ACKNOWLEDGEMENT

We would like to express our sincere gratitude to all those who provided us the possibility
to complete this design. This design would not have been possible without the supervision and
kind support of several persons.

First and foremost, we would like to thank Engr. Diosdado Doctor, our professor who
generously shared his knowledge and skills and contributed stimulating suggestions and
encouragement. His willingness to motivate us contributed tremendously to the completion of our
design.

In addition, we would like to thank our Mechanical Engineering classmates who willingly
shared references and ideas to us.

Furthermore, we would also like to acknowledge with much appreciation our families and
loved ones who gave us inspiration, financial support and motivation to finish this design.

Last but not the least, to God the Father of all, we give the greatest appreciation and
gratitude for the strength that keeps us standing and for the hope that keeps us believing that this
affiliation would be possible and more interesting.

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DEFINITION OF TERMS

Additives - Chemicals added to fuel in very small quantities to improve and maintain fuel quality
and/or to lower emissions.

Aftercooling / Intercooling - Cooling the engine intake air after the turbocharger and prior to
introduction into the cylinder. Aftercooling increases engine power and lowers NOx emissions.

Alternative Fuel - Fuel other than petroleum diesel or gasoline.

Biodiesel - The mono alkyl esters of long chain fatty acids derived from renewable lipid
feedstocks, such as vegetable oils and animal fats, for use in compression ignition (diesel)
engines. Manufactured by transesterification of the organic feedstock by methanol.

Carbon Dioxide (CO2) - A colorless, odorless, non-toxic gas. It is one of main products of
fossil-fuel combustion. Carbon dioxide is a greenhouse gas that contributes to the potential for
global warming.

Carbon Monoxide (CO) - A colorless, odorless and toxic gas. It blocks the lungs’ ability to
obtain oxygen. CO is produced by incomplete combustion of fossil fuels and is a major part of air
pollution. Compression ignition (diesel) engines generate significantly lower CO emissions than
spark ignited engines.

Carcinogens - Substances known to cause cancer.

Catalyst - A substance which influences the rate of a chemical reaction but is not one of the
original reactants or final products, i.e. it is not consumed or altered in the reaction. Catalysts are
used in many processes in the chemical and petroleum industries. Emission control catalysts are
used to promote reactions that change exhaust pollutants from internal combustion engines into
harmless substances.

Compressed Natural Gas (CNG) - Natural gas compressed to a volume and density that is
practical as a portable fuel supply.

Compression Ignition (CI) - The form of ignition that initiates combustion in a diesel engine.
The rapid compression of air within the cylinders generates the heat required to ignite the fuel as
it is injected.

Diesel Oxidation Catalyst (DOC) - Catalyst promoting oxidation processes in diesel exhaust.
Usually designed to reduce emissions of the organic fraction of diesel particulates, gas-phase
hydrocarbons, and carbon monoxide.

Dual-Fuel Vehicle - A vehicle designed to operate on a combination of alternative fuel, such as

compressed natural gas (CNG) or liquefied petroleum gas (LPG), and conventional fuel, such as

ii
diesel or gasoline. These vehicles have two separate fuel systems, which inject both fuels
simultaneously into the engine combustion chamber.

Evaporative Emissions - Hydrocarbon vapors that escape from a fuel storage tank or a vehicle
fuel tank or vehicle fuel system.

Flash Point - The temperature at which a combustible liquid gives off just enough vapor to
produce a vapor/air mixture that will ignite when a flame is applied. The flash point is measured
in a standardized apparatus using standard test methods, such as ASTM D93 or ISO 2719.

Fossil Fuel - Any naturally occurring organic fuel formed in the Earth’s crust, such as petroleum,
coal and natural gas.

Fuel cycle - The processes involved in extracting a fuel in its native form, converting it to a
useful product, transporting it to market, and consuming it at its final destination.

Gas Turbine - A turbine powered by a gas, such as the hot gas produced in combustion
processes.

Gas Turbine Engine - A combustion engine utilizing a turbine, such as a jet engine.

Genset - Generator set, a generating system comprising a combustion engine driving an electrical
generator.

Ignition Delay - The length of time or number of degrees of crankshaft rotation between the
beginning of injection and ignition of the fuel.

In-Direct Injection (IDI) - In diesel engines with in-direct injection the fuel is injected to an
auxiliary pre-chamber. Combustion starts in the pre-chamber and propagates to the cylinder.

In-Line Injection Pump - An injection pump with a separate cylinder and plunger for each
engine cylinder. Each plunger is rotated by a rack to determine metering via ports in the body of
the pump and helical cuts on the pump plungers. The plungers are driven off a camshaft, which
usually incorporates a centrifugal or electronically controlled timing advance mechanism.

Natural Gas (NG) - A mixture of hydrocarbon compounds and small quantities of various non
hydrocarbon components existing in the gas phase or in solution with crude oil in natural
underground reservoirs. The main component of natural gas is methane.

Overhead Cam - A camshaft used for operating both valves and unit injectors, located on top of
or within the cylinder head. Such camshafts are driven by a multi-gear geartrain off the
crankshaft. They simplify the design of the cylinder head and eliminate pushrods, allowing for
much larger, open intake and exhaust ports and better breathing.

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Ozone (O3) - Ozone is normally present at ground level in low concentrations. In cities where
high level of air pollutants is present, the action of the sun’s ultraviolet light can, through a
complex series of reactions, produces harmful concentrations of the ground level ozone. The
resulting air pollution is known as photochemical smog.

Particulate Matter (PM) - Particles formed by incomplete combustion of fuel. Compression

ignition (diesel) engines generate significantly higher PM emissions than spark ignited engines.
The particles are composed of elemental carbon, heavy hydrocarbons (SOF), and hydrated
sulfuric acid (“sulfate particulates”).

Petroleum - A generic term applied to oil and oil products in all forms. Examples include crude
oil, lease condensate, unfinished oil, refined petroleum products, and natural gas plant liquids.

Pour Point - A measure of the ability of a diesel fuel to operate under cold weather conditions.
Defined as the temperature at which the amount of wax out of solution is sufficient to gel the fuel
when tested under standard conditions (ASTM D97).

Precombustion Chamber - A small, auxiliary combustion chamber connected by a narrow

orifice with the main chamber. Fuel is injected into the pre-chamber and ignites there, causing hot
gases to expand into the main chamber (cylinder).

Renewable Energy - Energy obtained from sources that are essentially inexhaustible, unlike
fossil fuels. It includes conventional hydro-electric, wood, bio-feedstocks, waste, geothermal,
wind, photovoltaic, and solar thermal energy

iv
 Table of Contents

Acknowledgement ........................................................................................................................... i
Definition of Terms ........................................................................................................................ ii
List of Tables .................................................................................................................................. x
List of Figures .............................................................................................................................. xiii

CHAPTER I INTRODUCTION ................................................................................................. 1

CHAPTER II FUEL SELECTION .............................................................................................. 3
2.1 Combined Cycle Power Plant Operation ............................................................................. 3
2.2 Combined Cycle Gas Turbine Configurations ..................................................................... 4
2.3 Natural Gas........................................................................................................................... 5
2.4 Criteria for Natural Gas Fuel Selection ................................................................................ 7
A. Heating Value ................................................................................................................... 7
B. Cleanliness ......................................................................................................................... 9
C. Corrosivity ....................................................................................................................... 10
D. Fouling Tendencies ........................................................................................................ 12
E. Distance ....................................................................................................................... 13
2.5 Selected Natural Gas ............................................................................................................ 15
2.6 Summary............................................................................................................................... 16
CHAPTER III FUEL HANDLING AND STORAGE .............................................................. 34
3.1 LNG Supply Chain ............................................................................................................... 34
3.2 Fuel Consumption .............................................................................................................. 36
A. Natural .......................................................................................................................... 36
B. Supplementary Fuel ...................................................................................................... 36
3.3 Storage .................................................................................................................................. 39
3.3.1 Types of Storage Tank ............................................................................................... 40
A. In-ground Storage Tank ............................................................................................... 36
B. Above-ground Storage Tank ........................................................................................ 36
C. Underground Storage Tank .......................................................................................... 36

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 3.3.2 Selected LNG Storage Tank ....................................................................................... 40
3.4 Tank Farm ............................................................................................................................ 46
3.5 Supplementary Fuel .............................................................................................................. 47
A. Selection of Diesel Storage Tank ................................................................................. 36
3.5.1 Bund Wall ................................................................................................................... 51
A. Volumetric Capacity of the Bund................................................................................. 36
B. Bund-Tank Distance ..................................................................................................... 36
C. Length and Width of the Bund ..................................................................................... 36
D. Bund Wall Height......................................................................................................... 36
E. Adjustments on the Diesel Tank Farm Dimensions ..................................................... 36
F. Bund-Tank Distance ..................................................................................................... 36
G. Shell to Shell Spacing of the Tanks ............................................................................. 36
H. Height of the bund wall based on the proposed dimensions ........................................ 36
I. Over-all Tank Farm ....................................................................................................... 36
3.6 Auxiliary and Ancillary Equipment ..................................................................................... 50
3.6.1 Fire Protection System ................................................................................................ 51
A. Dry Chemical ............................................................................................................... 36
B. Carbon Dioxide ............................................................................................................ 36
C. Halogenated .................................................................................................................. 36
D. Deluge Fire Sprinkler System ...................................................................................... 36
3.6.2 Water Services ............................................................................................................ 51
3.6.3 Lubrication Oil Tanks ................................................................................................. 51
3.6.4 Recommendations ....................................................................................................... 51
3.6.5 Regasification .............................................................................................................. 51
A. Open Rack Vaporizer ................................................................................................... 36
B. Submerged Combustion Vaporizers ............................................................................. 36
C. Fluid-type Vaporizers ................................................................................................... 36
D. Ambient Air Vaporizers ............................................................................................... 36
E. Design and Construction of LNG Vaporizers .............................................................. 36
3.7 Chapter Summary................................................................................................................. 51
CHAPTER IV SYSTEM DESIGN AND CONFIGURATION ............................................... 63

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 4.1 Combined Cycle Power Plant System .................................................................................. 63
A. Brayton Cycle ............................................................................................................... 36
B. Rankine Cycle .............................................................................................................. 36
4.2 Combined Cycle ................................................................................................................... 74
A. Single Shaft Configuration ........................................................................................... 36
B. Multi-Shaft Configuration ............................................................................................ 36
4.3 Combined Cycle Power Plant Configuration ....................................................................... 79
A. Contract Capacity ......................................................................................................... 36
4.4 Gas Turbine .......................................................................................................................... 83
4.4.1 Air Compressor .......................................................................................................... 84
A. Axial-Flow Compressors .............................................................................................. 36
B. Centrifugal Compressors .............................................................................................. 36
C. Air Compressor Selection ............................................................................................. 36
4.4.2 Combustor .................................................................................................................. 86
4.5 Generator .............................................................................................................................. 89
4.6 Heat Recovery Steam Generator (HRSG) ............................................................................ 90
4.7 Steam Turbine ...................................................................................................................... 95
4.8 HRSG Comparison to Steam Turbine .................................................................................. 96
4.9 Supplementary Firing ........................................................................................................ 102
4.10 Summary .......................................................................................................................... 102
CHAPTER V GAS LOOP ......................................................................................................... 103
5.1 Combustion Analysis .......................................................................................................... 104
A. Air-Fuel Ratio............................................................................................................... 36
5.2 Combustion Analysis of Diesel Fuel .................................................................................. 106
A. Theoretical Air-Fuel Ratio ........................................................................................... 36
B. Actual Air-Fuel Ratio ................................................................................................... 36
C. Flue Gas Weight ........................................................................................................... 36
D. Mass Flow Rate of Diesel Fuel in Supplemental Firing .............................................. 36
E. Volume Flow Rate Diesel ............................................................................................. 36
F. Diesel Density ............................................................................................................... 36
G. Volume Flow Rate of Flue Gas produced by Supplemental Firing ............................. 36

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 5.3 Environmental Considerations ........................................................................................... 109
A. Reduction of NOx ........................................................................................................ 36
B. Catalytic Combustor Systems ....................................................................................... 36
5.4 Exhaust System .................................................................................................................. 117
5.5 Stack .................................................................................................................................. 131
5.6 Fans and Blowers .............................................................................................................. 132
5.6.1 Type of Fans ............................................................................................................... 84
A. Centrifugal Fans ........................................................................................................... 36
B. Axial Fans ..................................................................................................................... 36
5.7 Fans and Blowers .............................................................................................................. 132
A. Induced Draft Fan Computation ................................................................................... 36
B. Static Head .................................................................................................................... 36
C. Velocity Head ............................................................................................................... 36
D. Total Head .................................................................................................................... 36
5.8 Fan Selection ..................................................................................................................... 135
5.9 Chapter Summary .............................................................................................................. 135
CHAPTER VI WATER LOOP .............................................................................................. 134
6.1 Feed Water Source ............................................................................................................. 135
6.1.1 Water Quality ............................................................................................................. 84
6.1.2 Seawater Quality ........................................................................................................ 84
6.2 Feed Water Treatment ...................................................................................................... 135
6.2.1 External Treatment ..................................................................................................... 84
A. Filtration ....................................................................................................................... 36
B. Reverse Osmosis .......................................................................................................... 36
C. Stages of Reverse Osmosis ........................................................................................... 36
6.2.2 Deaerator ..................................................................................................................... 84
A. Tray-Type Deaerating Heaters ..................................................................................... 36
B. Spray-Type Deaerating Heaters ................................................................................... 36
6.2.3 Internal Treatment ....................................................................................................... 84
6.3 Cooling Water System ....................................................................................................... 136
6.3.1 Cooling Water Treatment ............................................................................................ 84

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 A. Filtration ....................................................................................................................... 36
B. Chlorination .................................................................................................................. 36
6.3.2 Condenser .................................................................................................................... 84
A. Surface Condenser........................................................................................................ 36
B. Direct Contact Type Condenser ................................................................................... 36
C. Condenser Selection ..................................................................................................... 36
6.3.3 Cooling Tower ............................................................................................................ 84
A. Cooling Tower Selection .............................................................................................. 36
6.4 Cooling Pond .................................................................................................................... 137
6.5 Chapter Summary .............................................................................................................. 141

REFERENCES ........................................................................................................................... 158

ANNEX A (Steam Turbine Generator Set) ............................................................................ 159
ANNEX B (Enthalphies) ............................................................................................................ 164
ANNEX C (Boiler)...................................................................................................................... 166
ANNEX D (Cooling Tower) ...................................................................................................... 169
ANNEX E (Condenser) ............................................................................................................. 172

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 List of Tables

CHAPTER II: FUEL SELECTION ........................................................................................... 3

Table 2.1: Ultimate and Proximate Analysis .............................................................................. 6

Table 2.2 Heating Value of Each Source .................................................................................... 8

Table 2.3: Summary of Computed Heating Value ..................................................................... 8

Table 2.4 Mercury Content of Each Source ............................................................................... 9

Table 2.5 Summary of Computed Mercury Content ................................................................ 10

Table 2.6 Water Content of Each Source ................................................................................. 11

Table 2.7 Summary of Computed Value of Water Content ..................................................... 12

Table 2.8 Sulfur Content of Each Source ................................................................................. 12

Table 2.9 Summary of Computed Value of Sulfur Content ..................................................... 13

Table 2.10 Distance of Each Source from the Philippines ....................................................... 14

Table 2.11 Summary of Computed Value in terms of Distance ............................................... 15

Table 2.12 Summary of Percentage Rating of Each Source ..................................................... 16

Table 2.13 CALTEX Diesel Fuel Properties ............................................................................ 17

Table 2.14 Ultimate and Proximate Analysis of the Brunei LNG ............................................ 18

Table 2.15 Combined Cycle Powerplant System Capacity ...................................................... 20

CHAPTER III: FUEL HANDLING AND STORAGE .......................................................... 21

Table 3.1: Combined Cycle Power Plant Specification ............................................................ 24

Table 3.2 Supplementary Firing Requirements .......................................................................... 26

Table 3.3: Fuel Consumption Summary ................................................................................... 27

Table 3.4: LNG Storage Tank Comparison ............................................................................... 32

Table 3.5: Selection of LNG Tank ........................................................................................... 33

Table 3.6: Specification of the LNG Storage Tank ................................................................... 34

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 Table 3.7: LNG Storage Composition ...................................................................................... 35

Table 3.8: Minimum Tank Shell to Shell Spacing .................................................................... 39

Table 3.9: Supplementary Firing Requirements ........................................................................ 41

Table 3.10 Selection of Diesel Storage Tank ............................................................................ 42

Table 3.11 Specification of the Diesel Storage Tank ................................................................ 43

Table 3.12 Recommended Separation Distances from NFPA 59A .......................................... 49

Table 3.13 Fire Classification .................................................................................................... 51

Table 3.14 LNG Vaporizer Qualitative Comparison ................................................................. 61

Table 3.15 Summary of Data ..................................................................................................... 66

CHAPTER IV: SYSTEM DESIGN AND CONFIGURATION ............................................ 67

Table 4.1: Combined Cycle Power Plant Configuration .......................................................... 73

Table 4.2: Gas Turbine Specification ....................................................................................... 75

Table 4.3: Compressor Characteristics ....................................................................................... 78

Table 4.4: Specification of the Axial Flow Compressor .......................................................... 79

Table 4.5: Combustor Specification .......................................................................................... 80

Table 4.6: Generator Specification ........................................................................................... 81

Table 4.7: Heat Recovery Steam Generator Specification ....................................................... 82

Table 4.8: Steam Turbine Specification .................................................................................... 84

Table 4.9: Comparison of HRSG to Steam Turbine ................................................................. 85

Table 4.10: Equipment Summary ............................................................................................. 86

CHAPTER V: GAS LOOP ....................................................................................................... 89

Table 5.1: Ultimate Analysis of the Brunei LNG ..................................................................... 90

Table 5.2: Combustion Equation ............................................................................................... 91

Table 5.3: Acquired Values based on Computation .................................................................. 95

Table 5.4: Ultimate Analysis of Diesel Fuel ............................................................................. 95

Table 5.5: Acquired Values based on Computation .................................................................. 99

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 Table 5.6: Stack Dimensions at Different Velocities ............................................................... 106

Table 5.7: Draft Requirements of Induced Draft Fan ............................................................. 110

Table 5.8: Selected Fan Specifications ................................................................................... 112

Table 5.9: Summary ............................................................................................................... 114

CHAPTER VI: WATER LOOP ............................................................................................. 116

Table 6.1 ASME Guidelines for Water Quality in Modern Industrial Water Tube Boilers for
Reliable Continuous ................................................................................................................ 117

Table 6.2 Ionic Composition of Seawater ............................................................................... 118

Table 6.3: Seawater Composition Based on Dissolved Gases ............................................... 119

Table 6.4: Chemical Percentage Rejected by Reverse Osmosis ............................................ 122

Table 6.5: Chemical Used in Internal Feed Water Treatment ................................................ 126

Table 6.6: General Guidelines for Chlorine Dose of Reasonably Good Cooling Water ........ 128

Table 6.7: Advantages and Disadvantages of Surface Condenser ......................................... 131

Table 6.8: Advantages and Disadvantages of Direct Contact Type Condenser ..................... 132

Table 6.9 Specifications of the Condenser to be Used ............................................................ 132

Table 6.10: Cooling Tower Specifications ............................................................................. 134

Table 6.11: Summary of Equipment ...................................................................................... 135

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 List of Figures

CHAPTER II: FUEL SELECTION ........................................................................................... 3

Figure 2.1: Combined Cycle Power Plant Diagram ..................................................................... 4

Figure 2.2: Photo Showing the Natural Gas Development .......................................................... 5

CHAPTER III: FUEL HANDLING AND STORAGE .......................................................... 21

Figure 3.1: Photo Showing the LNG Supply Chain .................................................................. 21

Figure 3.2: Photo Showing the LNG Process Flow Diagram ................................................... 22

Figure 3.3: Photo Showing the LNG Tanker ............................................................................. 22

Figure 3.4: Photo Showing the Unloading Arms ...................................................................... 23

Figure 3.5: Photo Showing the In-ground LNG Storage Tank ................................................. 29

Figure 3.6: Photo Showing the Above-ground LNG Storage Tank ........................................... 30

Figure 3.7: Photo Showing the Underground LNG Storage Tank ............................................. 31

Figure 3.8 Aboveground Storage LNG Tank ............................................................................. 36

Figure 3.9: Aboveground Storage Tank Composition .............................................................. 37

Figure 3.10: Aboveground Storage Wall Tank Composition ..................................................... 38

Figure 3.11: Photo Showing the LNG Storage Tank Layout ..................................................... 40

Figure 3.12: Photo Showing the Diesel Storage Tank Layout .................................................. 45

Figure 3.13: Photo Showing the Adjusted Diesel Storage Tank Layout ................................... 47

Figure 3.14: Photo Showing the Tank Farm Layout ................................................................. 50

Figure 3.15: Dry Chemical Fire Suppression System ................................................................ 52

Figure 3.16: Carbon Dioxide Fire Suppression System ............................................................. 53

Figure 3.17: Photo Showing the Deluge Fire Protection Skid ................................................... 54

Figure 3.18: Photo Showing the Service Water Tanks ............................................................... 55

Figure 3.19: Photo Showing the Service Water Tanks............................................................... 56

xiii
 Figure 3.20: Photo Showing the Lubrication Oil Tanks ............................................................. 57

Figure 3.21: Photo Showing the Flow Diagram of ORV ........................................................... 59

Figure 3.22: Photo Showing the SCV Configuration ................................................................. 59

Figure 3.23: Photo Showing the FV Schematic Layout ............................................................. 60

Figure 3.24: Photo Showing the Flow in an Ambient Air Vaporizer ........................................ 61

CHAPTER IV: SYSTEM DESIGN AND CONFIGURATION ............................................ 67

Figure 4.1: Photo Showing the T-S and P-V Diagrams for ideal Brayton Cycle ...................... 68

Figure 4.2: Photo Showing the Schematic for an open gas-turbine cycle ................................. 68

Figure 4.3: Photo Showing the Reheat Rankine Cycle ............................................................. 69

Figure 4.4: Schematic and T-S Diagram of Rankine Cycle ....................................................... 70

Figure 4.5: Photo Showing the Combined Cycle Power Plant Diagram ................................... 72

Figure 4.6: Photo Showing the Gas Turbine ............................................................................ 75

Figure 4.7: Photo Showing the Axial Flow Compressor ........................................................... 77

Figure 4.8: Photo Showing the Centrifugal Flow Compressor Schematic ................................ 78

Figure 4.9: Photo Showing the Typical Gas Turbine Combustor ............................................. 80

Figure 4.10: Photo Showing the Generator ............................................................................... 81

Figure 4.11: Photo Showing the Modular HRSG Diagram ....................................................... 82

Figure 4.12: Photo Showing the Steam Turbine ....................................................................... 84

Figure 4.13: Power Generation Layout ..................................................................................... 88

CHAPTER V: GAS LOOP ....................................................................................................... 89

Figure 5.1: Photo Showing Gas Loop Schematic Diagram ....................................................... 89

Figure 5.2: Photo Showing the NOx Equilibrium as a Function of Air Temperature ............. 101

Figure 5.3: Photo Showing the Catalytic Combustor .............................................................. 102

Figure 5.4. Photo Showing the Centrifugal Fan ...................................................................... 108

Figure 5.5: Photo Showing the Axial Fan ............................................................................... 109

Figure 5.6: Photo Showing the Selected Fan ........................................................................... 113

xiv
 Figure 5.7: Photo Showing the Schematic Diagram of Gas Loop .......................................... 115

CHAPTER VI: WATER LOOP ............................................................................................. 116

Figure 6.1: Photo Showing Water Loop System Diagram ....................................................... 116

Figure 6.2: Schematic Diagram of Feed Water Treatment ....................................................... 120

Figure 6.3: Diagram of Reverse Osmosis Membrane ............................................................. 121

Figure 6.4: Photo Showing Tray-type Deaerating heaters ....................................................... 124

Figure 6.5: Spray type Deaerating Heater ................................................................................ 125

Figure 6.6: Schematic Diagram of Cooling Water System ..................................................... 127

Figure 6.7: Photo Showing the Surface Condenser ................................................................. 130

Figure 6.8: Photo Showing the Direct Contact Type Condenser ............................................. 131

Figure 6.9: Summary of Feed Water System .......................................................................... 136

Figure 6.10: Summary of Cooling Water System ................................................................... 137

xv