
𝛾F = specific weight of fuel

For pump efficiency: (Assume pump efficiency of 80%)
Therefore,
Pump effy. = 80%
3 1 𝑚𝑖𝑛
[0.01735 𝑚 ⁄𝑚𝑖𝑛 (60 𝑠𝑒𝑐 ) ] (33.8 m) (9.81 𝑘𝑁⁄𝑚3 )
HP=
(0.80)
1 𝐻𝑃
HP=(0.12 kW) ( )
0.746 𝑘𝑊
HP = 0.16 horsepower
For Standard Pump size,

Use, ¼ Hp


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CHAPTER 3

FUEL OIL SYSTEM

3.0 Design of Fuel Storage Tank

3.1 Calculation Procedure:

3.1.2 Density of Fuel “𝝆f” and Specific Weight of Fuel “𝜹f”:

For density of fuel, 𝜌f:

Power Plant Engineering – Design of Diesel Power Plant 23

𝜌f = 0.844x 1000 kg/m3

3.1.3 Specific Weight of Fuel, 𝜹f:

𝛿𝑤 = specific weight of water, 9.81 𝑘𝑁⁄𝑚3

δf = 0.844 x 9.81 kN⁄m3

3.1.4 For Brake Power, PB:

PB =2850 kW from catalogue

50% Load 193 g/kWhr

Power Plant Engineering – Design of Diesel Power Plant 24

mfc = 535.88 kg/hr

𝜌f= Density of fuel = 844 kg/m3

PCF = Plant Capacity Factor, 55.06 %

3.1.9 Energy Produced for 3 months:

Power Plant Engineering – Design of Diesel Power Plant 25

MEP = 12,882,454.27 kW-hr

Power Plant Engineering – Design of Diesel Power Plant 26

3.1.13 Volume of Storage Tank, VT:

Let the fuel oil delivery to be every three months of

3.1.14 Dimensions of the Storage Tank,DT & H:

3.1.16 Surface Area of the Cone, SAcone:

SAcone = π R √R2 +hc 2

SAcone = π (5.75 m) √(5.75 m)2 +(1.0m)2

3.1.17 Surface Area of the Cylinder, SAc:

3.1.18 Total Surface Area of the Storage

SAT = SAcone + SAcylinder

SAT = 106 m2 +727 m2

Power Plant Engineering – Design of Diesel Power Plant 29

From A Textbook of Machine Design by Khurmi and Gupta,

p. 226. Therefore, the design of a pressure vessel must be

based on the maximum stress.

P = Maximum Allowable Internal Pressure

ri = Inside Diameter of the storage tank

𝜂𝑐 =efficiency of circumferential joint

𝜎2 =stress value of carbon steel SA-285

3.2.1 Pressure inside the Tank, P

P= δfuel ×hf + δair ×ha

3.2.2 Height of Fuel,hf

Substituting the value,

3.2.3 Height of Air, ha

3.2.4 Specific Weight of Fuel, δf

3.2.5 Density of Air

ρair =SGair × δwater

Pa =atmospheric pressure, 101.325 kPa

Power Plant Engineering – Design of Diesel Power Plant 31

3.2.6 Specific Weight of Air,𝛅𝐚𝐢𝐫

Substituting the values,

P= 𝛾fuel ×hf + 𝛾air ×ha

3.2.6 Maximum Allowable Working Stress, S

Table 4. Design Equation Data for Pressure Vessel

Recommended Stress Values

Power Plant Engineering – Design of Diesel Power Plant 32

Carbon Steel (SA-285, Gr. C) -20 to 650 13,700

From: Peters, M.S. and K.D. Timmerhaus. 1991. Plant

Design and Economics for Chemical Engineers 4thed. New York;

McGraw, Inc., Page 538

3.2.7 Welding Efficiency, EJ

Substituting the values,

tST = 0.369 inch