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1 Power Plant Design for Sagay, Camiguin ACKNOWLEDGEMENT

First of all, we would like to say thank you for giving us the strength and health to

do this project work until it done not forgotten to my our family for providing everything

such as money to buy anything that are related to this work and their advised, which is

the most needed for this project. Internet, books, computers and all that as my source to

complete this project they also supported us and encouraged us to complete this task

so that we will not procrastinate in doing it. Then we would like to thank our professor

for guiding us and our friends throughout this project. We had some difficulties in doing

this task, but he taught us patiently until we knew what to do, he tried and tried to teach

us until we understand what we supposed to do with the project work. Last but not the

least, our friends who were doing this project with us and sharing our ideas they were

helpful that when we combined and discussed together we had this task done.

Power Plant Design / MEP544D2

2 Power Plant Design for Sagay, Camiguin

INTRODUCTION

In a diesel power station, diesel engine is used as the prime mover. The diesel burns

inside the engine and the products of this combustion act as the working fluid to

produce mechanical energy. The diesel engine drives alternator which converts

mechanical energy into electrical energy. As the generation cost is considerable due to

high price of diesel, therefore, such power stations are only used to produce small

power.

Although steam power stations and hydro-electric plants are invariably used to generate

bulk power at cheaper costs, yet diesel power stations are finding favour at places

where demand of power is less, sufficient quantity of coal and water is not available and

the transportation facilities are inadequate. This plants are also standby sets for

continuity of supply to important points such as hospitals, radio stations, cinema houses

and telephone exchanges. Power Plant Design / MEP544D2

3 Power Plant Design for Sagay, Camiguin

The diesel engine is recognized as the most promising powertrain in the foreseeable

future due to its superior thermal efficiency and reliability. The diesel engine has been widely used in commercial vehicles, industrial applications and today’s passenger cars

and light-duty trucks.

A diesel engine is a type of compression-ignition engine using diesel fuel. Diesel

engines can be classified into various categories. Understanding the differences and the

unique characteristics of each category of diesel engines is important for diesel engine

system design.

HISTORY The first man, who had invented the engine with ignition from compression, was E. Steward. He was interested in engines, what can work without spark plugs. In Steward’s

engine the air was compressed and compressed air was blown into the combustion

Power Plant Design / MEP544D2

4 Power Plant Design for Sagay, Camiguin chamber. Unfortunately, Steward had not come into mind to test the efficiency of that

type of engines.

Developing the concept of “economy-type heat-engine”, Rudolph Diesel in 1890

invented the engine much more efficient due to high compression ratio. In his book he suggested to use the powdered coal, but it was difficult in real life – the coal dust has an

abrasive properties and it should be found the way to put it somehow in combustion

chamber. So it was suggested to use the tailing that remains after oil refining in such

engines. So in 1897 Diesel had patented the engine design, later named Diesel engine.

Rudolf Diesel was born in Paris in 1858. His parents were Bavarian immigrants. Rudolf

Diesel was educated at Munich Polytechnic. After graduation he was employed as a

refrigerator engineer. However, he true love lay in engine design. Rudolf Diesel

designed many heat engines, including a solar-powered air engine. In 1893, he

published a paper describing an engine with combustion within a cylinder, the internal

Power Plant Design / MEP544D2

5 Power Plant Design for Sagay, Camiguin combustion engine. In 1894, he filed for a patent for his new invention, dubbed the

diesel engine. Rudolf Diesel was almost killed by his engine when it exploded. However,

his engine was the first that proved that fuel could be ignited without a spark. He

operated his first successful engine in 1897.

POWER PLANT DESIGN FOR SAGAY Diesel Power Plant for Sagay, Camiguin produces power in the range of 6.4 MW.

And they are used standby sets for continuity of supply such as hospitals, cinema

theatres and industries.

ADVANTAGES OF A DIESEL ENGINE  More efficient and economical to use.  Fuel vapor is not explosive.  Exhaust gases are less poisonous – less carbon monoxide.  Greater lugging power and torque. Power Plant Design / MEP544D2

6 Power Plant Design for Sagay, Camiguin  Engines are durable and if properly cared for will maintain their economy.  Fuel is less volatile – no vapor lock problems  Can use a variety of fuels and mixtures.

DISADVANTAGES OF DIESEL ENGINE  The fuel in diesel engine is ignited by the heat of the compressed air.  HPFP of diesel engine is extremely unreliable unit.  The exhaust filter is warming up in the flow of exhaust gas.  it is expensive  Noise and vibration till the latest times could not be separated from the words “Diesel engine”.

Power Plant Design / MEP544D2

7 Power Plant Design for Sagay, Camiguin

ADVANTAGES OF DIESEL POWER PLANT  The design and layout of the plant are quite simple.  It occupies less space as the number and size of the auxiliaries is small.  It can be located at any place.  It can be started quickly and it can pickup load in a short time.  There are no standby losses.

DISADVANTAGES OF DIESEL POWER PLANT  The plant has high running charges as the fuel (diesel) used is costly.  The plant doesn’t work satisfactorily under overload conditions for a longer

period.  The plant can only generate small power.  The cost of lubrication is generally high.  The maintenances charges are generally high.

Power Plant Design / MEP544D2

8 Power Plant Design for Sagay, Camiguin

WHY WE CHOOSE DIESEL POWER PLANT

Purpose

 Diesel power plants produce energy though the combustion of chemical fuel, in

most cases diesel derived from petroleum, into mechanical energy. This energy

is then used to power an alternator which in turn generates electricity. Diesel is

preferred to other fuel types as these engines have a higher thermal efficiency

than other commercial generators of equivalent size.

Process

 Most modern generators harness mechanical energy through the process of

electromagnetic induction. In this system, the mechanical energy produced by

the diesel engine moves an electrical conductor, such as a magnetically charged

wire, in a magnetic field. The movement of the conductor creates a difference in

voltage between the two ends of the charged wire, creating a flow of electric

charges and thereby generating electricity.

Power Plant Design / MEP544D2

9 Power Plant Design for Sagay, Camiguin

LAYOUT OF DEISEL POWER PLANT

Power Plant Design / MEP544D2

10 Power Plant Design for Sagay, Camiguin

ESSENTIAL ELEMENTS OF DIESEL POWER PLANT

I.

DIESEL ENGINE

 Diesel engine is a compressor ignition (CI) engine.  The two – stroke cycle engine is more favored for diesel power plants.  The air required for the diesel engine is drawn through the air filter form the

atmosphere and compressed inside the cylinder.  The fuel (diesel) from the diesel engine is drawn though a filter from the all-day

tank and injected into the cylinder through fuel injector.  Because of the high temperature and pressure of the compressed air, the fuel

burns and the burn gases expand to do work on the moving part inside the

cylinder called piston.  This movement of the piston rotates a flywheel and the engine is directly couple

to electric generator.  The gases after expansion inside the cylinder are exhaust into the atmosphere

and passes through a silencer in order to reduce the noise.

Power Plant Design / MEP544D2

11 Power Plant Design for Sagay, Camiguin

II.

STARTING SYSTEM

 The starting motor will crank the engine. The starting motor will spin the engine at a high enough rpm to allow the engine’s compression to ignite the fuel and start

the engine running.  The engine will then accelerate to idle speed. When the starter motor is

overdriven by the running motor it will disengage the flywheel.

III.

FUEL SUPPLY SYSTEM

 It consists of storage tank, strainers, fuel transfer pump and all day fuel tank. The

fuel oil is supplied at the plant site by rail or road. The oil is stored in the storage

tank. From the storage tank, oil is pumped to smaller all day tank at daily or short

intervals. From this tank, fuel oil is passed through strainers to remove

suspended impurities. The clean oil is injected into the engine by fuel injection

pump.

Power Plant Design / MEP544D2

12 Power Plant Design for Sagay, Camiguin

IV.

AIR INTAKE SYSTEM

 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.

V.

EXHAUST SYSTEM

 This system leads the engine exhaust gas outside the building and discharges it

into atmosphere. A silencer is usually incorporated in the system to reduce the

noise level.

VI.

COOLING SYSTEM

 The temperature of the burning fuel inside the engine cylinder is in the order of 15000 0C to 20000 0C. In order to lower this temperature water is circulated

around the engine.

Power Plant Design / MEP544D2

13 Power Plant Design for Sagay, Camiguin  The water envelopes (water jacket) the engine. The heat from the cylinder,

piston, combustion chamber etc., is carried by the circulating water.  The hot water leaving the jacket is passed through the heat exchanger.  The heat from the heat exchanger is carried away by the raw water circulated

through the heat exchanger and is cooled in the cooling tower.

VII.

LUBRICATING SYSTEM

 The system minimises the wear of rubbing surfaces of the engine. It comprises of

lubricating oil tank, pump, filter and oil cooler. The lubrication oil is drawn from

the lubricating oil tank by the pump and is passed through filter to remove

impurities.

Power Plant Design / MEP544D2

14 Power Plant Design for Sagay, Camiguin LOCATION MAP

Power Plant Design / MEP544D2

15 Power Plant Design for Sagay, Camiguin

LOCATION

Sagay, Camiguin

Sagay is a Philippine municipality. It is located in the province Camiguin in Region

X Northern Mindanao which is a part of the Mindanao group of islands. The municipality

Sagay is seated about 16 km south of province capital Mambajao and about 732 km

south-south-east of Philippine main capital Manila. The geographic coordinates of

Sagay are 9° 6' 21'' N, 124° 43' 29'' E.

Administratively the Municipality of Sagay is subdivided into 9 barangays. One forms

the center of the city wheras the other 8 are in the outlying areas. Some of them are

even several kilometers away from the center of the Municipality.

According to the 2007 census, Sagay has a population of 11,198 residents and is part

of the big group of 1073 cities and municipalities in the Philippines which have more

than 10.000 residents but did not reach 50.000 population yet. Based on the number of

its inhabitants Sagay is number 1483 of the most populous cities of the Philippines and

Power Plant Design / MEP544D2

16 Power Plant Design for Sagay, Camiguin at 424 in Mindanao group of islands and at 4 of the most populous cities of province

Camiguin. With an area of 44.13 km² Sagay occupies a relatively small urban area.

Accordingly, there is a high population density. In Sagay, by average, 253.75 people

live in one square kilometer. With this value, Sagay is only number 105 in Mindanao

and is nationally ranked 728th of the most densely populated cities in the Philippines.

According to the Philippine income classification for provinces, cities and municipalities

Sagay is a 5th class municipality. The urbanization status of Sagay is classified as

partly urban.

Among the bigger cities and municipalities in the neighborhood of Sagay there

areCagayan De Oro City (Misamis Oriental) 69 km south, Gingoog City (Misamis

Oriental) 55 km south-east, Manolo Fortich (Bukidnon) 83 km south, City Of

Cabadbaran (Agusan Del Norte) 88 km east, Butuan City (Agusan Del Norte) 90 km

east, Balingasag (Misamis Oriental) 40 km south, Tagoloan (Misamis Oriental) 63 km

Power Plant Design / MEP544D2

17 Power Plant Design for Sagay, Camiguin south, Buenavista (Agusan Del Norte) 76 km east, Talakag (Bukidnon) 98 km south as

well as 50 km south of Sagay the municipality Jasaan (Misamis Oriental).

Municipalities

Total Population

Camiguin

74,232

100

37,847

Catarman

15,368

20.7

7,864 7,522

Guinsiliban

5,092

Mahinog

12,592

17.0

6,368 6,224

Mambajao (Capital) 30,806

41.5

15,657

Sagay

14.0

5,338 5,018

10,356

Percentage Male Female

6.9

36,385

2,620 2,472

15,149

Guinsiliban is 6.9% of total population of Camiguin therefore we can assume that out of

14,735 Occupied Housing Unit there are 1002 single houses which represents the

majority of the building structure on Guinsiliban and a household population of 1023.

Power Plant Design / MEP544D2

18 Power Plant Design for Sagay, Camiguin Demographic Data:

Total No. of Population: 5,092

Household Population: 1023

Structures:

Group A

Group B

Single House: 1002

Multi- Unit Residential: 3

Duplex: 6

Commercial/Industrial/Agricultural: 1

Power Plant Design / MEP544D2

19 Power Plant Design for Sagay, Camiguin GROUP A

GROUP B

Power Plant Design / MEP544D2

20 Power Plant Design for Sagay, Camiguin Total Power Consumption Table

Time

GROUP A

No. of Consumer

Power Consumption

GROUP B

No. of Consumer

Power Consumption

Total Load (whr)

1

1632960

2016

810

16000

8

2000

1648960

2

1632960

2016

810

24000

8

3000

1648960

3

1632960

2016

810

24000

8

3000

1648960

4

2237760

2016

1110

16000

8

2000

2253760

5

2136960

2016

1060

24000

8

3000

2160960

6

2136960

2016

1060

91200

8

11400

2228160

7

1532160

2016

760

94000

8

11750

1626160

8

2056320

2016

1020

102000

8

12750

2158320

9

2056320

2016

1020

110000

8

13750

2166320

10

2378880

2016

1180

32000

8

4000

2419880

11

1854720

2016

920

28000

8

3500

1882720

12

1854720

2016

920

61200

8

7650

1915920

13

1854720

2016

920

48000

8

6000

1902720

14

1310400

2016

650

16000

8

2000

1326400

15

1310400

2016

650

24000

8

3000

1334400

16

1310400

2016

650

29200

8

3650

1339600

17

1532160

2016

760

29200

8

3650

1561360

18

2136960

2016

1060

37200

8

4650

2174160

19

4354560

2016

2160

53200

8

6650

4407760

20

4677120

2016

2320

37200

8

4650

4714320

21

2459520

2016

1220

53200

8

6650

2512720

22

2459520

2016

1220

37200

8

4650

2496720

23

1632960

2016

810

64000

8

8000

1696960

24

1632960

2016

810

32000

8

4000

1664960

Total Load (w-hr / 24hrs.)

49815360 w-hr

1082800 w-hr Total Load (w-hr / 24hrs.)

50898160 w-hr

Power Plant Design / MEP544D2

21 Power Plant Design for Sagay, Camiguin Design Overview

Peak Load = 2357.16 kW, 2.35mW

Plant Capacity: 3200 kW, 3.2mW

No. of Engines: 5

Engine Capacity

Number of Hours of Operation/day

Unit 1 --- 800 kW

18hours/day

Unit 2 --- 800 kW

18hours/day

Unit 3 --- 800 kW

18hours/day

Unit 4 --- 800 kW

18hours/day

Unit 5 --- 800 kW

Reserve

Schedule of Engine Operation

Time of Operation

Engine Operating

Time Interval

12AM-6AM

Unit 1,2 and 3

6 hours Power Plant Design / MEP544D2

22 Power Plant Design for Sagay, Camiguin 6AM-12NN

Unit 2,3 and 4

6 hours

12NN-6PM

Unit 1,4 and 2

6 hours

6PM-12AM

Unit 3,4 and 1

6 hours

Each Unit has a 6 straight hours break

DESIGN FOR MACHINE FOUNDATION

For 800 kW Generator Set (Per Unit 1,2,3,4 and 5)

Mixture for Concrete Foundation: Power Plant Design / MEP544D2

23 Power Plant Design for Sagay, Camiguin Use 1:3:5 concrete mixture ratio (from PPE by F.T. Morse, Table 4-1 p.90)

Soil Bearing Pressure:

Use 50-98 tones / m2 for common brick masonry

(from PPE by F.T. Morse, Table 4-4 p. 105)

Soil Bearing Pressure (Sb) =

= 50,000 kg/m2

Weight of Foundation

Wf = e x W e x √

Where:

Wf = weight of the foundation, kgs

We = weight of the engine, kgs

N = engine speed, RPM

Use e = 0.11 (from PSME code, Table 2.4.2.3 (4), p.11)

Power Plant Design / MEP544D2

24 Power Plant Design for Sagay, Camiguin Wf = 0.11 x 7897 kg x √

= 36, 859.21 kg

Volume of Foundation

Vf =

Where:

Vf = Volume of foundation [m3]

c = density of concrete = 2406 kg/m3

Vf =

= 15.32 m3

Depth of Foundation

h=

Where:

Power Plant Design / MEP544D2

25 Power Plant Design for Sagay, Camiguin Hf = depth of foundation [m]

Lf = length of foundation [m]

Wf = width of the foundation [m]

Length of the Foundation

Lf = Lb + 10% Lb

Where:

Lb = length of bedplate [m]

Le = length of engine [m]

Lb = Lb + 6 in x

= 4,267 mm + 6 in x

5,047.4 mm

Lf = 4,419.4 mm + (0.10)(4,419.4 mm) = 4,861.34 mm

Lf = 4,861.34 mm x

= 4.86 = 5 m

Power Plant Design / MEP544D2

26 Power Plant Design for Sagay, Camiguin

Width of the Foundation

Wf = W b + 10%W b

Where:

Wb = Width of bedplate

We = width of the engine [m]

Wb = W b + 6 in x

= 2, 083 mm + 6 in x

= 2, 235.4 mm

Wb = 2,235.4 mm + (0.10)(2,235.4 mm) = 2,458.94 mm

Wf = 2,458.94 mm x

h=

= 2.46 m = 2.5 m

= 1.22 = 1.25 m

Soil Stress

Power Plant Design / MEP544D2

27 Power Plant Design for Sagay, Camiguin Soil Stress =

Soil Stress =

= 3,580.50 kg/m2

Foundation Materials:

Concrete Mixture Ratio = 1 : 3 : 5

X + 3x + 5x = 15.32 m3

9x = 15.32 m3

X = 15.32 m3 / 9

X = 1.70 m3

Absolute Volume Material = Specific Weight of Material / (Bulk S.G.)(Sp. Weight of

Water)

For Cement:

Power Plant Design / MEP544D2

28 Power Plant Design for Sagay, Camiguin 1 x 6.2 x 1.70 m3 = 10.54 m3

= 0.48 ft3/bag x

Absolute Volume Material =

No. of bags =

= 0.014 m3/bag

= 753 bags

3 x 0.52 x 1.70 m3 = 2.65 m3

= 2 ft3/bag x

Absolute Volume Material =

= 0.057 m3/bag

For Gravel:

5 x 0.86 x 1.70m3 = 7.31m3

= 2.89 ft3/bag x

Absolute Volume Material =

No. of Bags =

= 0.082 m3/bag

89 bags

For Reinforcing Bar:

Using 14 mm diam. Rebars

Power Plant Design / MEP544D2

29 Power Plant Design for Sagay, Camiguin WRB = 1%Wf = (0.01)(36.859.21 kg) = 368.59 kg

Weight of Rebar/pc = density of steel x VRB

Weight of Rebar/pc – 7800 kg/m3 x (π/4)(14 mm/1000m)2 (6.1m) – 29.3 kg

No. of Reinforcing Bars =

=

12.58 = 13 pcs

Flexure formula

Fb =

Eccentricity from mid-base

Y1 = 1/2h = ½ (1.25m) = 0.625m

Y2 = 1/3h = 1/3 (1.25m) = 0.42m

A1 = Lf = h = (5m) (1.25m) = 6.25m2

A2 = ½ Lf x b

Where:

Power Plant Design / MEP544D2

30 Power Plant Design for Sagay, Camiguin B=

=

= 0.36m

If b < W f, then W f = b; used b = W f = 2.5 m

A2 = ½ Lf x b = ½ (5m)(2.5m) = 6.25m2

∑A = A1 + A2 = (6.25 + 6.25) m2 = 12.5m2

∑AY = A1Y1 = A2Y2 = [(6.25) (0.625) + (6.25) (0.42)] m3 = 6.53 m3

C=

=

= 0.52 m

For Bolts:

Diameter = 1/8 x (bore) = 1/8 x (150mm) = 18.75 mm

Length = 7/8 x (stroke) = 7/8 x (160mm) = 140 mm

Use L = 30D (from ASME code)

Power Plant Design / MEP544D2

31 Power Plant Design for Sagay, Camiguin L = 30 (18.75 mm) = 562.5 mm

No. of bolts =

Where:

Tbolts =

From Table AT 7 – DME by V.M. Faires

Material: AISI 8630 (for connecting rods, bolts, shapes)

Sy = 100ksi = 100,000psi; Fy = 7 (max. for Shock)

Sy =

= 7,142.86 psi x

Tbolts =

No. of Bolts =

= 49,234.69 kpa

= 20.28 N.m

= 662.13 = 663 bolts

Design for Fuel Tank Power Plant Design / MEP544D2

32 Power Plant Design for Sagay, Camiguin For 800 kW Generator Set (Per Unit 1, 2, 3, 4, and 5)

Type of oil: Diesel Fuel Oil

Specific Gravity = 0.917 @ 600F

(From Power Plant Theory and design by P.J. Potter, Table 5-4, and p.186)

SGf =

;

= SGf x

= 0.917 x

= 917 kg/m3

Generator Output (EP) =

Where:

BP =

ηg = 97.8% (For 1800 rpm & 494.73 kW Ave. Load)

(From Power Plant Theory and Design by P.J. Potter, figure 9-27, p.445)

BP =

= 818 kW

Power Plant Design / MEP544D2

33 Power Plant Design for Sagay, Camiguin

Specific Fuel Consumption

=

= 0.25 kg / kW hr

Plant Operation = 24 hrs/day

Engine Operation Hrs/Day = 18 hrs/day

Expected Fuel Delivery Schedule = Every 15 days

% Rated Capacity

=

x 100% =

x 100% = 75%

From PPE by F.T. Morse, Fig. 6-15, p.164

Max. Fuel Consumption = 0.25 kg/kW-hr

Power Plant Design / MEP544D2

34 Power Plant Design for Sagay, Camiguin Min. Fuel Consumption = 0.21 kg/kW-hr

Volume of Day Tank

VDT =

Where:

mF = daily fuel consumption [kg/day],

= density of fuel = 917 kg/m3

mF = max. fuel consumption x BP x engine operating hrs/day

= (0.25 kg/kW-hr) (181kW) (18hrs/day)

= 3681 kg/day

VDT =

4.01 m3/day

Dimension of Day Tank

VDT =

DDT - √

DDT2 H

(From the above equation) - √

= 1.37m

Power Plant Design / MEP544D2

35 Power Plant Design for Sagay, Camiguin Assume:

HDT = 2DDT = 2(1.37m) = 2.74m

Thickness of fuel Tank

TDT =

Where:

PT = Pressure inside tank = HDT x YFuel

YFuel = 8.996 kN/m3

PT = 2.74m x 8.996 kN/m3 = 24.65 kN/m3 or kPa

Sy = Tensile Yield = 35,000 psi (from DME by V.M. Faires, Table AT 4, p. 568)

F.S.y = Design factor of Safety

F.S.y = 3(for stainless steel from DME by V.M. Faires Table 1.1, p.20)

N = 75%

Power Plant Design / MEP544D2

36 Power Plant Design for Sagay, Camiguin TDT =

= 0.3 mm; use 1 mm thickness

Storage Tank for 30 days operation

VST = VDT = x 30 days/month = 4.01 m3/day x 30 days/month = 120.3 m3/month

Dimension of storage tank

VST =

DST2 H

DST = √

(From the above equation) - √

= 4.25m

Assume:

HST = 2DST = 2(4.25 m) = 8.5m

Material for fuel tank: AISI No. 321 (Stainless steel)

Thickness of fuel storage tank

TST = Power Plant Design / MEP544D2

37 Power Plant Design for Sagay, Camiguin Where:

PT = pressure inside tank = HST x YFuel

YFuel = 8.996 kN/m3

PT = 8.5m x 8.996 kN/m3 = 76.46 kN/m2 or kpa

SY = Tensile Yield = 48,000 psi (from DME by V.M. Faires, Table AT 7, p.576)

F.S.y = 2(for stainless steel from DME by V.M. Faires Table 1.1, p.20)

n = 75%

TST =

= 1.31 mm

Transfer Pump from Fuel Storage Pump to Day tank

Assumption:

Desired operating time for fuel pump = 1 hr/day

ηP = 72%

Power Plant Design / MEP544D2

38 Power Plant Design for Sagay, Camiguin Power input for unit 1, 2, 3, 4, and 5

EPi =

Where:

EPi = electrical power input [kW] or [hp]

Yfuel = 8.996 kN/m3

THD = total dynamic head [m]

TDH = Z2 – Z1 +

+

TDH = (2.74)-(-8.5)m = 11.24 m

Q = volume flow rate [m3/s]

Q --

Where:

VDT = volume of fuel at day tank [m3/s]

Power Plant Design / MEP544D2

39 Power Plant Design for Sagay, Camiguin t = time of pump operation [sec]

Q --

0.00111 m3/s

EPi =

= 0.16 kW x

= 0.21 hp

1 hp is used for unit 1 transfer pump

VARIABLE LOAD CALCULATIONS

Plant Capacity = Peak Load + Peak Load (20)

= 2357.16kW + 471.432 kW = 2828.592 kW

(we use 3200kW from catalog 800kW x 4 genset)

Reserve over peak = plant capacity – peak load

= (3200kW – 2357.16kW) = 842.84kW

Average Load =

=

= 1060.378333kW

Power Plant Design / MEP544D2

40 Power Plant Design for Sagay, Camiguin Capacity Factory -

-

Annual capacity factor =

Load Factor -

Demand Factor –

= 33.14%

=

= 33.14%

– 44.99%

-

-

Plant Factor =

– 73.66%

=

= 33.14%

ENGINE APPLICATION DATA

Engine Specifications

Manufacturer

Mitsubishi Power Plant Design / MEP544D2

41 Power Plant Design for Sagay, Camiguin Engine Model #

S12A2 – Y2PTAW-2

Engine Type

4 Cycle, 12 Cylinder

Induction System

Turbochanged, Inter Cooler

Displacement, L (in3)

33.9 (2071)

EPA Emission Level

Tier 2

HP at Rated Speed BHP (KW)

1207 (900)

Rated RPM

1800

Bore and Stroke in (mm)

5.19 x 6.30 (150 x 160)

Compressor Ratio

15.3:1

Air Filter Type

Dry

Govermor Type/Model

Proact2

Govermor Manufacturer

Woodward

Freq Reg NL to FL

Isochronous Power Plant Design / MEP544D2

42 Power Plant Design for Sagay, Camiguin Freq Reg Steady State

+/- 0.25%

Engine Lubrication System

Oil Pan Capacity gal (L)

Oil Pan w/ Filter

Oil Filter Quantity

Oil Cooler

26.4 (100.0)

31.7 (120.0)

4

Water Cooled

Recommended Oil

15W – 40

Oil Press Psi (kPa)

57 (393)

Engine Cooling System

Genset Max Ambient Temperature

113 (45)

Engine Coolant Cap qt (L)

105.7 (100.0) Power Plant Design / MEP544D2

43 Power Plant Design for Sagay, Camiguin Engine + Radiant System Cap qt (L)

402.0 (380.4)

Water Pump Type

Centrifugal

Coolant Flow gpm (Lpm)

291 (1101.4)

Charge Cooler Flow gpm (Lpm)

124 (469.3)

Heat Rejected to Cooling Water

@ Rated kW: BTU/min (kW)

20418 (358.9)

Heat Rejected to Charge Cooler

@ Rated kW: BTU/min (kW)

16043 (282.0)

Heat Rejected to Ambient Air

@ Rated kW: BTU/min (kW)

4375 (76.9)

Max. Restriction of Cooling Air in

H20 (kPa)

0.5 (0.124)

Power Plant Design / MEP544D2

44 Power Plant Design for Sagay, Camiguin

Engine Exhaust System

Exhaust Manifold Type

Dry

Exhaust flow @ Rated kW cfm (c-mm)

8192 (232)

Exhaust Temp. (Dry manifold) 0F (0C)

953 (497)

Max. Back Pressure InH20 (kPa)

23.6 (5.9)

Exhaust Outlet Diameter in (mm)

8.35 (212)

Exhaust Outlet Type

JIS200A (approx. 8”)

Engine Electrical System

Changing Alternator Volts dc

Changing Alternator Amps

Grounding Polarity

24

25

Negative Power Plant Design / MEP544D2

45 Power Plant Design for Sagay, Camiguin Started Motor Volts dc

24

Battery Recommendations

Battery Volts dc

24

Min Cold Cranking Amps

1100

Quantity Required

2

Ventilation Requirements

Cooling Airflow scfm (cmm)

40042 (1134)

Combustion Airflow cfm (cmm)

3107 (88)

Heat Rejected to Ambient

From Engine BTU/min (kW)

4375 (77)

From Alternator BTU/min (kW)

2275 (40)

Recommended Free Area Intake Power Plant Design / MEP544D2

46 Power Plant Design for Sagay, Camiguin Louver Size ft2 (m2)

87.0 (8.09)

Engine Fuel System

Recommended Fuel

# 2 Diesel

Fuel Line at Engine

Supply Line Min ID in (mm)

0.75 (19)

Return Line Min ID in (mm)

0.75 (19)

Fuel Pump type

Engine Driven

Fuel Pump Max Lift ft (m)

3 (1)

Fuel Flow to Pump gpm (Lph)

148 (560.2)

Fuel Filter

Secondary Filter

2 µm

Secondary Water Separator

Not Included Power Plant Design / MEP544D2

47 Power Plant Design for Sagay, Camiguin Primary Filter

Optional

Primary Water Separator

Optional

Fuel Consumption – Standby Rating

100% Load gph (Lph)

65.2 (246.5)

75% Load gph (Lph)

46.8 (177.1)

50% Load gph (Lph)

32.2 (121.9)

25% Load gph (Lph)

19.3 (73.1)

Fuel Consumption – Prime Rating Power Plant Design / MEP544D2

48 Power Plant Design for Sagay, Camiguin 100% Load gph (Lph)

59.3 (224.5)

75% Load gph (Lph)

42.6 (161.2)

50% Load gph (Lph)

29.3 (110.9)

25% Load gph (Lph)

17.6 (66.6)

Engine Output Deratings – Standby

Rated Temp

400C

Rated Altitude

1500 m

Max Altitude

5000 m

Temperature Derate

Altitude Derate

-5% / 100C

-1% / 100 m

Power Plant Design / MEP544D2

49 Power Plant Design for Sagay, Camiguin

Alternator Specifications

Alternator Type

4-Pole Rotating Field

Exciter Type

Brushless

Excitation

PMG

Insulation

per NEMA MG1

Material

Class H

Standby Temp Rise

150 0C

Prime Temp Rise

125 0C

Lead Connection

12 Lead, Reconnect able

Stator Pitch

2/3 Power Plant Design / MEP544D2

50 Power Plant Design for Sagay, Camiguin Amortisseur Winding

Full

Bearing

Single Double Shielded

Drive Coupling

Flexible Disk

Unbalance Load

20% of Standby Rating

Automatic Voltage Regulator

PMG

Std MX321

Voltage Regulation

No Load to Full Load

PMG Regulator

+/- 0.5%

Load Acceptance

100% of Rating

Subtransient Reactance

480V, Per Unit

18%

TIF (1960 Weighting)