SCALED BUILT PLAN OF A 44 MW DIESEL POWER PLANT

A Mechanical Engineering Project presented to the

Faculty of the College of Engineering
University of Southeastern Philippines
Obrero, Davao City

In Partial Fulfillment of the Requirements for the Course

ME 516 – Mechanical Engineering Project

Arsen C. Largo
Stephen Gilner M. Payan
Angelie L. Unbay

May 2018
 Table of Contents

ABSTRACT ...................................................................................................... 1
CHAPTER I: INTRODUCTION .......................................................................... 2
Background of the Study ............................................................. 2
Objectives of the Study ................................................................ 4
Significance of the Study ............................................................. 4
Scope and Limitations of the Study .............................................. 4
CHAPTER II: REVIEW OF RELATED LITERATURE AND STUDIES ................... 5
Review of Related Literature ......................................................... 5
Thermodynamics ....................................................................................... 5
Combustion .............................................................................................. 6
Electricity .................................................................................................. 7
Power Generation ...................................................................................... 8
Engine Types ........................................................................................... 10
Engine Components ................................................................................ 11
Mechanical Energy .................................................................................. 13
Conservation of Mechanical Energy ......................................................... 13
Types, Advantages and Disadvantages ..................................................... 14
Review of Related Studies .......................................................... 16
Study of Various Parameters in Diesel Generator Sets ............................. 19
The Numerical Modeling of Transient Regimes of Diesel Generator Sets ... 20
CHAPTER III: METHODS ............................................................................... 21
Methodology .............................................................................. 21
CHAPTER IV: DISCUSSION ........................................................................... 23
Applications of a Diesel Power Plant........................................... 23
Diesel Engine Components ........................................................ 25
Discussion ................................................................................. 27
Feasibility of the Study .............................................................. 28
 Practicability of the Study .......................................................... 28
Affordability of Materials ............................................................ 29
CHAPTER V: SUMMARY AND RECOMMENDATIONS..................................... 30
Summary ................................................................................... 30
Scaled Built Plan of a 44 MW Diesel Power Plant ....................... 31
Recommendations ..................................................................... 32
REFERENCES............................................................................................... 33
APPENDICES ................................................................................................ 34
Appendix A – Bill of Materials .................................................... 34
Appendix B – Outline Defense Minutes ...................................... 35
Appendix C – Outline Defense Presentation ............................... 36
Appendix D – Final Defense Minutes .......................................... 38
Appendix E – Final Defense Presentation ................................... 39
Appendix F – Product Demo Grading Sheet………………………….41
Appendix G – Miniature Model ................................................... 42
CURRICULUM VITAE .................................................................................... 43
 List of Figures

Figure1: Davao Light and Power Company Inc. ................................................ 3

Figure2. Schematic Diagram of a Diesel Power Plant ....................................... 8

Figure3: Map of Mindanao ............................................................................ 17

Figure4: National Power Corporation Generating Plants ................................ 18

 List of Tables

Table 1. Types/Advantages/Disadvantages ................................................... 14

 ABSTRACT

A power plant is an industrial facility used to generate electric power with

the help of one or more generators which converts different energy sources into

electric power. This mechanical engineering project come up with a scaled

prototype of a diesel power plant. Desktop research on its essential components

and an ocular visit of an operating diesel plant were conducted to guide in the

construction of the built-to-scale power plant. The layout of the built prototype

featured proximate similarity of the plant. This ME project will be donated to the

mechanical engineering laboratory as an instructional visual aid for various

mechanical engineering courses in industrial and power plant engineering.

Energy conversions take place in the power plant. Power plant is an

electrical installation with one or several electric current generators driven by

diesel engines equipped with it. Diesel Power Plant, especially, is comprised of

diesel engines and other support systems common to any power plant.

The following chapters describe the basic components of diesel engine,

Schematic Diagram and the basic features of the support systems which are

mostly common in the industrial atmosphere. These basic components and

support systems will be covered in the following chapters.

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 CHAPTER I: INTRODUCTION

This chapter presents the background of the study, objectives of the study,

significance of the study, and the scope and limitations of the study.

Background of the Study

In the past decades, engineers have developed and innovated advanced

diesel featuring higher pressures, lighter parts, cleaner emission and better

efficiencies. Power plants or power generating stations are basically an industrial

location that is utilized for the generation and distribution of electrical power in

massive scale known as electricity for commoners.

Electricity is used in multiple ways and is considered as a necessity in all

domains, in health, business, education, and industry. It is an indication of a

progressive community as it is essential for development, innovation and

inventions. Hence, its importance has been observed as a potential market.

Without losing its common purpose, power plants were constructed and are

operating in almost every region in the Philippines.

It is significant for Mechanical engineers to know and understand the

holistic structures and functions of diesel power plants since it is mandated and

relevant to their field. It is providing information and clarification on how

electricity is generated and distributed to the consumers.

Davao Light and Power Company (DLPC) is the third largest privately-

owned electric distribution utility in country in terms of customer and annual

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kilowatt-hour (kWh) with a franchise covering Davao City and Davao del Norte

areas of Panabo City and the Municipalities of Carmen, Dujali and Santo Tomas.

Figure1: Davao Light and Power Company Inc.

Davao Light and Power Company, Inc. is a Davao-based electricity company and the third
largest privately owned electric utility in the Philippines and is owned by Aboitiz Power
Corporation.

In relevance, this project entitled “Scaled Built Plan of a 44 MW Diesel

Power Plant” aims to give understanding and knowledge of the structures and

workflow in the diesel power plants, through a miniature to present the build

plan of Davao Light and Power Company.

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Objectives of the Study

1) To determine the essential requirements in building a Diesel Power Plant.

2) To illustrate the process flow of a Diesel Power Plant.

3) To build a miniature model by scale of a real Diesel Power Plant.

Significance of the Study

This study will provide a model by scale inspired by a real Diesel Power

Plant. A model by scale is a representation of an object physically to demonstrate

the real object by scaling or building a miniature model. It will give an excellent

data and analysis of the said Power Plant.

To the students, future researchers, teachers and engineers, this study

focuses on building a scaled model to be used as a credible reference of studying

the actual flow of a Diesel Power Plant.

Scope and Limitations of the Study

This research aims to build a miniature of Diesel Power Plant inspired by

the Davao Light and Power Company. This is to organize a proper and exact

process flow of a Diesel Power Plant using principle of the laws of

Thermodynamics.

This engineering project requires 3-4 students to complete the research

with a challenge to build a miniature model of a Diesel Power.

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 CHAPTER II: REVIEW OF RELATED LITERATURE AND STUDIES

Review of Related Literature

Mechanical engineering is the discipline that applies engineering, physics,

and materials science principles to design, analyze, manufacture, and maintain

mechanical systems. It is one of the oldest and broadest of the engineering

disciplines.

The mechanical engineering field requires an understanding of core areas

including mechanics, dynamics, thermodynamics, materials science, structural

analysis, and electricity. In addition to these core principles, mechanical

engineers use tools such as computer-aided design (CAD), and product life cycle

management to design and analyze manufacturing plants, industrial equipment

and machinery, heating and cooling systems, transport systems, aircraft,

watercraft, robotics, medical devices, weapons, and others. It is the branch of

engineering that involves the design, production, and operation of

machinery.

Thermodynamics

Thermodynamics employs the four laws of thermodynamics as a form of

basis. The zeroth law of thermodynamics underlies the definition of temperature.

Thermodynamic equilibrium leads to the large-scale definition

of temperature, as opposed to the small-scale definition related to the kinetic

energy of the molecules. The first law specifies conservation of energy, and states

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that heat is a form of energy. This law is sometimes taken as the definition of

internal energy, and introduces an additional state variable, enthalpy. The

second law can remain constant for a reversible process but must always increase for

an irreversible process. When energy is converted to another form, some of it is

lost to heat. The third law concerns the entropy of an object as an absolute zero

temperature, and implies that it is impossible to cool a system all the way to

exactly absolute zero.

Combustion

Combustion is a chemical process in which a substance reacts rapidly

with oxygen and gives off heat. The original substance is called the fuel, and the

source of oxygen is called the oxidizer. The fuel can be a solid, liquid, or gas,

although for airplane propulsion the fuel is usually a liquid.

During the combustion process, as the fuel and oxidizer are turned into

exhaust products, heat is generated. Interestingly, some source of heat is also

necessary to start combustion. Gasoline and air are both present in your

automobile fuel tank; but combustion does not occur because there is no source

of heat. Since heat is both required to start combustion and is itself a product of

combustion, we can see why combustion takes place very rapidly. Also, once

combustion gets started, we don't have to provide the heat source because the

heat of combustion will keep things going. We don't have to keep lighting a

campfire, it just keeps burning.

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 To summarize, for combustion to occur three things must be present: a

fuel to be burned, a source of oxygen, and a source of heat. Because of

combustion, exhausts are created, and heat is released. You can control or stop

the combustion process by controlling the amount of the fuel available, the

amount of oxygen available, or the source of heat.

Electricity

Power engineering, also called power systems engineering, is a subfield of

electrical engineering that deals with the generation, transmission, distribution

and utilization of electric power, and the electrical apparatus connected to such

systems. Although much of the field is concerned with the problems of three-

phase AC power – the standard for large-scale power transmission and

distribution across the modern world – a significant fraction of the field is

concerned with the conversion between AC and DC power and the development

of specialized power systems such as those used in aircraft or for electric railway

networks. Power engineering draws most of its theoretical base from electrical

engineering.

Electricity generation covers the selection, design and construction of

facilities that convert energy from primary forms to electric power. Electric power

transmission requires the engineering of high voltage transmission lines and

substation facilities to interface to generation and distribution systems. Power

system protection is the study of the ways an electrical power system can fail,

and the methods to detect and mitigate for such failures.

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Power Generation

Figure2. Schematic Diagram of a Diesel Power Plant

Initially the engine pre-lube pump should be run to ensure proper

lubrication of the bearing surfaces. Where the engines remain idle like in

standby/ emergency units, the pre-lube pump should be operated at regular

intervals to keep the engine in "ready to start" condition. All engine auxiliary

systems should be periodically checked to verify proper status for engine

operation. Failure to properly pre-lube the engine prior to starting can result in

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damage to the internal components of the engine and significantly decrease

engine life.

The engine should then be started without any load connected to the

generator (By keeping its main circuit breaker in open condition) and brought

up to operating temperature before load is applied. The lube oil pressure shall

be verified for normal range immediately after starting.

Under normal circumstances, the engine loads are generally restricted

between 50 percent to 100 percent load for extended periods of time. Operation

at lower loads can cause carbon formation and rapid deterioration of the lube

oil. Operation at high loads results in higher temperatures and pressures in the

combustion chamber and can lead to more frequent maintenance or replacement

of components. Priority should be given to maintaining correct lube oil and

coolant levels and checking the pressure difference across the inlet air filters,

fuel filters and lube-oil filters.

Diesel engine should be unloaded and allowed to cool down prior to

shutdown of the unit. The engine should be operated without load at rated speed

for some time until the exhaust temperature decreases to recommended level

and then at low idle speed for about five minutes without load or as directed by

manufacturer.

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Engine Types

Engines may be classified as internal combustion engines and external

combustion engines. Though external combustion is not common terminology,

the basic steam turbine that is used in many power plants can be termed an

external combustion engine. Here the power is generated by combusting the fuel

external to the prime mover to produce steam, which is used by the turbine to

generate power.

An internal combustion engine is an engine that is powered by the

expansion of hot combustion products of fuel directly burnt within the engine.

The internal combustion diesel engine is piston operated, also called

reciprocating. The internal combustion engine works by burning hydrocarbon or

hydrogen fuel that is compressed by the piston action.

There are two primary reciprocating engine designs relevant to electrical

power generation applications, which are spark ignition Otto-cycle engine and

compression ignition Diesel-cycle engine.

The essential mechanical components of the Otto-cycle and Diesel-cycle

are the same. Both the engines use a cylindrical combustion chamber in which

a close-fitting piston travels the length of the cylinder. The piston connects to a

crankshaft that transforms the linear motion of the piston into the rotary motion

of the crankshaft. Most engines have multiple cylinders that power a single

crankshaft. Spark ignition engines typically use a gaseous fuel such as natural

gas or propane. Compression ignition engines typically use a liquid fuel such as

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Diesel. There are advantages and disadvantages to both in: fuel type, fuel

consumption, power output, maintenance requirements and air emissions.

Engine Components

The following are the essential components of an engine.

 Drive Train: basically, refers to the pistons, connecting rods,

crankshaft, flywheel, coupling, if any, and associated bearings of

the engine.

 Valve Train and Timing: includes the gearing from the crankshaft

to the camshaft, Camshaft itself, push rods, rocker arms, valves,

valve springs, and guides. The camshaft controls the fuel

injection timing and actuates the injector in most of the engines

with unit injectors in four-cycle engines. Two-cycle engines move

air into the cylinder and exhaust out through ports in the

cylinder wall which are exposed by the movement of the piston.

Some two-cycle engines have both ports and valves. Injection

timing and actuation on two-cycle engines are still controlled by

a camshaft.

 Governor/Control: Governor/control. The governor is a

sophisticated device that controls the speed of the engine by

varying the fuel input. The engine speed droops down when the

load increases. A reverse phenomenon occurs when the load is

suddenly thrown out. The governor gets the crankshaft speed

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 feedback and reacts to small deviations in the speed due to the

load changes and maintains proper engine speed by adjusting

the amount of fuel injected.

 Turbocharger/Blower: This is basically a centrifugal compressor,

which is driven by the exhaust gases and in turn compresses the

intake air to provide an increased mass of air to the combustion

chamber. In-line engines typically have one turbocharger, and V

type engines may adopt one or two turbochargers. Turbochargers

are used on both two and four stroke engines, but many two

stroke engines utilize blowers to assist in scavenging air from the

combustion chamber without significant increase in the density

of the air.

 After Cooler: Turbocharged engines have an after cooler

downstream of the turbocharger basically to reduce the air

temperature and increase the density of the air entering the

combustion chamber. Cooling water is circulated through the

after cooler, which is composed of finned tubes to cool the air to

approximately 40° C.

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Mechanical Energy

In the physical sciences, mechanical energy is the sum of potential

energy and kinetic energy. It is the energy associated with the motion and

position of an object. The principle of conservation of mechanical energy states

that in an isolated system that is only subject to conservative forces the

mechanical energy is constant. If an object is moved in the opposite direction of

a conservative net force, the potential energy will increase and if the speed (not

the velocity) of the object is changed, the kinetic energy of the object is changed

as well. In all real systems, however, non-conservative forces, like frictional

forces, will be present, but often they are of negligible values and the mechanical

energy's being constant can therefore be a useful approximation. In elastic

collisions, the mechanical energy is conserved but in inelastic collisions, some

mechanical energy is converted into heat.

Conservation of Mechanical Energy

The mechanical energy of an isolated system remains constant in time, if

the system is free of friction and other non-conservative forces. In any real

situation, frictional forces and other non-conservative forces are present, but in

many cases their effects on the system are so small that the principle of

conservation of mechanical energy can be used as a fair approximation. Though

energy cannot be created or destroyed in an isolated system, it can

be converted to another form of energy.

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Types, Advantages and Disadvantages

Table 1. Types/Advantages/Disadvantages

Fuel/Prime Advantages Disadvantages

Mover
Coal  Economical  Calorific values differ

 Good availability  More carbon dioxide per

kWH of energy

 Ash disposal issues

 Sulphur content can cause

acid rain

Natural Gas  Lower capital cost  Cost not favorable for

 Compact sizes smaller sizes

 Lesser carbon dioxide  Natural gas reserves are

compared to coal or oil limited

Oil  Lower cost  Limited oil reserves

 Compact generators  Oil spills

 Produces less carbon  High level of Sulphur

dioxide resulting acid rain

Hydel  Compact size  Ecological imbalance due

 Pollution free to large dams

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  Relocation of population for

constructing dams

Nuclear  Compact size  Expensive

 Radiation release issues

 Plutonium used can be and

indirect contributor for

nuclear bombs

 Disposal of radioactive

materials

Wind Turbines  Non-polluting  Dependent on wind

Diesel Powered  Small  Major noise

Generators  Relatively low cost  Carbon dioxide producers

 Portability  Limited fuels in availability

 Faster installation

Solar Electric  Abundant source  Higher capital cost

Panels  Non-polluting  High area requirements for

 More useful for isolated large capacities

locations  Need alternating power for

nights and no sun days

 Cost generation is high

15
Review of Related Studies

This chapter presents the related studies from local sources. This also

includes the brief history of Davao Light and Power Company (DLPC) as an

existing diesel power plant in Davao City and maps of generating plants in

Mindanao.

According to the Rondez Engineering Center, Davao Light and Power Company

is the third largest privately – owned electric utility in the Philippines. It holds

the franchise for distributing electric power to Davao City, the largest city in the

world in terms of land area, as well as Panabo City and the municipalities of

Carmen, Dujali, and Sto. Tomas in Davao del Norte. On September 29, 2000, the

franchise was renewed for another 25 years by virtue of Republic Act 8960.

In 2011, the company sold 1.583 billion kilowatt–hours to 294,159 customers

with a peak demand of 288 megawatts (MW). Among the country’s most

efficiently run power utilities, its systems having a loss rate of 8.44% is below

the government mandated cap of 8.50%.

Davao Light & Power Company (DLPC) is the power distribution utility in Davao

City, Panabo City and Carmen, Santo Tomas and Dujali municipalities in Davao

del Norte.

Davao Light operates in a Geographic Information System which has the

Automated Tools for Locating Assets (ATLAS) as one of its subsystems and

16
utilizes the Supervisory Control and Data Acquisition (SCADA) Systems for the

whole franchise, which allow remote control and monitoring of distribution

facilities.

Figure3: Map of Mindanao (DLPC)

Davao Light has close to 295,000 customers, with 23 distribution substations

and 2 subs – transmission substations strategically located throughout its

franchise. On hot standby is its 54.8 MW Bunker C – fired standby plant with a

rated capacity of 58.7 MW, but can provide an average of 40 MW on a sustaining

basis. The standby plant is capable of supplying 19% of Davao Light’s electricity

requirement.

17
High – end computers, sophisticated software, and other devices are being used

to speed up meter reading, streamline billing, provide efficient and prompt

response to customer inquiries, generate management information, and analyze

electrical grid information.

Special attention has been devoted to improving Davao Light’s service standards.

Innovative re – engineering efforts have cut down service cycle times.

Outsourcing of tasks and reallocating manpower and other resources has

allowed the utility to improve productivity while keeping costs relatively stable.

Current efforts focus on teamwork, service excellence, and professionalism, in

preparation for a deregulated and competitive environment.

Now and in the future, Davao Light is committed to deliver reliable and efficient

service at reasonable rates.

Figure4: National Power Corporation Generating Plants (DLPC)

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 As per data collected by the researchers, the said Power Plant has twelve

(12) operational engines together with their respective auxiliaries as a whole.

Their performances greatly vary, but it still provides approximately thirteen

thousand eighteen Volts (13,800 V) and sixty – nine thousand Volts (69,000 V)

of voltage to different households and investors (e.g. hospitals, malls, BPO

companies, hotels, etc.). An approximation has been foreseen due to its losses in

the actual rating.

Study of Various Parameters in Diesel Generator Sets

Diesel generator is the combination of a diesel engine with an electric

generator (often an alternator) to generate electrical energy. Diesel generating

sets are used in places without connection to the power grid, as emergency

power-supply if the grid fails, as well as for more complex applications such as

peak-lopping, grid support and export to the power grid. Set sizes range from 8

to 30 kW (also 8 to 30 kVA single phase) for homes, small shops & offices with

the larger industrial generators from 8 kW (11 kVA) up to 2,000 kW (2,500 kVA

three phase) used for large office complexes, factories. In addition to this there

are factors which diesel generators depend on they are Ambient Temperature,

Load on the Generator, Altitude of operation of the generator. Ambient generator

refers to the Inlet temperature. Because the generator works with the diesel

engine, the heat that the diesel engine emits make ambient temperature more

than 40 Celsius. However, temperature should be less than 40 Celsius for

operation. In the present work behavior of 62.5 KVA Diesel-Generator is studied

in ANSYS V13.0 licensed Institute software.) First a schematic approximation of

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the diesel-generator is drawn in the ANSYS Software and then the Experiments

are made to determine the temperature conditions of various surfaces under

constant load. These observations are taken for the simulation in the software

and the results are displayed.

The Numerical Modeling of Transient Regimes of Diesel Generator Sets

Main parts of a diesel generator are: the internal combustion engine,

usually air- or water-cooled; the electric generator usually of synchronous type;

the mechanical coupling; the support chassis; the battery for generator start-up;

the fuel tank; the starter motor; the command panel, etc. The main

characteristics of a diesel generator set are: rated power, rated voltage, rated

frequency, number of phases, etc. The diesel generator sets are usually designed

to run at 3000 rpm or 1500 rpm at a frequency of 50 Hz. The primary movers

are internal combustion engines equipped with mechanical regulators to keep

the imposed speed, integrated in the injection pump and adjusted to obtain an

output frequency of about 52 Hz without load and 50 Hz for rated load.

The proper operation of a diesel generator set is determined by two main

components, the speed regulator and the voltage regulator. The speed regulator

is designed to keep constant the internal combustion engine speed by changing

the quantity of fuel consumed by the motor. The main role of the voltage

regulator is to control the voltage at the generator terminals and to keep it

constant by limiting as fast as possible the voltage peaks and over voltages that

occur due to load variations.

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 CHAPTER III: METHODS

This chapter presents the desktop research and the cost estimation of its
miniature model of the said Power Plant Company.

Methodology

Consultation. The group consulted the reliable teachers and engineers for
this project proposal. After the consultation, thorough examination and
suggestions, the decision has been made to continue with this project entitled
Scaled Built Plan of a 44 MW Diesel Power Plant.

Further research and interviewing. Once the group received the notice to
start the conduct, they do further research and interviewing. Personnel and
authorities from Davao Light and Power Company were interviewed to gather
more information regarding the process flow of power generation in diesel power
plant.

Retrieval of schematic diagram. The group retrieved the schematic diagram

of the said power plant company which will be necessary for the completion of
the project.

Analysis. Then, thorough research and analysis were made to holistically

understand the structure and build plan of the power plant. Teachers and
engineers were constantly consulted with respect to the progress of the study for
clarifications and suggestions.

Listing of materials. Once the proposal will be approved, the group will do
the listing of the necessary materials for the feasibility of this project. After the
list of requirements will be validated and approved, they will be estimating the
total cost needed for the project.

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 Cost estimation. In scaling a model of the said Power Plant, many materials
are needed to acquire in building a miniature model. The estimated amount for
this project would range from ₱3,000 to ₱5,000.

Project construction. After the materials will be completely bought and

gathered. The group will then proceed to creating the miniature model. Once the
model project will be completed, the group will present the project which will be
subjected to examination, questioning and approval.

22
 CHAPTER IV: DISCUSSION

This chapter comprise the discussion of the applications of a diesel power

plant, diesel engine components and general discussion of the project that

includes the feasibility and practicability of the study.

Applications of a Diesel Power Plant

 Engine Starting System

For starting a diesel engine, initial rotation of the shaft is provided

for a small set. But for large diesel power station, compressed air is used

for starting.

 Fuel Supply System

Pump draws diesel from storage tank and supplies it to the small

day tank through the filter. Day tank supplies the daily fuel need of the

engine. The day tank is usually placed high so that diesel flows to engine

under gravity. Diesel is again filtered before injected to the engine by the

fuel injection pump. The fuel is supplied to the engine according to the

load on the plant.

 Air Intake System

Air filters are used to remove dust from the incoming air. This

system supplies necessary air to the engine for fuel combustion. It consists

23
 of a pipe for supplying of fresh air to the engine. Filters are provided to

remove dust particles from air because these particles can act as an

abrasive in the engine cylinder.

 Exhaust System

The exhaust gas is removed from engine, to the atmosphere. A

silencer or a muffler is normally used in this system to reduce noise level

of the engine.

 Engine Cooling System

The heat produced due to internal combustion, drives the engine.

But some parts of this heat raise the temperature of different parts of the

engine. High temperature may cause permanent damage to the machine.

Hence, it is essential to maintain the overall temperature of the engine to

a tolerable level. The cooling system requires a water source, water pump

and cooling towers. The pump circulates water through cylinder and head

jacket. The water takes away heat from the engine and it becomes hot. The

hot water is cooled by cooling towers and is re-circulated for cooling.

 Engine Lubrication System

This system minimizes the wear of rubbing surface of the engine.

Here lubricating oil is stored in main lubricating oil tank. This lubricating

oil is drawn from the tank by means of oil pump. From the filtering point,

this clean lubricating oil is delivered to the different points of the machine

where lubrication is required. The oil cooler is provided in the system to

keep the temperature of the lubricating oil as low as possible.

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Diesel Engine Components

 Bedplate

Bedplate is the foundation on which the engine is built. It must be

rigid enough to support the rest of the engine and maintain the crankshaft.

 Engine Frame

The structure which connects, or ties together, the various parts of

an engine.

 Cylinder Block

A cylinder block is the part of an engine containing the cylinders.

 Cylinder Liner

A cylinder liner is a thin-walled hard metal cylinder inserted into a

cylinder block of an engine in which the piston runs.

 Cylinder Head

A cylinder head is the part of an engine that closes the upper ends

of the cylinders.

 Piston

A piston is a cylinder that is part of an engine. Pistons slide up and

down inside tubes and cause various parts of the engine to move.

 Piston Rod

A piston rod connects the piston and the crankshaft.

 Piston Ring

A piston ring is one of the rings, made of hard, springy material, that

are part of a piston in an internal combustion engine.

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 Crosshead

A crosshead is a block or bar between the piston and the connecting

rod of an engine, that prevents the piston from moving from side to side

and damaging the piston and cylinder.

 Crankshaft

A crankshaft is the main shaft of an internal combustion engine.

 Bearings

A bearing is a device that supports moving parts and allows them to

move more smoothly by reducing friction.

 Valves

There are inlet and outlet valves in an engine. The inlet valves let in

air and fuel, and the outlet valves let out the exhaust fumes. Both have

high importance in keeping the engine running at optimum temperatures.

When combustion and compression take place, then both the valves stay

closed. The combustion chamber remains sealed at that time.

26
Discussion

Diesel Engines, also known as Compression-Ignition Engines are believed

to be more efficient replacement for stationary steam engines. Diesel engines,

which are classified as two-stroke engines and four-stroke engines, have the

highest thermal efficiency of any feasible internal or external engines due to its

very high expansion ratio which allows heat dissipation by the excess air.

Diesel Power Plants are divided into two classes: stationary and mobile.

The main advantages of the diesel power plant compared to the others are;

favorable economy due to its cheaper overall cost than other power plants of

same size, quickly started and picks up load in a short time, requires less water

for cooling, and no stand-by losses. However, it also holds disadvantages, such

as; high running charges due to costly price of diesel, it generates small amount

of power, cost of lubrication is very high, and maintenance charges are complex

and costs high.

Due to small amount of power generated, Diesel Power Plants are

popularly used as standby power supply of some different industries, commercial

complexes, and other establishments. During power cut, these diesel power

generators are running to fulfill the required amount of power demanded by the

consumers.

Anchored on the aim of providing a representation of how a diesel power

plants are structured; this project promotes a comprehensive representation of

the Diesel Power Plant in form of a miniature. During the synthesis of the project,

27
we have understood that this project considers three things: Feasibility,

Practicability and Affordability. After which the project had been made and is

ready for submission, the effectivity of the project must not be compromised

when considering these three variables.

Feasibility of the Study

The feasibility of this project depends on the time plan, efficient time

management and self-discipline. A power plant is not a singled-building. It is

consisting of multiple parts that individually function for the holistic operation

of the power plant itself. It requires patience and piles up tons of tasks to be

done, from measuring to cutting, to creating and painting.

There are wee details also that are challenging to make, the pipe line

connections for example is complicated. Studying thoroughly on how exactly pipe

connections works is the best solutions. Its feasibility is also affected by the

expertise and knowledge of the creator. It will prolong the time period of the

synthesizing if you have not studied thoroughly the construction, connections,

and parts of the diesel power plant.

Practicability of the Study

In terms of money spent on the project, it is certainly cost-efficient. But

for better and well-ordered project, we need to paint some parts of our project.

So buying paint can cost more. But overall, it is still cost-efficient. All materials

28
used in the project are local materials, there is no need for shipping and

importing of materials.

We also improvised some of the materials to create parts. With the limited

monetary budget available, we have not wasted a single coin for the materials

bought. The project is practical since the money spent were all used for the

general progress and outcome of the project. It is time, transportation and cost

efficient.

Affordability of Materials

Most of the materials can be easily bought and are affordable. As

mentioned, they are local materials which are available in hardware shops and

stores that sell materials used for building miniature. Some of our materials are

even improvised. The materials used in our project only costed 3,500.00 pesos

(estimated). The project, given this amount fully is fully equipped with all the

necessary details, parts, functions and processes of the diesel power plant. If the

budget is bigger the better the possible output can be.

29
 CHAPTER V: SUMMARY AND RECOMMENDATIONS

This chapter summarizes the main points in conducting the study.

Conclusions had been drawn based on the results of the miniature made and

added some recommendations on how to develop and improve the project who

would take the same study in the near future.

Summary

This engineering project entitled Scaled Built Plan of a 44 MW Diesel Power

Plant is intended to study to create a scaled model of a Diesel Power Plant.

The purpose of the study is to determine the applications and the essential

requirements in building a scaled model of a Diesel Power Plant. Also, to show

the flow of how a diesel engine starts to how the power produced by elaborating

the pipe connections and plant processes by building a miniature which is

designed and built to allow the future generations in using this project as a

credible reference in studying the actual processes and flow of a real Diesel Power

Plant for an easier access instead of visiting an actual power plant.

In this study, we showed a schematic diagram in a form of miniature and

stated the focus of our study which is to know and understand the structures

and functions of a diesel power plant especially significant in Mechanical

Engineering students which is relevant to their field. Moreover, it provides the

information on how electricity is generated.

30
 It is also emphasized that feasibility, practicability and affordability should

be best considered in creating this project. More than that, the goal and

objectives were strictly observed to attain the purpose of this study as it is

beneficial to the students, teachers, institutions and common people.

Scaled Built Plan of a 44 MW Diesel Power Plant

31
Recommendations

This study is a credible reference for the future researchers who plan to

embark in this kind of project and its relevance, the following recommendations

are suggested by the researches to improve the future study:

 This kind of study is highly recommended to be a project for its cost-

efficiency but still covers the importance of any power plant and the

course relevancy especially for Mechanical Engineering students.

 For better elaboration, create or build a miniature that is functional

and can produce power. Though, it would cost more.

 Design and build a miniature of other power plants.

 Design and build a miniature of a Diesel Power Plant that includes

a bunker.

32
 REFERENCES

https://www.studentenergy.org/topics/power-plant

https://www.grc.nasa.gov/www/k-12/airplane/combst1.html

https://www.grc.nasa.gov/www/k-12/airplane/thermo.html

http://bankpoclerknotes.blogspot.com/2016/05/list-of-all-diesel-based-
power-station.html

https://www.researchgate.net/publication/220036919_Operation_of_Diesel_P
ower_Plant

http://www.idc-online.com/downloads/DG_IDCBookextract.pdf

http://ethesis.nitrkl.ac.in/5135/1/109ME0423.pdf

https://www.uni-obuda.hu/journal/Tudorache_Roman_23.pdf

http://www.thehistoryof.net/the-history-of-the-light-bulb.html

https://www.collinsdictionary.com/dictionary

https://www.electrical4u.com/diesel-power-station/

http://mechanical-engineering-info.blogspot.com/2011/12/diesel-power-
plant.html

33
 APPENDICES

Appendix A – Bill of Materials

Quantity Item Price (Php)

3 pcs Spray Paint 330

5 sheets Sintra Board 740

3 sheets Cartolina 24

5 bundles Barbecue Sticks 90

2 pcs Scissor 40

5 bundles Plastic Straws 200

1 sheet Ply board 4x8 500

1 bundle Wood 1x2 280

15 pcs Stick Glue 25

20 pcs Shoes Glue 200

1 pc Double Sided Tape 75

10 pcs Printed Signboards and 200

Textures

7 pcs LED lights 245

Total 2,949

34
Appendix B – Outline Defense Minutes

35
Appendix C – Outline Defense Presentation

36
37
Appendix D – Final Defense Minutes

38
Appendix E – Final Defense Presentation

39
40
Appendix F – Product Demo Grading Sheet

41
Appendix G – Miniature Model

42
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Stephen Gilner M. Payan

Nickname : Steve

Date of Birth : February 27, 1997

Place of Birth : Mati City, Davao Oriental

Civil Status : Single

Religion : Faith Tabernacle

Father’s Name : Gilbert F. Payan

Mother’s Name : Analiza M. Payan

Address : Block 10 Lot 3, Esmeralda North, Tagum City

Email Address : stephengilner@gmail.com

EDUCATIONAL ATTAINMENT

Primary : Magugpo Pilot Central Elementary School

Tagum City

S.Y 2004-2009

Secondary : Tagum City National High School

Mangga, Visayan Village, Tagum City

S.Y 2012-2013

Tertiary : University of Southeastern Philippines

College of Engineering

Bo. Obrero, Davao City

43
SEMINARS AND TRAININGS ATTENDED

 2nd JPSME Mindanao Conference

“JPSME Supports the PSME Gearing towards Global Recognition”

August 19-20, 2014

 3rd JPSME Mindanao Conference

“Responding Towards Global Professional and Student Recognition”

August 16-17, 2015

PRACTICUM

 Monark-CAT

Km. J.P., 5 J.P. Laurel Ave, Lanang, Davao City

 JS DUMS Fabrication and Services

Durian St., Buhangin, Davao City

AFFILIATIONS

 Junior Philippine Society of Mechanical Engineers (JPSME) Member

 Students’ Association of Mechanical Engineering (SAME) Member

44
PERSONAL PROFILE

Name : Arsen C. Largo

Nickname : Arsen

Date of Birth : August 24, 1996

Place of Birth : Davao City

Civil Status : Single

Religion : Roman Catholic

Father’s Name : Arsenio O. Largo

Mother’s Name : Olympia C. Largo

Address : Prk. 39 Doña Assuncion Village, Davao City

Email Address : arsenlargo34@gmail.com

EDUCATIONAL ATTAINMENT

Primary : St. Dominic Academy

Davao City

S.Y 2008-2009

Secondary : Holy Cross College of Sasa

Davao City

S.Y 2009-2013

Tertiary : University of Southeastern Philippines

College of Engineering

Bo. Obrero, Davao City

45
SEMINARS AND TRAININGS ATTENDED

 2nd JPSME Mindanao Conference

“JPSME Supports the PSME Gearing towards Global Recognition”

August 19-20, 2014

 3rd JPSME Mindanao Conference

“Responding Towards Global Professional and Student Recognition”

August 16-17, 2015

PRACTICUM

 Monark-CAT

Km. J.P., 5 J.P. Laurel Ave, Lanang, Davao City

 JS DUMS Fabrication and Services

Durian St., Buhangin, Davao City

AFFILIATIONS

 Junior Philippine Society of Mechanical Engineers (JPSME) Member

 Students’ Association of Mechanical Engineering (SAME) Member

46
PERSONAL PROFILE

Name : Angelie Umbay L.

Nickname : Gel

Date of Birth : May 7, 1996

Place of Birth : Davao City, Davao del Sur

Civil Status : Single

Religion : Roman Catholic

Father’s Name : Angelito S. Umbay

Mother’s Name : Emelia L. Umbay

Address : Block 3, Brgy. Duterte, Sta. Cruz, Agdao, Davao City

Email Address : angelieumbay1996@gmail.com

EDUCATIONAL ATTAINMENT

Primary : Don Julian Rodriguez Sr. Elementary School

Davao City

S.Y 2004-2009

Secondary : Holy Cross of Agdao

Davao City

S.Y 2009-2013

Tertiary : University of Southeastern Philippines

College of Engineering

Bo. Obrero, Davao City

47
SEMINARS AND TRAININGS ATTENDED

 2nd JPSME Mindanao Conference

“JPSME Supports the PSME Gearing towards Global Recognition”

August 19-20, 2014

 3rd JPSME Mindanao Conference

“Responding Towards Global Professional and Student Recognition”

August 16-17, 2015

PRACTICUM

 Monark-CAT

Km. J.P., 5 J.P. Laurel Ave, Lanang, Davao City

 JS DUMS Fabrication and Services

Durian St., Buhangin, Davao City

AFFILIATIONS

 Junior Philippine Society of Mechanical Engineers (JPSME) Member

 Students’ Association of Mechanical Engineering (SAME) Member

48