TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES

Ayala Blvd., Ermita, Manila

College of Engineering
Department of Mechanical Engineering

DIESEL POWER PLANT

DESIGN

Submitted by:

Sy, Patrick John G.

BSME – 5A

Submitted to:

Dr. Mario Regino M. Norbe

 POWERPLANT DESIGN

LOCATION: TIWI, ALBAY BICOL

RATED PLANT CAPACITY : 70 MW

DAILY LOAD CURVE

MW
70
65
60
55
50
45
40
35
30
25
20
12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
MN NN MN
TIM 12M 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12N
E N M M M M M M M M M M M N
MW 25 22 20 24 28 30 35 36 40 43 47 49 51

TIME 1PM 2PM 3PM 4PM 5PM 6PM 7PM 8PM 9PM 10PM 11PM 12MN

MW 52 54 55 58 58.5 60 62.5 65 45.7 30 28 25

SCHEDULE 1

70
65
MW 65
62.5
60 60
58 58.5
55 54 55
50 51 52
49
45 47 45.7
43
40 40 MW
35 35 36
30 30 30
28 28
25 25 24 25
20 22
20
12 MN

12 MN
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
10
11
12 NN

10
11
BRAND: Wartsila
UNIT LOAD SCHEDULE OF OPERATION COLOR
16V46F 19.2 MW 24 HRS
16V46F 19.2 MW 24 HRS

12V46F 14.4 MW 09:25:30 AM – 11:19:48 PM

12V46F 14.4 MW 12:30:00 PM – 10:15:00 PM

Average Load = 41.75 MW

Peak Load = 65 MW

Rated Capacity = 67.2 MW

𝐴𝑉𝐸𝑅𝐴𝐺𝐸 𝐿𝑂𝐴𝐷
LOAD FACTOR = 𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷

41.75 𝑀𝑊
=
65 𝑀𝑊
= 𝟎. 𝟔𝟒𝟐
 𝐴𝑉𝐸𝑅𝐴𝐺𝐸 𝐿𝑂𝐴𝐷
CAPACITY FACTOR = 𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌

41.75 𝑀𝑊
=
67.2 𝑀𝑊
= 𝟎. 𝟔𝟐𝟏

𝐿𝑂𝐴𝐷 𝐹𝐴𝐶𝑇𝑂𝑅
RESERVE FACTOR = 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌 𝐹𝐴𝐶𝑇𝑂𝑅

0.642
=
0.621
= 𝟏. 𝟎𝟑𝟒
𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷
UTILIZATION FACTOR = 𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌

65 MW
=
67.2 MW

= 𝟎. 𝟗𝟔𝟕

OUTPUT FACTOR WITH 15 MINS HOTSTART

19.2 (24) + 19.2 (24) + 14.4 (8.475 + 5.347) + 14.4 (3.19 + 2.875)

= 1207.97 MW-HR

𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷
=
𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌
1207.97 MW − HR
=
67.2 (24)

OUTPUT FACTOR = 𝟎. 𝟕𝟓
SCHEDULE 2

70
65 MW 65
62.5
60
58 58.560
55 55
50 51 52 54
45 47 49 45.7
43
40 40 MW
35 35 36
30
28 30 30 28
25 25 24 25
20 22 20
12 MN

12 MN
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
11
10

12 NN

10
11
BRAND: Wartsila
SCHEDULE OF COLOR
UNIT LOAD
OPERATION
12V46F 14.4 MW 24 HRS

16V46F 19.2 MW 24 HRS

12V46F 14.4 MW 09:10:51 AM –10:05:13 PM
16V46F 19.2 MW 01:33:36 PM –09:24:54 PM

Average Load = 41.75 MW

Peak Load = 65 MW

Rated Capacity = 67.2 MW

𝐴𝑉𝐸𝑅𝐴𝐺𝐸 𝐿𝑂𝐴𝐷
LOAD FACTOR = 𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷

41.75 𝑀𝑊
=
65 𝑀𝑊
= 𝟎. 𝟔𝟒𝟐
𝐴𝑉𝐸𝑅𝐴𝐺𝐸 𝐿𝑂𝐴𝐷
CAPACITY FACTOR = 𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌

41.75 𝑀𝑊
=
67.2 𝑀𝑊
= 𝟎. 𝟔𝟐𝟏
 𝐿𝑂𝐴𝐷 𝐹𝐴𝐶𝑇𝑂𝑅
RESERVE FACTOR = 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌 𝐹𝐴𝐶𝑇𝑂𝑅

0.642
=
0.621
= 𝟏. 𝟎𝟑𝟒
𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷
UTILIZATION FACTOR = 𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌

65 MW
=
67.2 MW

= 𝟎. 𝟗𝟔𝟕

OUTPUT FACTOR WITH 15 MINS HOTSTART

14.4 (24) + 19.2 (24) + 14.4 (8.475 + 5.347) + 19.2 (3.19 + 2.875)

= 1121.88 MW-HR

𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷
=
𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌
1207.97 MW − HR
=
67.2 (24)

OUTPUT FACTOR = 𝟎. 𝟔𝟗𝟓𝟔

SCHEDULE 3

70
65
MW 65
62.5
60
58 58.560
55 55
50 51 52 54
45 47 49 45.7
43
40 40 MW
35 35 36
30
28 30 30 28
25 25 25
20 22 20 24
12 MN

12 MN
1
2
3

5
6
7
8
9

1
2
3

5
6
7
8
9
10

10
11
12 NN

11
 BRAND: Wartsila
UNIT LOAD SCHEDULE OF OPERATION COLOR
16V46F 19.2 MW 24 HRS
16V46F 19.2 MW 24 HRS
14V46F 16.8 MW 07:30:51 AM – 10:05:18 PM
12V46F 14.4 MW 11:33:36 AM – 09:24:54 PM

Average Load = 41.75 MW

Peak Load = 65 MW

Rated Capacity = 69.6 MW

𝐴𝑉𝐸𝑅𝐴𝐺𝐸 𝐿𝑂𝐴𝐷
LOAD FACTOR = 𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷

41.75 𝑀𝑊
=
65 𝑀𝑊
= 𝟎. 𝟔𝟒𝟐
𝐴𝑉𝐸𝑅𝐴𝐺𝐸 𝐿𝑂𝐴𝐷
CAPACITY FACTOR = 𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌

41.75 𝑀𝑊
=
69.6 𝑀𝑊
= 𝟎. 𝟓𝟗𝟗
𝐿𝑂𝐴𝐷 𝐹𝐴𝐶𝑇𝑂𝑅
RESERVE FACTOR = 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌 𝐹𝐴𝐶𝑇𝑂𝑅

0.642
=
0.599
= 𝟏. 𝟎𝟕
𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷
UTILIZATION FACTOR = 𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌

65 MW
=
69.6 MW

= 𝟎. 𝟗𝟑𝟒
OUTPUT FACTOR WITH 15 MINS HOTSTART
19.2 (24) + 19.2 (24) + 16.8 (8.475 + 5.347) + 14.4 (3.19 + 2.875)

= 1241.14 MW-HR

𝑃𝐸𝐴𝐾 𝐿𝑂𝐴𝐷
=
𝑃𝐿𝐴𝑁𝑇 𝐶𝐴𝑃𝐴𝐶𝐼𝑇𝑌
1241.14 MW − HR
=
69.6 (24)

OUTPUT FACTOR = 𝟎. 𝟕𝟒𝟑

SCHEDULE 1 SCHEDULE 2 SCHEDULE 3

LOAD FACTOR x 20 0.642 0.642 0.642

CAPACITY FACTOR x 25 0.621 0.621 0.599
RESERVE FACTOR x 10 1.034 1.034 1.07
UTILIZATION FACTOR x 15 0.967 0.967 0.934
OUTPUT FACTOR x 30 0.75 0.6956 0.743

TOTAL 100 75.71 74.078 74.815

USE SCHEDULE 1
DIESEL ENGINE GENERATOR SPECIFICATIONS

The Wärtsilä 46F is a 4-stroke, non-reversible, turbocharged and intercooled diesel engine with direct fuel
injection (twin pump).

WARTSILA 46 F
Cylinder bore 460 mm
Stroke 580 mm
Piston displacement 96.4 l/cyl
Number of valves 2 inlet valves and 2 exhaust valves
Cylinder configuration 6, 7, 8 and 9 in-line; 12, 14 and 16 in V-form
Direction of rotation clockwise, counter-clockwise on request
Speed 600 rpm
Mean piston speed 11.6 m/s
FROM : https://cdn.wartsila.com/docs/default-source/product-files/engines/ms-engine/product-guide-o-
e-w46f.pdf?sfvrsn=9

DESIGN OF MACHINE FOUNDATION

FOR 16V46F (19.2 MW)

We = 195918 kg

N= 600 rpm

Length = 11.4 m.

Width = 4.65 m.

Bore = 460 mm

No. of Cylinders = 16

a) WEIGHT OF FOUNDATION (Wf)

Wf = e x We x √𝑁

Where:
We = weight of the engine in kg
N = engine speed in rpm
e = empirical coefficient (e = 0.11 from Table 2.4.2.3 (4) of PSME CODE)
𝑊𝑓 = 0.11 𝑥 195918 𝑘𝑔 𝑥 √600 𝑟𝑝𝑚
= 𝟓𝟐𝟕 𝟖𝟖𝟗. 𝟎𝟒𝒌𝒈
b) VOLUME OF FOUNDATION (VF)
VF = Wf/ρC

Where:
Wf = weight of foundation in kg
ρC = density of concrete in kg/m3 (2406 kg/m3)
527 889.04 𝑘𝑔
𝑉𝑓 =
2406 𝑘𝑔/𝑚3
= 𝟐𝟏𝟗. 𝟒 𝒎𝟑

c) DEPTH OF FOUNDATION (DF)

𝑉𝑓
𝐷𝑓 =
𝐴𝑓

o AREA OF FOUNDATION
AF = [L + 2(0.305)] [W + 2(0.305)]

Where:
AF = Area of foundation in m2
L = Length
W= Width
Note:
Allowance of 1 ft. (0.305 will be used)
= [11.4 + 2(0.305)][4.65 + 2(0.305)]
= 63.17 𝑚2
219.4 𝑚3
=
63.17 𝑚2
= 𝟑. 𝟒𝟕 𝒎

d) BOLT DESIGN (DB)

DB = 1/12 X B

Where:
DB = diameter of bolt in mm
B = Bore in mm (in catalog)
1
= 𝑥 460 𝑚𝑚
12
= 𝟑𝟖. 𝟑𝟑 𝐦𝐦

e) LENGTH OF BOLT (LB)

LB = 30 X DB
= 30 𝑋 38.33 𝑚𝑚
= 𝟏. 𝟏𝟓𝟎 𝒎
f) NUMBER OF BOLT (NB)
NB = 2N + 2

Where:
N = no. of Cylinders
= 2(16) + 2
= 𝟑𝟒 𝒃𝒐𝒍𝒕𝒔

g) WEIGHT OF REINFORCING BAR (WRB)

WRB = (.5% TO 1%) X WF

USE AVERAGE VALUE OF 0.75 %

Wrb = (0.0075)( 527 889.04 𝑘𝑔)
= 𝟑𝟗𝟓𝟗. 𝟏𝟕 𝒌𝒈

h) VOLUME OF REINFORCING BAR (VRB)

𝜋
VRB = (𝐷)2 𝐿 x pc
4

Where:
D = Diameter of Bar (use #18 (2.25’’) or 0.057 m)
L = Length of Bar (use 20 ft or 6.1 m)
Pc = density of steel (use 7800 kg/m3)

𝜋 𝑘𝑔
= (. 057 𝑚)2 (6.1𝑚) 𝑥 7800 3
4 𝑚
𝑾𝒆𝒊𝒈𝒉𝒕 𝒐𝒇 𝑹𝒆𝒊𝒏𝒇𝒐𝒓𝒄𝒊𝒏𝒈 𝒃𝒂𝒓
= 𝟏𝟐𝟏. 𝟒𝟏 𝒌𝒈
𝒑𝒄

i) NUMBER OF REINFORCING BAR (NRB)

NRB = WRB/Weight of Reinforcing bar/pc
3959.17 𝑘𝑔
=
121.41 𝑘𝑔
= 32.6 ≈ 𝟑𝟑 𝒑𝒄𝒔

j) CONCRETE MIXTURE (USE 1:3:5)

from table 4-1 of PPE by Morse p. 90
o Cement = 6.2 sacks/ m3
o Sand = 0.52 m3/ Vf m3
o Stone = 0.86 m3/Vf m3

 For Cement
No. of Sacks of Cement = 6.2 sacks/m3 x Vf
𝑠𝑎𝑐𝑘𝑠
= 6.2 𝑥 219.4 𝑚3
𝑚3
= 1360.3 ≈ 𝟏𝟑𝟔𝟏 𝒔𝒂𝒄𝒌𝒔
  For Sands
Volume of Sands = 0.52 m3/ Vf m3 x Vf
𝑚3
= 0.52 𝑥 219.4 𝑚3
𝑚3

= 𝟏𝟏𝟒. 𝟎𝟖𝟖 𝒎𝟑

 For Stones
Volume of Stones = 0.86 m3/Vf m3 x Vf
𝑚3
= 0.86 3 𝑥 219.4 𝑚3
𝑚

= 𝟏𝟖𝟖. 𝟕 𝒎𝟑

FOR 12V46F (14.4 MW)

We = 158730.16 kg

N= 600 rpm

Length = 10.3 m.

Width = 4.026 m.

Bore = 460 mm

No. of Cylinders = 12

a) WEIGHT OF FOUNDATION (Wf)

Wf = e x We x √𝑁

Where:
We = weight of the engine in kg
N = engine speed in rpm
e = empirical coefficient (e = 0.11 from Table 2.4.2.3 (4) of PSME CODE)
𝑊𝑓 = 0.11 𝑥 158730.16 𝑘𝑔 𝑥 √600 𝑟𝑝𝑚
= 𝟒𝟐𝟕𝟔𝟖𝟖. 𝟕 𝒌𝒈

b) VOLUME OF FOUNDATION (VF)

VF = Wf/ρC

Where:
Wf = weight of foundation in kg
ρC = density of concrete in kg/m3 (2406 kg/m3)
427688.7 𝑘𝑔
𝑉𝑓 =
2406 𝑘𝑔/𝑚3
= 𝟏𝟕𝟕. 𝟕𝟔 𝒎𝟑
c) DEPTH OF FOUNDATION (DF)
𝑉𝑓
𝐷𝑓 =
𝐴𝑓

o AREA OF FOUNDATION
AF = [L + 2(0.305)] [W + 2(0.305)]

Where:
AF = Area of foundation in m2
L = Length
W= Width
Note:
Allowance of 1 ft. (0.305 will be used)
= [10.3 + 2(0.305)][4.026 + 2(0.305)]
= 50.58 𝑚2
177.76 𝑚3
=
50.58𝑚2
= 𝟑. 𝟓𝟏 𝒎

d) BOLT DESIGN (DB)

DB = 1/12 X B

Where:
DB = diameter of bolt in mm
B = Bore in mm (in catalog)
1
= 𝑥 460 𝑚𝑚
12
= 𝟑𝟖. 𝟑𝟑 𝐦𝐦

e) LENGTH OF BOLT (LB)

LB = 30 X DB
= 30 𝑋 38.33 𝑚𝑚
= 𝟏. 𝟏𝟓𝟎 𝒎

f) NUMBER OF BOLT (NB)

NB = 2N + 2

Where:
N = no. of Cylinders
= 2(12) + 2
= 𝟐𝟔 𝒃𝒐𝒍𝒕𝒔
g) WEIGHT OF REINFORCING BAR (WRB)
WRB = (.5% TO 1%) X WF

USE AVERAGE VALUE OF 0.75 %

Wrb = (0.0075)( 427688.7 𝑘𝑔)
= 𝟑𝟐𝟎𝟕. 𝟔𝟔 𝒌𝒈

h) VOLUME OF REINFORCING BAR (VRB)

𝜋
VRB = (𝐷)2 𝐿 x pc
4

Where:
D = Diameter of Bar (use #18 (2.25’’) or 0.057 m)
L = Length of Bar (use 20 ft or 6.1 m)
Pc = density of steel (use 7800 kg/m3)

𝜋 𝑘𝑔
= (. 057 𝑚)2 (6.1𝑚) 𝑥 7800 3
4 𝑚
𝑾𝒆𝒊𝒈𝒉𝒕 𝒐𝒇 𝑹𝒆𝒊𝒏𝒇𝒐𝒓𝒄𝒊𝒏𝒈 𝒃𝒂𝒓
= 𝟏𝟐𝟏. 𝟒𝟏 𝒌𝒈
𝒑𝒄

i) NUMBER OF REINFORCING BAR (NRB)

NRB = WRB/Weight of Reinforcing bar/pc
3207.66 𝑘𝑔
=
121.41 𝑘𝑔
= 26.4 ≈ 𝟐𝟕 𝒑𝒄𝒔

j) CONCRETE MIXTURE (USE 1:3:5)

from table 4-1 of PPE by Morse p. 90
o Cement = 6.2 sacks/ m3
o Sand = 0.52 m3/ Vf m3
o Stone = 0.86 m3/Vf m3

 For Cement
No. of Sacks of Cement = 6.2 sacks/m3 x Vf
𝑠𝑎𝑐𝑘𝑠
= 6.2 3
𝑥 177.76 𝑚3
𝑚
= 1102.11 ≈ 𝟏𝟏𝟎𝟑 𝒔𝒂𝒄𝒌𝒔
 For Sand
Volume of Sands = 0.52 m3/ Vf m3 x Vf
𝑚3
= 0.52 𝑥 219.4 𝑚3
𝑚3

= 𝟗𝟐. 𝟒𝟑 𝒎𝟑
  For Stones
Volume of Stones = 0.86 m3/Vf m3 x Vf
𝑚3
= 0.86 𝑥 219.4 𝑚3
𝑚3

= 𝟏𝟓𝟐. 𝟖𝟕 𝒎𝟑

FUEL SYSTEM DESIGN

FOR UNIT 1&2 16V46F (19.2 MW)

𝑙𝑏
𝐵𝑟𝑎𝑘𝑒 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐹𝑢𝑒𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 = 0.294
𝑏ℎ𝑝 − ℎ𝑟

a) FUEL CONSUMPTION FOR 30 DAYS (WF)

WF = rate of fuel consumption x bhp

but;

rate of fuel consumption:

𝑙𝑏 1𝑘𝑔 24 ℎ𝑟𝑠 30 𝑑𝑎𝑦𝑠
= 0.294 𝑥 𝑥 𝑥
𝑏ℎ𝑝 − ℎ𝑟 2.205 𝑙𝑏 1 𝑑𝑎𝑦 1 𝑚𝑜𝑛𝑡ℎ

𝒌𝒈
= 𝟗𝟔
𝒃𝒉𝒑 − 𝒎𝒐𝒏𝒕𝒉

Bhp= Wo/effg

Where;

Wo = 19200 x 1hp/0.746 Kw

= 25737.26 hp

Use;

effg = 96 %, for diesel engine generator sets are available at standard low pressure

25737.26 ℎ𝑝
𝑏ℎ𝑝 =
0.96
= 𝟐𝟔𝟖𝟎𝟗. 𝟔𝟓 𝒉𝒑

Solving for WF:

𝑘𝑔
𝑊𝑓 = 96 𝑥 26809.65 ℎ𝑝
𝑏ℎ𝑝 − 𝑚𝑜𝑛𝑡ℎ

𝒌𝒈
= 𝟐 𝟓𝟕𝟑 𝟕𝟐𝟔. 𝟓𝟒𝟐
𝒎𝒐𝒏𝒕𝒉
FOR UNIT 3&4 12V46F (14.4 MW)
𝑙𝑏
Brake Specific Fuel Consumption= 0.294 𝑏ℎ𝑝−ℎ𝑟

a) FUEL CONSUMPTION FOR 30 DAYS (WF)

WF = rate of fuel consumption x bhp

but;

rate of fuel consumption:

𝑙𝑏 1𝑘𝑔 24 ℎ𝑟𝑠 30 𝑑𝑎𝑦𝑠
= 0.294 𝑥 𝑥 𝑥
𝑏ℎ𝑝 − ℎ𝑟 2.205 𝑙𝑏 1 𝑑𝑎𝑦 1 𝑚𝑜𝑛𝑡ℎ

𝒌𝒈
= 𝟗𝟔
𝒃𝒉𝒑 − 𝒎𝒐𝒏𝒕𝒉

Bhp= Wo/effg

Where;

Wo = 14400 x 1hp/0.746 Kw

= 19 302.95 hp

Use;

effg = 96 %, for diesel engine generator sets are available at standard low pressure

19 302.95 ℎ𝑝
𝑏ℎ𝑝 =
0.96
= 𝟐𝟎 𝟏𝟎𝟕. 𝟐𝟒𝒉𝒑

Solving for WF:

𝑘𝑔
𝑊𝑓 = 96 𝑥 20 107.24 ℎ𝑝
𝑏ℎ𝑝 − 𝑚𝑜𝑛𝑡ℎ

𝒌𝒈
= 𝟏 𝟗𝟑𝟎 𝟐𝟗𝟒. 𝟗𝟏
𝒎𝒐𝒏𝒕𝒉

VOLUME OF FUEL PER MONTH (VF)

For Diesel Fuel @ 30O API

SG = 0.8762

Ρf = 875.3 kg/m3
Volume of Fluid for Unit 1 16V46F (19.2 MW)

𝑘𝑔
2 573 726.542
𝑉𝑓1 = 𝑚𝑜𝑛𝑡ℎ
875.3𝑘𝑔/𝑚3

𝑚3 1000𝑙
= 2940.40 𝑥
𝑚𝑜𝑛𝑡ℎ 𝑚3
𝒍
= 𝟐 𝟗𝟒𝟎 𝟑𝟗𝟑. 𝟔𝟑
𝒎𝒐𝒏𝒕𝒉
Volume of Fluid for Unit 2 16V46F (19.2 MW)

𝑘𝑔
2 573 726.542
𝑉𝑓1 = 𝑚𝑜𝑛𝑡ℎ
875.3𝑘𝑔/𝑚3

𝑚3 1000𝑙
= 2940.40 𝑥
𝑚𝑜𝑛𝑡ℎ 𝑚3
𝒍
= 𝟐 𝟗𝟒𝟎 𝟑𝟗𝟑. 𝟔𝟑
𝒎𝒐𝒏𝒕𝒉
Volume of Fluid for Unit 3 12V46F (14.4 MW)

𝑘𝑔
1 930 294.91
𝑉𝑓1 = 𝑚𝑜𝑛𝑡ℎ
875.3𝑘𝑔/𝑚3

𝑚3 1000𝑙
= 2092.512 𝑥
𝑚𝑜𝑛𝑡ℎ 𝑚3
𝒍
= 𝟐 𝟐𝟎𝟓 𝟐𝟗𝟓. 𝟐𝟐𝟒
𝒎𝒐𝒏𝒕𝒉
Volume of Fluid for Unit 4 12V46F (14.4 MW)

𝑘𝑔
1 930 294.91
𝑉𝑓1 = 𝑚𝑜𝑛𝑡ℎ
875.3𝑘𝑔/𝑚3

𝑚3 1000𝑙
= 2092.512 𝑥
𝑚𝑜𝑛𝑡ℎ 𝑚3
𝒍
= 𝟐 𝟐𝟎𝟓 𝟐𝟗𝟓. 𝟐𝟐𝟒
𝒎𝒐𝒏𝒕𝒉
NUMBER OF STORAGE TANKS

from table 12.4 p. 459 PPE by Morse

𝑉𝑓
Nt = 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝑡𝑎𝑛𝑘

TANK CAPACITY

Capacity Plate
Diameter (m) Length (m) Weight (kg)
(liters) Thickness(mm)
3.05 15.04 109716 7.94 10399

Number of Storage Tanks for Unit 1 16V46F (19.2 MW)

2 940 393.63 𝑙𝑖𝑡𝑒𝑟𝑠

𝑁𝑡 =
109716 𝑙𝑖𝑡𝑒𝑟𝑠/𝑡𝑎𝑛𝑘

= 𝟐𝟔. 𝟖 ≈ 𝟐𝟕 𝒕𝒂𝒏𝒌𝒔

Number of Storage Tanks for Unit 2 16V46F (19.2 MW)

2 940 393.63 𝑙𝑖𝑡𝑒𝑟𝑠

𝑁𝑡 =
109716 𝑙𝑖𝑡𝑒𝑟𝑠/𝑡𝑎𝑛𝑘

= 𝟐𝟔. 𝟖 ≈ 𝟐𝟕 𝒕𝒂𝒏𝒌𝒔

Number of Storage Tanks for Unit 3 12V46F (14.4 MW)

2 205 295.224 𝑙𝑖𝑡𝑒𝑟𝑠

𝑁𝑡 =
109716 𝑙𝑖𝑡𝑒𝑟𝑠/𝑡𝑎𝑛𝑘

= 𝟐𝟎. 𝟏 ≈ 𝟐𝟏 𝒕𝒂𝒏𝒌𝒔

Number of Storage Tanks for Unit 4 12V46F (14.4 MW)

2 205 295.224 𝑙𝑖𝑡𝑒𝑟𝑠

𝑁𝑡 =
109716 𝑙𝑖𝑡𝑒𝑟𝑠/𝑡𝑎𝑛𝑘

= 𝟐𝟎. 𝟏 ≈ 𝟐𝟏 𝒕𝒂𝒏𝒌𝒔
AIR SUPPLY SYSTEM

From PPE by Morse p.174

- Engine needed from 0.056 to 0.0884 m3 of air/hp- min developed, Use 0.056 m3/hp-min
For Unit 1 16V46F (19.2 MW)

Solving for the Volume of air

1 𝑚3
Vair = (19200) (0.746) (0.056 ℎ𝑝−min)

𝒎𝟑
= 𝟏𝟒𝟒𝟏. 𝟐𝟗
𝒎𝒊𝒏

From Diesel Engine Handbook by Stinton

Recommended velocity for medium speed engine = 75 fps (22.86 m/s)

𝑄
𝐴=
𝑉

𝜋𝐷 2 4𝐴
𝐴= 𝐷 = √𝜋
4

𝑚3 1𝑚𝑖𝑛
(1441.29 𝑚𝑖𝑛) (60 sec)
𝐴=
22.86𝑚/𝑠

𝑨 = 𝟏. 𝟎𝟓𝒎𝟐

4(1.05 𝑚2 )
𝐷= √
𝜋

𝑫 = 𝟏. 𝟏𝟓𝟕 𝒎

For Unit 2 16V46F (19.2 MW)

Solving for the Volume of air

1 𝑚3
Vair = (19200) (0.746) (0.056 ℎ𝑝−min)

𝒎𝟑
= 𝟏𝟒𝟒𝟏. 𝟐𝟗
𝒎𝒊𝒏

From Diesel Engine Handbook by Stinton

Recommended velocity for medium speed engine = 75 fps (22.86 m/s)

𝑄
𝐴=
𝑉

𝜋𝐷 2 4𝐴
𝐴= 𝐷 = √𝜋
4

𝑚3 1𝑚𝑖𝑛
(1441.29 𝑚𝑖𝑛) (60 sec)
𝐴=
22.86𝑚/𝑠

𝑨 = 𝟏. 𝟎𝟓𝒎𝟐

4(1.05 𝑚2 )
𝐷= √
𝜋

𝑫 = 𝟏. 𝟏𝟓𝟕 𝒎

For Unit 3 12V46F (14.4 MW)

Solving for the Volume of air

1 𝑚3
Vair = (14400) (0.746) (0.056 ℎ𝑝−min)

𝒎𝟑
= 𝟏𝟎𝟖𝟎. 𝟗𝟔𝟓
𝒎𝒊𝒏

From Diesel Engine Handbook by Stinton

Recommended velocity for medium speed engine = 75 fps (22.86 m/s)

𝑄
𝐴=
𝑉

𝜋𝐷 2 4𝐴
𝐴= 𝐷 = √𝜋
4

𝑚3 1𝑚𝑖𝑛
(1080.965 𝑚𝑖𝑛) (60 sec)
𝐴=
22.86𝑚/𝑠

𝑨 = 𝟎. 𝟕𝟖𝟖 𝒎𝟐

4(1.05 𝑚2 )
𝐷= √
𝜋

𝑫 = 𝟏. 𝟎𝟎𝟏𝟕 𝒎
For Unit 4 12V46F (14.4 MW)

Solving for the Volume of air

1 𝑚3
Vair = (14400) (0.746) (0.056 ℎ𝑝−min)

𝒎𝟑
= 𝟏𝟎𝟖𝟎. 𝟗𝟔𝟓
𝒎𝒊𝒏

From Diesel Engine Handbook by Stinton

Recommended velocity for medium speed engine = 75 fps (22.86 m/s)

𝑄
𝐴=
𝑉

𝜋𝐷 2 4𝐴
𝐴= 𝐷 = √𝜋
4

𝑚3 1𝑚𝑖𝑛
(1080.965 𝑚𝑖𝑛) (60 sec)
𝐴=
22.86𝑚/𝑠

𝑨 = 𝟎. 𝟕𝟖𝟖 𝒎𝟐

4(1.05 𝑚2 )
𝐷= √
𝜋

𝑫 = 𝟏. 𝟎𝟎𝟏𝟕 𝒎

EXHAUST PIPE SYSTEM

From PPE by Morse p. 176

Exhaust system must carry appox. 0.196 to 0.224 m3/min per hp developed.

Use: 0.196 m3/min

From Diesel Engine Handbook by Stinton

Exhaust gas velocity of medium engines 6000 to 8000 fpm

Use: 6000 fpm (1829.27 m/min)

For Unit 1 16V46F (19.2 MW)

1 0.196𝑚3
(19200 𝑘𝑤) ( ) (
0.746 𝑚𝑖𝑛 )
𝐴=
1892.27 𝑚/𝑚𝑖𝑛

= 𝟐. 𝟔𝟔𝟓 𝒎𝟐

For Diameter,

4(2.665 𝑚2 )
𝐷= √
𝜋

𝑫 = 𝟏. 𝟖𝟒𝟐 𝒎

For Unit 2 16V46F (19.2 MW)

1 0.196𝑚3
(19200 𝑘𝑤) ( ) (
0.746 𝑚𝑖𝑛 )
𝐴=
1892.27 𝑚/𝑚𝑖𝑛

= 𝟐. 𝟔𝟔𝟓 𝒎𝟐

For Diameter,

4(2.665 𝑚2 )
𝐷= √
𝜋

𝑫 = 𝟏. 𝟖𝟒𝟐 𝒎

For Unit 3 12V46F (14.4 MW)

1 0.196𝑚3
(14400 𝑘𝑤) ( ) (
0.746 𝑚𝑖𝑛 )
𝐴=
1892.27 𝑚/𝑚𝑖𝑛

= 𝟐 𝒎𝟐

For Diameter,

4(2 𝑚2 )
𝐷= √
𝜋

𝑫 = 𝟏. 𝟓𝟗𝟔 𝒎
For Unit 4 12V46F (14.4 MW)

1 0.196𝑚3
(14400 𝑘𝑤) ( ) (
0.746 𝑚𝑖𝑛 )
𝐴=
1892.27 𝑚/𝑚𝑖𝑛

= 𝟐 𝒎𝟐

For Diameter,

4(2 𝑚2 )
𝐷= √
𝜋

𝑫 = 𝟏. 𝟓𝟗𝟔 𝒎

AIR STARTING SYSTEM

From Wärtsilä 46F Product Guide for operating diesel engine:

Operating standard for diesel engine, air starting in air injection engines equipped with high pressure air
compressor use air pressure from 200-350 psig. Use 300 psig.

For Unit 1 16V46F (19.2 MW)

Bore: 460 mm

Stroke: 580 mm
𝜋
Volume Displacement = 4 (𝐷)2 𝐿
𝜋
= (. 46 𝑚)2 (. 58𝑚)
4
= 𝟎. 𝟎𝟗𝟔𝟒 𝒎𝟑 /𝒄𝒚𝒍𝒊𝒏𝒅𝒆𝒓
For Unit 2 16V46F (19.2 MW)

Bore: 460 mm

Stroke: 580 mm
𝜋
Volume Displacement = 4 (𝐷)2 𝐿
𝜋
= (. 46 𝑚)2 (. 58𝑚)
4
= 𝟎. 𝟎𝟗𝟔𝟒 𝒎𝟑 /𝒄𝒚𝒍𝒊𝒏𝒅𝒆𝒓
For Unit 3 12V46F (14.4 MW)

Bore: 460 mm

Stroke: 580 mm
𝜋
Volume Displacement = 4 (𝐷)2 𝐿
π
= (. 46 m)2 (. 58m)
4
= 𝟎. 𝟎𝟗𝟔𝟒 𝐦𝟑 /𝐜𝐲𝐥𝐢𝐧𝐝𝐞𝐫
For Unit 4 12V46F (14.4 MW)

Bore: 460 mm

Stroke: 580 mm
π
Volume Displacement = 4 (D)2 L
π
= (. 46 m)2 (. 58m)
4
= 𝟎. 𝟎𝟗𝟔𝟒 𝐦𝟑 /𝐜𝐲𝐥𝐢𝐧𝐝𝐞𝐫

Volume of air tank

Volume of air tank for large engine may be taken as 6 times the piston displacement.

From Internal Combustion Engine by Maleev, p. 573-574, in stationary multi-cylinder oil

engine, starting valves are put only two or three and not more than one half of cylinder. Use 3

Vair tank = VD (6)(3)

Since four engines,

Vair tank = 3 x VD (6)(3)

Vair tank = 4 x (0.0964 )(6)(3) = 𝟔. 𝟗𝟒𝟏 𝐦𝟑

Engine must have its own starter to its volume must be supplied by air receiver tanks

Assume 25 kpa pressure drop from air tank to air receiver

101.325
Pair receiver = (300 +14.7) ( ) + 25 kpa
14.7

Pair receiver = 2194.18 kpa

AIR COMPRESSOR

- Consider air compressor is reciprocating.

Computing for isentropic compression

P1V1K = P2V2K

Where;

P1 = 101.325 Kpa V1 =?

P2 = 1849.54 Kpa V2 = 0.0017 m3

1
𝑃2 𝐾
V1 = [𝑃1]

1
2194.18 1.4
= (0.0017) [101.325]

1003 𝑐𝑚3
3
= 0.01529 𝑚 𝑥
1𝑚3
= 15290.3 𝑐𝑚3

Assuming 5 hours for filled up (300 mins)

15290.3𝑚3
𝑐𝑓𝑚 =
300 𝑚𝑖𝑛
𝑐𝑚3
= 50.97
𝑚𝑖𝑛
Using 25 % for leakage

𝑐𝑚3
= 50.97 𝑥 1.25
𝑚𝑖𝑛
𝑐𝑚3
= 63.71
𝑚𝑖𝑛

From Kents ME Handbook Power Volume page 1-38

200 – 1000 psi requires 3 stages compressor

𝑘 𝑃𝑠𝑉𝑠 𝑘−1
𝐻𝑝 = 𝑁 ( ) [ 𝑅𝑝 ( − 1) ]
𝑘 − 1 229.2 𝑁𝑘
Where;

Hp = Horsepower (Isentropic)

N = no. of stages

PsVs = pressure and volume at suction (14.7psi) (50.814ft3)

R = Standard (21.7)

1.4 (14.7)(50.814) 1.4 − 1

𝐻𝑝 = 3 ( ) [ 21.7 ( − 1) ]
1.4 − 1 229.2 3(1.4)

= 𝟑𝟔. 𝟓𝟎 𝒉𝒑

From Kents page 1-41

Bore and stroke ratio = 1.25

Clearance = 3- 12 % (use 3%)

From Volumetric Eff;

1
Effv = 1 + 𝑐 − (𝑐)𝑅𝑝𝑘𝑁
1
= 1 + 0.03 − (0.03)(21.7)3(1.4)

= 𝟗𝟔. 𝟕𝟓 %

Capacity of Compressor (VD)

𝑉𝑓
Vd = 𝐸𝑓𝑓𝑣

𝑚3
= 1.034
𝑚𝑖𝑛

From Thermodynamics by Faires

FHP = 0.105 (𝑉𝑑)0.75

= 0.105 (1.034)0.75

= 𝟎. 𝟏𝟎𝟖 𝑯𝒑

𝐵ℎ𝑝 = 𝐻𝑝(𝑖𝑠𝑒𝑛𝑡𝑟𝑜𝑝𝑖𝑐) − 𝐹ℎ𝑝

= 36.5 − 0.108

= 𝟑𝟔. 𝟒𝟗 𝒉𝒑
LUBE OIL TANK DESIGN

From PPE by Morse p. 174, Lubrication oil is 1% of fuel consumption.

VLT = 0.01VF

Where VLT = volume of lubricating oil, VF = volume of fuel

The lube oil tank is to be designed to have an oil capacity that would last for 30 days.

Assuming L = 1.5 D, where L = length, D = diameter.

πD2 L
V=
4
Note: Plate thickness will be the same as the fuel tank.

For Unit 1 & 2

𝑉𝐹𝐴 = 2 940 393.63 𝐿⁄𝑚𝑜𝑛𝑡ℎ

𝑉𝐿𝑇 = 0.01 x (2 940 393.63) = 29 403.94 𝐿⁄𝑚𝑜𝑛𝑡ℎ

3
𝑉𝐿𝑇 = 29.4 𝑚 ⁄𝑚𝑜𝑛𝑡ℎ

𝜋𝐷 2
29.4 = (1.5𝐷)
4
D = 𝟐. 𝟗𝟐𝟐 𝐦; L = 1.5(2.922) = 𝟒. 𝟑𝟖𝟑 𝐦

For Weight of the tank; WTA

πDA 2
WTA = [cLt + (2t)] x ρs
4

Where c = circumference

L = length

t = thickness = 6.35 mm (Table 11-4 p. 459, PPE by Morse)

ρs = density of the steel tank = 7800 kg / m3

for c

2.922
c = 2πrA = 2π ( ) = 9.18 m
2
 π(2.922)2
WTA = [(9.18)(4.383)(0.00635) + (2)(0.00635)] x 7800
4

WTA = 𝟐 𝟔𝟓𝟕. 𝟏𝟔 𝐤𝐠

For Unit 3 & 4

𝑉𝐹𝐴 = 2 205 295.224 𝐿⁄𝑚𝑜𝑛𝑡ℎ

𝑉𝐿𝑇 = 0.01 x (2 205 295.224) = 22 052.95 𝐿⁄𝑚𝑜𝑛𝑡ℎ

3
𝑉𝐿𝑇 = 22.05 𝑚 ⁄𝑚𝑜𝑛𝑡ℎ

𝜋𝐷2
22.05 = (1.5𝐷)
4
D = 𝟐. 𝟔𝟓𝟓 𝐦; L = 1.5(2.655) = 𝟑. 𝟗𝟖𝟑 𝐦

For Weight of the tank; WTA

πDA 2
WTA = [cLt + (2t)] x ρs
4

Where c = circumference

L = length

t = thickness = 6.35 mm (Table 11-4 p. 459, PPE by Morse)

ρs = density of the steel tank = 7800 kg / m3

for c

2.655
c = 2πrA = 2π ( ) = 8.341 m
2

π(2.655)2
WTA = [(8.341)(3.983)(0.00635) + (2)(0.00635)] x 7800
4

WTA = 𝟐 𝟏𝟗𝟑. 𝟗𝟐 𝐤𝐠

DESIGN OF CRANE FOR DIESEL ENGINES

Using 1 ¾“, 6 x 19 IPS Wire Ropes, velocity when lifting: assume 10 fps (3.048 m/s).
Time of lifting until top end: assume 20 secs

For acceleration,

Vf − Vi 10 − 0
a= = = 0.5 ft/s 2
t 20
Using static approach

Fu − Fb
N=
Ft

N=8

Fu = 248,000 lb ; 1 ¾“ 6 x 19 IPS Table AT 28 Machine Design by Faires

Fb = EDwAm / Ds

Where E = 12 x 106 psi

Dw = 0.067Dr

Am = 0.4Dr2

Ds = 45Dr

Dr = ¼“ to 2 ¾“; use 1 3/4“

L = 50 m (164.042 ft)

Wr = 1.6(Dr)2L

For Multiple Rope Arrangement

Ft = [(WL/n) + Wr][1 + (a/g)]

WL = 343 tonnes (maximum weight among units)

Using 2 sheaves: WL = 171.5 tonnes

g = 32.174 ft/s2

3 3 2
(12 x 106 )(0.067) (1 ") (0.4) (1 ")
248,000 − 4 4
3
45 (1 4 ")
8=
2205 lbs
171.5 tonnes x ( 1 tonne ) 3 2 0.5
[ + 1.6 (1 ") (164.042)] (1 +
n 4 32.174)

n = 13.991 ≈ 14 ropes

Since 2 sheaves, 7 ropes per sheave