Diesel Power Plant Design

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
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
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 24 1800 9am-11am 2hrs 43200 86.4
2
stove
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
198 110 9am-9pm 12hrs 10780 129.36
sets
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 total
Appliances Wattage kw-hr
Appliances Use hr/day Wattage
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
Appliances Wattage total Wattage kW-hr
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
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
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
3
 Hotel
Air
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
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
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
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 &
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
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
4
9am-11am &
drill press 1 750 4hrs 380 1.52
1pm-3pm
9am-11am &
radio 1 180 4hrs 110 0.44
1pm-3pm
welding 9am-12nn &
1 13000 5hrs 13000 65
machines 1pm-3pm
9am-12nn &
1pm-4pm
TOTAL 98.302
 Hardware
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
fluorescent
20 40 6pm-6am 12hrs 800 9.6
lamp
radio/karaoke 3 180 8am-1pm 5hrs 540 2.7
air
unit
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
Christmas
4 25 6pm-6am 12hrs 100 1.2
lights
TOTAL 160.148
 Bakeries
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
TOTAL 26.63
 Gasoline Stations
fluorescent
15 40 5pm-5am 12hrs 600 7.2
lamp
5
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
christmas
4 25 6pm-6am 12hrs 100 1.2
lights
TOTAL 202.064
 Barber Shops
8am-10am &
Karaoke 1 180 5hrs 180 6.9
1pm-4pm
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 CONSUMPTIO LOAD VALUE
N
1 9544.212 397.6755
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
6
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
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
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.
Morse; Cooling System; page 178; using the equation below we are to use the
given equation to obtain the required circulating cooling water.
W = 674.58
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 be equal to the generator output. Losses would
be present so the net efficiency would be used to offset the generator output.
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.
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.
Rated Bhp =
= 600.47 kW ( )
Rated Bhp = 805.24 hp
8
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...
Wc = 674.58
= 674.58
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:
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
9
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,
V=
Computing now for the velocity at the suction we have…
Vs =
Vs = 379.97 m/min (1min/60secs)
Vs = 6.33 m/sec
Computing now for the velocity at the discharge we have…
Vd =
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

Discharge head = FL+ZD+
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
Discharge head = FL+ZD+
Discharge head = 0.75 + 2.302 m +
Discharge head = 3.052 m
10
Computing now for the suction head…
Suction head = FL + ZS + V
Suction head = FL + ZS +
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
Suction head = FL + ZS +
Suction head = 0.75 – 4.5m +
Suction head = -1.71 m

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…
Pump supply power =
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%
Pump supply power =
Pump supply power =
Pump supply power = 2.74 hp (2.75 hp)
11
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)
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…
QR =
= 3018.33 L/min
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…
12
VS =
VS =
VS = 633.29 m/min (1min/60 secs)
VS = 10.55 m/sec
VD =
VD =
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
Discharge Head = FL + ZD +
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
Discharge Head = 0.75 + 5m +
Discharge Head = 19.28 m
Suction Head = FL + ZS + VS
Suction Head = FL +ZS +
Where: FL = Friction Losses at Suction; 0.75
13
ZS = Elevation from Datum to Suction; 4.5 m (- due to location)
VS = Velocity Head at Suction; 10.55 m/sec
Suction Head = FL +ZS +
Suction Head = 0.75 – 4.5 m +
Suction Head = 1.92 m

Pump Operating Head = Discharge Head – Suction head
= 19.28 m - 1.92 m
Pump Operating Head = 17.36 m
Pump supply power =
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%
Pump supply power =
Pump supply power =
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:

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.
14
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…
WW =
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
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
15
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…
WW =
–
=
–
WW = 1.27 kJ/kg dry air
Since 3007 kg/min of raw water is given, the air flow is…
Air flow =
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
16
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
Make-up Water =
Make-up Water = 39.67 L/min
6. Forced Draft Fan:
Based from https://my.amca.org/members/documents/catalogs/64_91_Catalog-

157-B%20NOV99.pdf, 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
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 = √
17
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%.

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.
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.
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…
Maximum Rate of Fuel =

= 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
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
18
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:

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:

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
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
19
(American Petroleum Institute) standard, assuming an oil temperature of 6° C
and the equations 5 – 3, the °API would be…
°API = - 131.5
= – 131.5
°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
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…
V=
20
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…
d2 =
d2 =
d2 =
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:
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)
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…
21
A = π d2/4
Where: A = Cross-sectional Area; m2
d = Internal Diameter; m
V=
VS =
VS = 238.24 m/min (1min/60secs)
VS = 3.97 m/sec
VD =
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,
Discharge Head = FL + ZD + V
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
Discharge Head = 0.75 + 4.5 +
22
Suction Head = FL + ZS + V
Suction Head = FL + ZS +
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
Suction Head = FL + ZS +
Suction Head = 0.75 – 2.5 +
Suction Head = -0.95 m

= 6.73 m + 0.95 m
Pump supply power =
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 %
Pump supply power =
Pump supply power = 0.70 hp
23
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)

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:
24
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)
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
25
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
http://www.engineeringtoolbox.com/compressed-air-receivers-d_846.html with
the topic Compressed Air Receivers and using the provided tables…
Recommended Receiver Volume per HP
Compressor Power Recommended Receiver Volume

(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:

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
26
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…
Rated Bhp =
= 600.47 kW
For a continuous operation, the generated power would be…
Generated Power = 600.47 kW * 24 hours

Generated Power = 14411.28 kW-hour

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
27
= 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.
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…
VS =
VS = 292.28 m/min (1min/60secs)
VS = 4.87 m/sec
VD =
28
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,
Discharge Head = 0.75 + 4.5 +
Suction Head = 0.75 – 2.5 +
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…
= 7.48 m + 0.54 m
Pump supply power =
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 %
Pump supply power =
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
29
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
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…
30
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
Deviating from the equation & computing we have…
b=
b=
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:
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…
V F = WF / ρ
VF =
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.
V F = L F * WF * H F
HF =
31
HF = 2.48 m
H. Materials for the Machine Foundation:
Table 4-1: Data on Concrete Mixes to Yield 1 cu. m Concrete; page 90; using a mixture
of 1:3:5 as it is often used for foundations we have the following data…
Using a Mixture of 1:3:5 (1 part of cement, 3 parts of sand, and 5 parts of stone) to
produced 1 cu. meter of concrete using 1:3:5 mixtures, the ff. are needed:
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:
Article 2.4 Machinery & Equipment; Section 2.4.1.7, 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:
32
Article 2.4 Machinery & Equipment; Section 2.4.1.7, 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:
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..
33
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.
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.
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
34
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 2010, then we are to follow the
proposed schedule given below…
Time & Month Target Work Output Relevance

Load Survey for the Initial work frame for the
consumer kilowatt project; idealization for the
consumption; Gathering & project’s continuity
surveying of the
January to March 2013
environment within the
location; Planning &
securing necessary permits
Computation for the Initial work frame for the

required plant operation plant’s construction &
which includes the operation; Idealization for
following: Selection of the plant layout, operation
Diesel Engine type, & maintenance
Design of the Generator Set,
Design of its Fuel Oil
System,
Design for its Cooling Water
System,
April to June 2013 Design for its Lubricating
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 Idealization of the plant

site; Purchase of site
equipments; Construction of
July to February 2014 Administration Building &
Others; Installation of the
equipments
Initial operation; Testing phase of the

Recalibration of equipments project; Checking for
March to April 2014
flaws & defects
35
Turnover of Plant operation Final project phase
May 2014 to the owner/firm
36

Diesel Power Plant Design

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DESIGN PROBLEM

Number of population: 14098

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

Households: 3873 Satellite market: 6

3. Identifying the number of customers per zone.

Zone No. of Population No. of households

4. Time usage of the customers per 24 hours.

No. of Schedule of Schedule

5. Determining the total power requirement for the area.

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T.

Where: W – circulating cooling water; liter per hour

Rated Bhp – Rated Brake horsepower

Rated Bhp = 805.24 hp

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

Therefore, we need 108639.76 Liters/hour or 1765.14 kg/min for the circulating

2. Water Jacket Circulating Pump:

Suction line pipe:

Discharge line pipe:

Where: Q – volume flow rate; m3/min

Where: A – Cross-sectional area; m2

Computing now for the velocity at the suction we have…

Vs = 379.97 m/min (1min/60secs)

Computing now for the velocity at the discharge we have…

Vd = 586.53 m/min (1min/60secs)

Discharge head = FL+ZD+V

Discharge head = FL+ZD+

Discharge head = 0.75 + 2.302 m +

Discharge head = 3.052 m

Suction head = 0.75 – 4.5m +

Suction head = -1.71 m

Based from Power Plant Engineering (Adapted to MKS Units) by Frederick T.

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…

Pump supply power =

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%

Pump supply power =

Pump supply power =

Pump supply power = 2.74 hp (2.75 hp)

3. Required Raw Water for the Cooling Tower:

QC (tC1 – tC2) = QR (tR1 – tR2)

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

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…

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

4. Raw Water Pump:

Computing now for the velocity at the suction we have…

VS = 633.29 m/min (1min/60 secs)

Computing now for the velocity at the discharge we have…

VD = 977.56 m/min (1 min/60 secs)

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

Discharge Head = 0.75 + 5m +

Discharge Head = 19.28 m

Computing now for the suction head…