Don Bosco Technical College

Mandaluyong City
Mechanical Engineering Department

In partial fulfilment for the requirements of

Power Plant Engineering
(PME 528)

Hydroelectric Power Plant Design

Submitted by:
Baybay, Julia Nikki G.
De Dios, Prince Albert III R.
Nicolas, Kiel A.
Reynancia, Justine Roie D.C.
Villaluna, Marvin S.

Submitted to:
Dr. Mario Regino Norbe
May 22, 2020
Abstract

The design of the project is based on the knowledge of the designers in power plant
engineering. The project is designed to develop a hydroelectric power plant in Lingayen,
Pangasinan. This design project is intended to propose a design for a 9-MW Hydroelectric Power
Plant and its constituents. The calculations for the design were based on gathered information
conditions, certain assumptions and estimations. Some standards were considered in order to
make a brief design and to further give details in various parts of the power plant. Topics related
in the design process are discussed in this paper. This paper is presented by Julia Nikki G.
Baybay, Prince Albert R. De Dios III, Kiel A. Nicolas, Marvin S. Villaluna and Justine Roie
D.C. Reynancia to comply with the requirements for Powerplant Engineering (PME 528). The
design also considers the location of the proposed plant as well as the accessibility of to its main
source which is the Agno River.
Acknowledgement

We, the designers, would like to express our utmost gratefulness first of all, to God –
because without Him, there would be nothing at all; Our creator has given us everything we have
today which we use as our resources for our daily life and sustain everything we need as a human
being. Our God has created everything around us to take care and use with respect and love.

We also express our gratitude to Dr. Mario Norbe for sharing his knowledge and
expertise that helped us analyze the design of the power plant for our paper. Our knowledge in
this design is based on what you have taught and shared to us. We also want to extend our
gratitude to our previous professors who also shared their knowledge which without it would be
impossible to finish this design paper.

And lastly, we would like to thank our families for their unwavering support throughout
our education that helped and allowed us to gain the knowledge we all have. We wouldn’t have
done anything of this without the support and guidance of these people. So from our group, we
thank everyone.
Preface

The paper intends to be used as the basis for design of HydroElectric Powerplant that will
be helpful for future Mechanical Engineering Students which will undergo the design of
PowerPlants under PME 528: Power plant Engineering.

This paper is a result of hard work and time management of student designers despite
their hectic schedules due to some other requirements. This paper also serves a partial fulfillment
in the said subject or course.

This paper is open for criticisms that will help for the betterment of the design of the
HydroElectric PowerPlant. The designer hopes that this paper can serve as a basis and guide to
those who will design the said powerplant.

This paper would not be possible without the help of Dr. Mario Norbe - professor in PME
528: PowerPlant Engineering, the designers extend their utmost respect and gratitude to him.
Thank you for your effort, time and knowledge Dr. Mario Norbe.
Table of Contents:

Chapter 1: Introduction

Introduction

Problem Statement

Objectives

Scope and Limitations

Plant Location and Background

Layout of HydroElectric PowerPlant

Chapter 2: Review of Related Literature

History of Hydroelectric PowerPlant

Hydropower Energy

Chapter 3: Design Considerations

Variable Loading

Hydropower

Penstock

Surge Tank

Gravity Dam

Catchment and Spillway

Powerhouse Foundation

Cost Analysis
 Chapter 1 - Introduction

Introduction
Hydropower is energy obtained from the ocean, waterfalls and rivers. Humans have been
depending on hydropower as a source of energy which different kinds of watermills were
constructed as a way to harness the energy from the water and used for irrigation and give
lightning and electricity in some areas.

Hydroelectricity is the term referring to electricity generated from flowing or running

water or simply by hydropower. From potential energy transformed to kinetic energy and some
mechanical devices such as turbines to harness these energy. It is the most widely used form of
renewable energy, accounting for 16% of global electricity generation and installed 1292 GW of
hydropower capacity.

Running and flowing water creates energy that can be harnessed and generated into
electricity, this phenomenon is called hydroelectric or hydropower. There are different types of
hydroelectric power plants but the most common type uses a dam on a river to store water in a
reservoir. These power plants consist of a reservoir for storage and a valve which controls the
release of the water from the reservoir, flowing through a turbine while spinning and transfers to
a generator to generate electricity. The size of a hydroelectric power plant does not necessarily
need to be a huge or large dam, some power plants channel rivers through a small canal that will
flow through a turbine.

Statement of the Problem:

The province of Pangasinan has experienced power interruptions in the recent years,
some reasons may be corrective or maintenance works in the power supply but this also means
that the Province is lacking another source of power which supposedly avoid these power
interruptions.
Objectives

Design a Hydroelectric PowerPlant that can supply additional power supply for the
province of Pangasinan particularly in Lingayen, Pangasinan. This Hydroelectric PowerPlant
should help in addressing the current power shortage in the province.

Scope and limitations

The design of the hydroelectric power plant is based on the energy requirement of
Lingayen, Pangasinan. It also includes all appliances and electrical equipment that are utilized in
the said location. The load is based on the average monthly consumption of each residence in the
said province.

This project design mainly focuses only on the energy demand of the said location, the
material selections, equipment and the project cost were estimated based on the output energy of
the plant.

Plant location and background

The 9-MW Hydroelectric power plant was designed to supply the electricity demand of the
whole area of Lingayen, Pangasinan. Shown in Figure 1 is the map of location of the area.

Figure 1:​ Lingayen, Pangasinan

 The energy generated of the plant will be from the Agno River. The location of the plant
will be in Barangay Malimpuec, Lingayen Pangasinan which is a desirable plant location
because the Agno River traverses the provinces of Benguet and Pangasinan. In addition, it is the
5th largest river system in the Philippines.

Figure 2:​ Basin of Agno River

The Agno River, with a drainage area of 5,952 square kilometers is the third largest river
in Luzon, and fifth in the Philippines. The length of the river system from its source in the
Cordillera Mountains to its mouth in Lingayen Gulf is about 270 kilometers, 90 kilometers of
which runs through mountainous terrain and canyons.

The municipality of Lingayen, is a first class municipality in the province of Pangasinan.

The municipality has 32 barangays and the 2nd district in Pangasinan. According to the 2015
census, it has a population of 103,278 people and an approximate 21,325 households.
Figure 3:​ Location of power plant (from google map)

Figure 4:​ Layout of hydro electric power plant

 Chapter 2 - Review of Related Literature

History of Hydroelectric PowerPlant in the Philippines

In 1913, hydropower was developed in the Philippines. The first ever Hydroelectric
PowerPlant in the country was built in Baguio City, which is named as Camp John Hay
Hydroelectric PowerPlant which supplies 560 kW. The National Power Corporation was built in
1936 under the establishment of Commonwealth Act no. 120 which until now, regulates the
operation of renewable energy PowerPlants which energy source can be harnessed was given the
right under this Act.

The abundant water resources in the country have urged more developed hydroelectric
PowerPlant in the country. A total of 21 Hydroelectric PowerPlants are being managed by
HedCor which generates and supplies a total of 258 MW of clean and renewable energy in the
country.

HydroPower Energy

Hydropower refers to the energy generated from flowing or running water, which is also
considered as a renewable resource of energy since the water cycle is affected by the Sun. About
6.7% of the world's electricity generation comes from hydro energy. Hydropower energy is an
abundant source of power even with its upfront costs it is still a cost efficient and flexible source.
According to law of conservation, which states that no energy can be created nor destroyed it can
only be transformed from one form to another, is like how hydropower works, the energy is
gained from the flowing or running water which is kinetic energy, transformed to mechanical
energy through the turbines and electrical energy through the use of generators.
 Chapter 3 - Design Considerations

Variable loading

The formulas used in the following calculations are from Chapter 17 of “Power Plant
Engineering” by R. S. Capote and J. A. Mandawe.
For the loading computation, Table 1 shows the projected load curve data in 1-month
intervals based on typical power consumption of households in the Philippines. Figure 5 shows
the graph of the load curve.

Projected
Monthly Projected Municipality
Consumption Projected Power Power Consumption
Month Households (Kw-h) Consumption (Kw) (Kw-H)
January 21,325 250 0.3360215 7165.6586
February 21,325 254 0.3413978 7280.3091
March 21,325 224 0.3010753 6420.4301
April 21,325 264 0.3548387 7566.9355
May 21,325 270 0.3629032 7738.9113
June 21,325 225 0.3024194 6449.0927
July 21,325 235 0.3158602 6735.7191
August 21,325 243 0.3266129 6965.0202
September 21,325 245 0.3293011 7022.3454
October 21,325 221 0.2970430 6334.4422
November 21,325 238 0.3198925 6821.7070
December 21,325 240 0.3225806 6879.0323
Table 1:​ Projected Monthly load curve data

From the load curve data, the peak load, L​peak​, is:
L​peak​ = 7566.94 kW
Assuming a reserve over peak, ROP, of 18% of the peak load, the ROP is:
ROP = (18%) (7566.94 kW)
ROP = 1362.05 kW
 Figure 5.​ Projected Consumption curve

The total capacity of the plant is the sum of the peak load and the ROP. The total plant capacity,
TPC, is therefore:
TPC = L​peak​ + ROP
TPC = 7566.94 kW + 1362.05 kW
TPC = 8928.99 kW ≈ 9MW
The daily connected load, DCL, is the sum of the energy consumption per day. From the load
curve data, the DCL is:
DCL = 83379.60 kW per day
The average load, AL, is the daily connected load per 24 hours. Substituting, we have:
AL = DCL / 24 hrs
AL = (83379.60 kW per day) / 24 hrs
AL = 3474.15 kW
The annual energy produced, AEP, is:
83379.60 kW 365 days
AEP = day
x year

AEP = 30,433,554 kW-hr per year

The load factor, LF, is defined as the ratio of the average load to the maximum demand (the peak
load). Therefore:
LF = AL / L​peak
LF = 3474.15 kW / 7566.94 kW
LF = 0.4591 or 45.91%

For the annual capacity factor, ACF:

Annual energy production
ACF = (T otal plant capacity) (8760 hours
year )

30,433,554 kW −hr per year

ACF = (8928.99 kW ) (8760 hours
year )

ACF = .3891 or 38.91%

For the used factor, UF, it is assumed that the plant is operational for 18 hours per day.
Therefore, the used factor s:
Annual energy production 30,433,554 kW −hr per year
UF = UF = (8928.99 kW ) (18 hours
365 days
day x year )
(T otal plant capacity) (no. of operational hours)

UF = 0.5188 or 51.88%

For the plant factor, PF, it is defined as the ratio of the average load to the plant capacity. Thus:
PF = AL / TPC
PF = 3474.15 kW / 8928.99 kW
PF = 0.3891 or 38.91%

For the utilization factor, UTF, it is defined as the ratio of the maximum demand to the plant
capacity. Thus:
UTF = L​peak​ / TPC
UTF = 7566.94 kW / 8928.99 kW
UTF = 0.8475 or 84.75%
Variable loading design summary:

Plant Capacity 9 MW
Peak Load (Max.) 7566.94 kW
Reserve over peak (ROP): 1362.05 kW
ROP Percentage: 18%
Daily connected load: 83379.60 kW/day
Average load: 3474.15 kW
Annual Energy Produced: 30,433,554 kW-hr/year
Load Factor 45.91%
Annual Capacity Factor 38.91%
Used Factor 51.88%
Plant Factor 38.91%
Utilization Factor 84.75%
Table 2: ​Summary of Design from Variable loading

Hydropower Design Calculation

Turbine
 The Francis turbine may be a style of turbine, a category of turbine within which the
working fluid involves the turbine under immense pressure and therefore the energy is extracted
by the turbine blades from the working fluid. an element of the energy is given up by the fluid
due to pressure changes occurring within the blades of the turbine, quantified by the expression
of degree of reaction, while the remaining part of the energy is extracted by the volute casing of
the turbine. (Source: ​https://en.wikipedia.org/wiki/Francis_turbine​)

Generator

Vertical axis is the type of generator we use. A hydroelectric generator could be a

salient-pole synchronous generator whose rotor is connected to the rotor of a hydraulic turbine.
The planning of a hydroelectric generator is essentially determined by the position of its rotor’s
axis, still as by the frequency of rotation and power of the turbine. High-capacity, low-speed
generators are usually manufactured with a vertical axis of rotation, whereas high-speed units
with a bucket-type hydraulic turbine are made with a horizontal axis of rotation. (Source:
https://encyclopedia2.thefreedictionary.com/Hydroelectric+Generator​)

For the turbine, The designers chose the ​HL110-LJ-140 Francis type turbine from
electway to be used in the design since it allows for medium-head application of up to 172
meters and a capacity of 12,913 kW (12.9 MW) which provides more potential for the plant.
Let's assume the efficiency of Turbine is 90%. Refer to the book since the efficiency range of the
Francis type turbine was 90-94%.
For the generator, The Designers Chose chose the SF12.5-10/2860 Vertical Shaft
synchronous generator from the electway since it is the recommended generator for the turbine
we selected. Its efficiency is 96.8%.
Summarizing the data from the selection, we have:

Turbine efficiency =​e​T​ =90%

Generator Efficiency= ​e​G =96.8%

​

P​E​ =9MW

Computing for the turbine power. P​T​:

P​T​ = P​E​ / e​G​ = 9 MW / 96.8%
P​T​ = 9.2975 MW
The water power, P​w​ is:
PE 9 MW
PW = eT eG
= (90%) (96.8%)

P​W​ = 10.3306 MW
With the water power known, the tailstock can now be designed. The net head is given by:
h = h​g​ – h​f
It is desirable to have head water (h​hw​) and tail water (h​tw​) elevations of 180 m. and 50 m.
respectively. Since the maximum allowable friction head is 30% of the gross head (h​f = 0.30 h​g​),
the net head (h) to be computed is:
h = h​g​ – 0.30 h​g
h = 0.70 h​g
Since h​g​ = h​hw​ – h​tw
h = 0.70 (h​hw​ – h​tw​)
h = 0.70 (180 m – 50 m)
h = 91 m
Since h = 0.70 h​g​, the gross head is:
 h​g​ = h / 0.70 = 91 m / 0.70
h​g​ = 130 m
Since h = h​g​ – h​f​, the friction head is:
h​f​ = h​g​ – h = 130 m – 91 m
h​f​ = 39 m
Next, the specific speed of the turbine, N​S​, is given by:
0.2623 N √kW
NS = h5/4

Where kW is the water power value in kilowatts and N is the rated angular speed. From the
catalog, the rated angular speed of the generator is 600 rpm​.
N= 600 rpm

Substituting the values, the specific speed of the turbine is:

0.2623 (600 rpm) √10.3306 KW
NS = (91 m)5/4

N​S​ = 56.9123
Hydropower design summary:

Required power output: 9MW

Turbine efficiency: 90%
Generator efficiency: 96.80%
Water power: 10.33 MW
Headwater elevation: 180 m
Tail water elevation: 50 m
Gross head: 130 m
Friction head: 39 m
Net head: 91 m
Specific speed: 56.91
Table 3: ​Summary of Hydropower design
Penstock design

Penstocks are channels or long channels that carry water down from the hydroelectric
supply to the turbines interior the real control station. For the most part, they are made of steel
and water beneath tall weight streams through the penstock. (Source:
https://energyeducation.ca/encyclopedia/Penstock​)

To compute for the area of the penstock, the velocity of the turbine must first be determined.
The turbine velocity, V​T​, is given by
VT = √2 g h
Where g is the acceleration due to gravity and h is the net head. Using the previously computed
net head value of 91 m, we have:
VT = √2 (9.81 m/s2 ) (91 m)
V​T​ = 42.2542 m/s
Next, the volumetric flow rate (Q) of the penstock must be determined. It is given by:
PW
Q = γh

Where γ is the specific weight of water. Computing for Q, we have:

10.3306 M W
Q =
(9810 mN3 ) (91 m)
Q = 11.572 m​3​/s
With the velocity and volumetric flow rate of the penstock known, the diameter of the penstock
can now be computed. Since the volumetric flow rate is given by:
Q=AV
Where A is the cross-sectional area and V is the velocity. Since the velocity along the penstock is
known as V​T​, and the cross-sectional shape of the penstock is circular, we have:
Q = ( π4 D2 ) (V T )
Where D is the penstock diameter. Substituting the values and solving for the penstock diameter,
D, we have:

√
Q
√
11.572 m3 /s
D = 2 πVT
D = 2 π (42.2542 m/s)

D = 590.506 mm
The Designer chose a valve – a valve within which the disk is turned about 90 degrees
from the near the open position, a couple of spindles supported on the body of the valve on an
axis transverse to it of the valve.
Using the Darcy-Weisbach equation, the length of the penstock can now be computed.
The equation is given by:
f LP V T 2
h = 2 g DP

Where: h = Head loss

f = Darcy friction factor = 0.0032
L​P = Penstock length
V​T = Flow velocity
g = Acceleration due to gravity
D​P = Penstock diameter
Thus, the penstock length, L​P​, is:
h g DP 2
LP = 2 f V 2 LP = 2 (91 m)(0.0032)
(9.81 m/s ) (590.5206 mm)
(42.2542 m/s)
T

L​P​ = 184.533 m
From this, the penstock angle is given by:
h
sin (θ) = LP

Where θ is the penstock angle. Solving for θ, we have:

91 m
sin (θ) = 184.533 m

θ = 29.547 deg
Next, the peripheral coefficient, Φ, is given by:
πDN
Φ =
√2 g h
The peripheral coefficient, now, is:
π (590.506 mm) (600 rpm)
Φ =
√2 (9.81 m/s2 ) (91 m)
π (590.506 mm) (62.83 rad/s)
Φ =
√2 (9.81 m/s2 ) (91 m)
Φ = 2.76
Finally, the penstock efficiency, e​P​, is given by the ratio of the net head to the gross head
previously computed. Substituting:
h 91 m
eP = hg
= 130 m
= 70%

Penstock design summary:

Penstock diameter: 590.51 mm

Penstock length: 184.53 m
Penstock angle: 29.55 deg
Flow velocity: 42.25 m/s

Volumetric flow rate: 11.57 ​m3​​ /s

Peripheral coefficient: 2.76

Penstock efficiency: 70%
Control gate type: Butterfly valve
Table 4: ​Summary of Penstock design
Surge Tank

Surge tank is a device that is inserted into a hydropower water conveyance system with a rather
long pressure conduit to absorb the increase in excess pressure in the event of a sudden valve
close. The surge tank is positioned between the slight angle or almost horizontal conduit and
steeply sloping penstock and is built as a chamber excavated in the mountain.
(Source : ​https://www.aboutcivil.org/surge-tanks-functions-types.html​)

Surge Tank Design

The surge tank is a component to a pressurized environment designed to withstand changes in
pressure. The aim is to neutralize rising and falling pressures to prevent machine failures,
blowouts and other problems. This unit is used for controlling the water levels in the penstock in
this design method.
For the application, the Designer proposes to have a surge tank with a 5 m elevation (E​ST​)
from the tailwater level.
E​ST​ = 5m
The length of the penstock, connected from the surge tank (LST) to the turbine, can be
measured using similar triangles.
LST LP LP E ST (184.533 m) (5 m)
E ST
= L
hhw ST
= hhw
= 150 m

L​ST​ = 16.1511 m
Next, the amount of water that may flow through the penstock as it passes through the surge
tank: V​PST​.This will determine how much water the surge tank can hold. As the surge tank is of a
cylindrical nature, the V​PST​ is provided by:
 V P ST = π
4 (DP 2 ) (LST )
V P ST = π
4
(590.506 mm)2 (16.1511 m)

V​PST​ = 4.4232 m​3

With the volume of water known after the surge tank, the volume of water to be carried by the
surge tank, V​ST​, is designed to be 120 percent of the V​PST​ to ensure reliability.
V​ST​ = (120%) (V​PST​) = (1.20) ( 4.423 m​3​)
V​ST​ = 5.3076 m​3
The diameter and height can now be calculated, since the volume of the surge tank is now
known. The capacity of the surge tank is centered on a cylinder 's volume, and is given by:
V ST = π
4 (DST 2 ) (H ST )

Where D​ST​ is the surge tank diameter and H​ST​ is the height.
The highest pressure point in a thin-walled cylindrical vessel is at the 2/3 of its height.
With this, the designer will assign the surge tank height to be thrice its diameter.
H​ST​ = 3 D​ST
The volume of the surge tank is now:
V ST = π
4 (DST 2 ) (3 DST ) = 5.3076 m3

Solving for the surge tank diameter, D​ST​:

D​ST​ = 1.3108 m
Notice that since the surge tank volume equation is a cubic equation, The designer neglected the
first 2 imaginary roots, and used the real one.
Now that the surge tank diameter is known, The designer stated that the height of the surge tank
is thrice the diameter. Thus:

H​ST​ = 3 D​ST
H​ST​ = 3.9324 m
Finally, to complete the surge tank design the wall thickness of the surge tank must be
determined. The thickness of the surge tank should be able to resist the pressure of water inside
the tank.
The pressure at the bottom of the surge tank, P​B​ is given by:
 P​B​ = γ H​ST
Note that γ is the specific weight of water. Substituting the values and solving for P​B​, we have:
P​B​ = (9810 N/m​3​) (3.9324 m)
P​B​ = 38,576 Pa

Since the point where the highest pressure, P​C​, is located at 2/3 of the height of the surge tank,
the pressure exerted there must be determined as well. With this, P​C is estimated to be 2/3 of P​B​,
therefore:
P​C​ = (2/3) (P​B​) = (2/3) (38,576 Pa)
P​C​ = 25,717.3 Pa
For the material of the surge tank, We selected the annealed AISI 410 martensitic stainless steel
for its high yield strength (S​Y = 276 MPa), high ductility (30% elongation per 50.8 mm length),
and corrosion resistance.
The factor of safety, FOS, is designed to be 6.0. With these parameters, the design stress,
S​D​, can now be computed.
S​D​ = S​Y​ / FOS
S​D​ = 276 MPa / 6.0
S​D​ = 46 MPa
Computing for the wall thickness, T​ST​, of the surge tank based from the water pressure inside of
it:
P C DST (25717.3 P a) (1.3108 m)
T ST = 2 (S D )
= 2 (46 M P a)

T​ST​ = 0.3664 mm
The measured thickness is still not final. The thickness of the surge tank based on the headwater
pressure, T​ST-HW​, is also to be measured. The designer will assign the final thickness of the surge
tank to which the calculation will yield a greater thickness.
The headwater pressure, P​ST-HW​, is given by:
P​ST-HW​ = γ (h​hw​ – E​ST​)
P​ST-HW​ = (9810 N/m​3​) (180 m – 5m)
P​ST-HW​ = 1.716 MPa
With the P​ST-HW​ known, the T​ST-HW​ will be:
P ST −HW DST (1.707 M P a) (1.3108 m)
T ST −HW = 2 (S D )
= 2 (46 M P a)
 T​ST-HW​ = 24.32 mm
For the surge tank the required wall thickness is therefore 24.32 mm. The closest normal value to
meet this is 25 mm. So, for the build, the designer will allocate 25 mm as the final wall thickness
of the surge tank. It rounds out the configuration of the surge tank.
Surge tank design summary

Surge tank elevation: 5m

Penstock length from surge tank: 16.15 m

Surge tank volume: 5.31 ​m3​

Surge tank diameter: 1.31 m

Surge tank height: 3.93 m
Wall thickness: 25 mm
Material: AISI 410 stainless steel
Table 5: ​Summary of Surge tank design

Gravity Dam

A gravity dam is a dam developed from concrete or stone brick work and intended to keep down
water by essentially using the heaviness of the material alone to oppose the even weight of water
pushing against it.​ ​(Source: ​https://www.britannica.com/technology/dam-engineering​)

Dam design
For this design of the hydroelectric power plant, we decided to use a gravity dam.
The dimensions of the dam are mostly made from assumptions. The values would be checked
through the design process using the factors of safety due to sliding or FSS and FSO.
Base width = W​1​ = 95 m
Top width = W​2​ = 35 m
Overall dam height = H​D​ = 200 m
Overall dam length = L​D​ = 180 m
Remember that the headwater elevation, h​hw​, is 180m. The cement to be used for the dam, ρ​C​, has
an estimated density of 3.15 g/cm​3​.
ρ​C​ = 3.15 g/cm​3​ = 3150 kg/m​3
From the given parameters, the dam area, A​dam​, is:
A​dam​ = (W​1​) (L​D​) = (95 m) (180 m)
A​dam​ = 17100 m​2
For the weight of the dam, W​dam​, is given by:

W dam = ( W1 + W2
2 ) (H D ) (LD ) (ρC )

W dam = ( 95 m +2 35 m ) (200 m) (180 m) (3150 kg/m3 )

W​dam​ = 7.371​9​ kg
Solving for the weight of the water in the dam, W​water​, is given by:

W water = 1
4 ( W1 + W2
HD ) (hhw )
2
(LD ) (ρC )

W water = 1
4 ( 95 m200+ m35 m ) (180 m)2 (180 m) (3150 kg/m3 )
W​water​ = 2.99 x 10​9​ kg
The total weight of the dam, W​T​, is the sum of the water and the dam itself. Therefore:
W​T​ = W​dam​ + W​water​ = 1.0661 x 10​10​ kg = 1.0455 x 10​11​ N
To check if the dam design is sufficient to hold its maximum capacity, two factors of safety are
considered: the factor of safety against sinking (FSS) and the factor of safety against overturning
(FSO). The basis for a safe dam design is where the FSS and FSO are approximately equal to
each other.
The factor of safety against sinking, FSS, is given by:
(SBP )(Adam )
F SS = WT

Where SBP is the soil bearing pressure. The standard soil bearing pressure we will use in the
design is 20.68 MPa.
 Substituting the values:
(21.8 M P a)(17100)
F SS = 1.0455 x 1011 N

FSS = 3.3824
The factor of safety against overturning, FSO, is given by:
(W dam )(0.5 W 1 ) + (W water )(Z)
F SO = (P H )(Y P )

Where:

Z = W1 – 1
6 ( W1 + W2
HD ) (hhw )

And:
PH = 1
(ρ )(hhw )2 (LD )
2 W

And:
1
YP = (h )
3 hw

Solving for Z:
1
Z = 100 m – 6 ( 100190
m + 40 m
m ) (180 m)
Z = 75.5 m
Solving for P​H​:
PH = 1
2
(1000 kg/m3)(180 m)2 (180 m)

P​H​ = 2.916 x 10​9​ kg

Solving for Y​P​:
1
YP = 3
(180 m) = 60 m

Substituting the values of Z, P​H​, and Y​P​ to solve for the FSO:
(W dam )(0.5 W 1 ) + (W water )(Z)
F SO = (P H )(Y P )

(7.371 x 109 kg)( 952m ) + (2.99x 109 kg)(75.5 m)

F SO =
(2.92 x 109 kg)(60 m)
FSO = 3.2869
The FSO and FSS are approximately equal to each other, the dam design is now complete.
Dam design summary

Cross section: Trapezoidal

 Base width: 95 m
Top width: 35 m
Overall dam height: 200 m
Overall dam length: 180 m
Dam weight: 7.37
FSS: 3.38
FSO: 3.29
Table 6: ​Summary of Dam design

Catchment Area

The catchment area of a hydro plant is the whole area behind the dam, draining into a
stream or river across which the dam has been built at a suitable place. (Source:
https://www.slideshare.net/shaikafzal/hydro-power-plant-60272560​)
 A spillway is a structure used to give the controlled arrival of streams from a dam or
levee into a downstream region, normally the riverbed of the damned waterway itself. In the
United Kingdom, they might be known as flood channels. Spillways guarantee that the water
doesn't flood and harm or wreck the dam. (Source: ​https://en.wikipedia.org/wiki/Spillway​)

Spillway and Catchment Area design

A catchment area is a hydrology unit where water from rains are collected often bounded
by hills and separated by watersheds. As the water flows over the landscape it finds its way into
streams and down into the soil, eventually feeding the river and makes its way into the ocean.
A spillway is a structure used to provide a safe controlled release of flows or flooding
from a dam into a downstream area, typically being the river that was dammed. Spillways release
water or floods to supply the demand and also to avoid damage in the dam before it overtop or
overflow.
According to Napocor, the Drainage area of the San Roque dam is 1250 sq. km.
 Figure 5: ​Excerpt from the book ,Small Dams Planning, Construction and Maintenance

For the design runoff coefficient contours, C​Y​, we assumed the 0.20%. Based on the
catchment or drainage area of 1250 sq. km and 25% C​Y​, the rainfall intensity and spillway design
rainfall coefficient, Q​Y​, are:

Rainfall intensity = 34 mm/hr (Design run-off coefficient)

Q​Y​ = 28.4 m​3​/s
The assumed cross section of the river is in trapezoidal shape. The nominal river data of the San
Roque dam are as follows:
Top width = R​TW​ = 14 m
Bottom width = R​BW​ = 12 m
Average depth = R​D​ = 2.47 m
The intake entrance area, A​i​, is given by:

Ai = RD ( RT W + RBW
2 )
Ai = 2.47 m ( 14 m +2 12 m )
A​i​ = 32.11 m​2
According to the data gathered by NAPOCOR, the average flow of the river, V​W​, is 0.68 m/s.
The volumetric flow rate of the river, Q​W​, can be obtained by:
QW = (Ai ) (V W )

QW = (32.11 m2 ) (0.68 m/s)

Q​W​ = 21.83 m​3​/s

According to “Small Dams Planning, Construction and Maintenance” p. 58 by Barley Lewis, the
relation to obtain the spillway width is given by:
Q​S​ = 1.546 (SW​W​) (H)​1.5 ​{Eq. 1}
Where SW​W is the spillway width in meters, H is the height or the depth in meters, and Q​S is the
capacity in cubic meters per second. Q​S​ is defined as:
Q​S​ = Q​X​ + Q​Y
Where Q​X​ is the typical discharge flow of spillways.According to Peter E. Haug, Pg. 8 of
“Spillway Capacity and Discharge Uncertainty”

“The typical discharge flow in spillways is 25%-35% of the volume flow of the water.”

We assumed 35% as the value of Q​X to make clearance for uncertainties. Therefore, the typical
discharge flow of the spillway is:
Q​X​ = 0.35 (Q​W​)
Q​X​ = 0.35 (21.83 m​3​/s)
Q​X​ = 7.64 m​3​/s
With Q​X​ known, Q​S​ can now be obtained. Since:
Q​S​ = Q​X​ + Q​Y
The total discharge flow (Q​S​) is:
Q​S​ = 7.64 m​3​/s + 28.4 m​3​/s
Q​S​ = 36.04 m​3​/s
According to “Small Dams Planning, Construction and Maintenance” p. 60 by Barley Lewis: the
usual height of spillways are 1 meters to 1.5 meters in magnitude. We assumed the highest height
which is 1.5 m as the spillway height.
H = 1.5 m
Recalling Eq 1.:
Q​S​ = 1.546 (SW​W​) (H)​1.5
The spillway width, SW​W​, can now be obtained.
36.04 m​3​/s = 1.546 (SW​W​) (1.5 m)​1.5
SW​W​ = 12.69 m
Spillway and Catchment Area design summary:

Intake entrance area: 32.11 ​m2​

Volumetric flow rate of river: 21.83 ​m3​​ /s

Total discharge flow: 36.04 ​m3​​ /s

Spillway width: 12.69 ​m

Table 6: ​Summary of Catchment and Spillway design

Power house foundation design

Power house is the home of the generators, alternators, and assistant factory. For
effortlessness reasons the designer will consolidate a surface force house in the plan.
The bounding box dimensions (length x width x height) and the mass of the generator set
are the following from the catalogue:
Dimensions: 4324 mm x 2300 mm x 2414 mm
Mass = 7000kg
Based from page XV-1 of Power Plant Engineering by R. S. Capote and J. A. Mandawe:
1. The clearance or the distance of the edge of the foundation from the bedplate must be 6
in. (120 mm) to 12 in (300 mm) to secure the belts embedded within the foundation.
2. The vertical distance from the floor or soil level to the top edge of the foundation must be
around 6 in. (120 mm) as a minimum distance
3. The foundation depth may be taken to be 3.2 to 4.2 times the engine stroke; the lower
factor for a well-balanced multi-cylinder engine and increased factors for engines with
fewer cylinders or on less firm soil.
The length of the foundation, L​F​, is given by the formula:
L​F​ = L​B​ + 2 C
Where L​B is the length of the bedplate and C is the clearance. From the bounding box
dimensions, the length of the bedplate is 4324mm. For the clearance, We decided to use a
generous 12 inches as the value so as to provide extra space.
With these, the length of the foundation is:
L​F​ = 4324mm + 2(12 in)
L​F​ = 4324 mm + 2(304.8mm)
L​F​ = 4933.6 mm
According to the same book, the width of the foundation, W​F​, is given by:
W​F​ = W​B​ + 2 C
W​B is the width of the bedplate and C is the clearance. From the bounding box dimensions, the
width of the bedplate is 2300 mm. Using the same clearance of 12 inches, the width of the
foundation is:
W​F​ = 2300 mm + 2 (12 in)
W​F​ = 2300mm + 2 (304.8 in)
W​F​ = 2909.6mm
Height of the foundation, H​F​, is based on a table from page 132 of “Building construction” by B.
C. Punmia. Table 3​ ​shows the excerpt.
Weight of machine Minimum depth of
(tons) foundation block (m)
under 1.0 0.5
1.0 to 2.0 0.75
2.0 to 4.0 1.0
4.0 to 6.0 1.25
over 6.0 1.5
Table 7:​ Recommended minimum depth
of foundation block

Hence the mass of the machine is well over 6 tons, the depth of the foundation block the designer
will use in the design is 1.5 m.
H​F​ = 1.5 m
With the length, width, and height of the foundation known, the volume of the foundation, V​F​,
can now be computed. Note that, for simplicity, the volume takes the shape of a bounding box –
the volume of a rectangular prism.
V​F​ = L​F​ W​F​ H​F
V​F​ = (4933.6 mm) (2909.6 mm) (1.5 m)
V​F​ = 21.55 m​3
Coming back to the same book, the foundation's weight, WOF, is defined as 3–5 times the
machine 's mass. The designer should pick a value of 4.5 in the design. Instead, we have:
WOF = 4.5 (7000kg) = 31500kg
The soil-bearing power, SBC, is described from the same book as:
SBC W OF + mref
nSF
= LF W F
Where n​SF is the factor of safety and m​ref is the mass of the machine (catalog value). For the
factor of safety, the designer will use a value of 5.0. Substituting the values, the soil bearing
capacity is:
SBC/5.0 = 31500kg+ 7000kg/ (4933.6mm) (2909.6mm)
SBC = 13410.15kg/m​2​ = 13.41015 tons/m​2​f
The basis for a safe soil bearing capacity is when the measured value is less than 74 tons /
m2 of average soil bearing capacity. The value is safe, since the measured SBC is far below the
average value.
For the weight of reinforcing steel, W​RS​, the formula is given by the same book as 0.5%
to 1% of the weight of the foundation (WOF). To be on the safer side, the designer will choose a
value of 0.75% of the WOF. Thus:
W​RS​ = 0.75% (31500 kg)
W​RS​ = 236.25 kg
For the volume of the reinforcing steel, V​RS​, the value is given by:
W RS
V RS = ρsteel

Where ρ​steel​ is the density of steel. Steel has a nominal density of 7920 kg/m​3​.
Vrs = 236.25/7920 k
V​RS​ = 0.02982 m​3
For the length of the reinforcing steel, L​RS​, the value can be obtained by:
V RS
LRS =
( π4 DRS 2 )
Hence D​RS is the diameter of the reinforcing steel. Remember that, for purposes of
simplicity, the reinforcing steel members take the shape of a plain cylinder.
We will use a diameter of 0.75 in. due to the fact it’s an without difficulty obtainable
standard cost among structural metal members:
0.02982 m3
LRS =
( π4 (0.75 in)2 )
0.02982 m3 0.02982 m3
LRS = = 2
( mm)2 )
π (19.05
4 ( π4 ( 19.05
1000 m) )

L​RS​ = 104. 623 m

the number of reinforcing steel members, N​RS​, the value can be obtained using the equation:
LRS
N RS = 20 f t/piece
Take note that the standard length of reinforcing steel members is 20 feet. Substituting, N​RS​ is:
Nrs = 343.25 ft / 20 ft/ piece
N​RS​ = 17.16 pcs (use 17pcs)

The designers chose the 1:3:5 mixture hence it is the one suggested for foundations and footings.
A summary of the mix are as follows:
Table 8 indicates a subset of the same book of available choices for the aggregate ratio of the
content for the foundation.
Mixture ratio = 1:3:5
Cement = 6.2 sacks
Sand = 0.52 m​3
Stone = 0.86 m​3
Weight = 2.66 tons/m​3
Safe compressive stress: 218.73 tons/m​3

Cement Sand Stone Weight Safe

Mixture 3​ 3​ Application (tons/m​3 compressive
(sacks) (m​ ) (m​ )
) stress (tons/m​3​)
Roofs, sills,
1:2:3 9.2 0.51 0.77 2.66 328.78
tanks, tunnels
R.C., floors,
1:2:4 7.8 0.44 0.88 beams & 2.66 328.10
columns
1 : 2.5 :
7.3 0.52 0.83 Building walls 2.66 273.42
4
Foundations &
1:3:5 6.2 0.52 0.86 2.66 218.73
footings
1:2:4 8.6 0.49 0.98 R.C. floors 1.99 153.11
1:2:4 8.6 0.49 0.98 R.C. floors 2.13 153.11
Table 8:​ Data on concrete mixes to yield
1 m​3​ of concrete

Since the specified output for the following calculations is based totally on bags (now not
on volume), the subsequent conversion elements might be followed:
1 barrel = 4 sacks = 0.1589873 m​3

For the number of cement bags, B​cement​, for the whole volume of the foundation (V​F​), we
have:
B​cement​ = 29.713 (6.2 sacks/m)
 B​cement​ = 184.2206 sacks = use 184 sacks

For the quantity of sand needed, B​sand​, the value is defined from the mixture as 0.52 m​3​sand
per m​3​concrete​. Therefore, with respect to the volume of the foundation, the value can be obtained
by:

B sand = V F ( 0.52 (m3 sand )

m3 concrete )
B​sand​ = 11.206 m​3

For the amount of stone needed, B​stone​, the value is defined from the mixture as 0.86 m​3​stone per
​
m​3​concrete​. Therefore, with respect to the volume of the foundation, the value can be obtained by:
B stone = V F ( 0.86 (m3 stone )
m3 concrete )
3
B​stone​ = 18.533 m​

For the volume of water for the concrete mix, B​water​, the recommended volume of water
per bag (or sack) of cement is 7 gallons. Therefore, the value can be obtained by:
B water = B cement ( 7 gallons of water
bag )
B​water​ = 945 gallons of water

Machine foundation design summary

Foundation Length: 4933.6 mm

Foundation Width: 2909.6 mm
Foundation Height: 1.5 m

Foundation Volume: 21.55 ​m3​

Foundation weight: 31500 kg

Soil bearing capacity (SBC) 13.41 ​tons/m​2

Reinforcing steel weight: 236.25 kg

Reinforcing steel volume: 0.02982 ​m3​

Reinforcing steel diameter: 19.05 mm

No. of Reinforcing steel members: 17 pcs.
Concrete mixture ratio: 1:03:05
No. of cement sacks: 135 bags

Quantity of sand: 11.206 ​m3​

Quantity of stone (gravel): 18.533 ​m3​

Quantity of water: 945 gal

Table 9. ​Summary of Machine foundation design
Cost analysis
The average cost of real estate in Lingayen is about 4000 per square meter for the cost, REC. To
be completely functional the plant requires around 5000 m2 of land. And the cost of real estate
is:
₱4000
REC = 5000 m2 x m2
= ₱20, 000, 000

For the cost of the building, BC, the average cost per square meter of total aggregate building
area is ₱20,000. Since the total aggregate floor area of the plant is approximately 1500 m2, the
building cost is:

₱20,000
B C = 1500 m2 x m2
= ₱30, 000, 000

Summary of Costs:

A. Cost of Machineries and Equipment:

Component Qty. Cost/unit Total Cost

Turbine Generator Set 1 490,000,000 490,000,000.00
Butterfly Valve 5 2,000,000 10,000,000.00
500,000,000.00

B. Cost of foundation of machines:

Material Price Qty. Total Cost

Cement (bag) 230 135 31,050.00
Sand (m3) 150 9.25 1,387.50
Gravel (m3) 550 15.62 8,591.00
Reinforced Steel (tons) 120,000 0.18 21,600.00
62,628.50

C. Cost of operation (annually):

Position of Employees Number Monthly Salary Annual Salary

Professional Mechanical Engineer 1 100,000.00 1,200,000.00
Engineer/s 4 23,000.00 1,104,000.00
Plant Manager 2 50,000.00 1,200,000.00
 Maintenance 7 15,000.00 1,260,000.00
Technician 7 15,000.00 1,260,000.00
Office Staff 5 18,000.00 1,080,000.00
Labor 10 13,000.00 1,560,000.00
8,664,000.00

D. Cost of yearly miscellaneous:

Work Monthly cost Annual Cost

Maintenance in Machines
and Equipments 36,000 432,000.00
Maintenance in Site 13,000 156,000.00
Other Expenses 37,000 444,000.00
1,032,000.00

E. Total Costs:

Machine and Equipment 500,000,000.00

Machine Foundation 62,628.69
Real Estate Cost 20,000,000.00
Building Cost 30,000,000.00

Yearly salary of Employees 8,664,000.00

Misc. Yearly cost 1,032,000.00
559,758,628.69

The annual income of the power plant, AIP, recalls that the plant can generate
30,433,554kW-hr per year. If each kW-hr of energy is sold for ₱8.50, the annual income of the
plant is:
30,433,554 kW −hr ₱8.50
AIP = year
x kW −hr

AIP = ₱258,685,209 per year

For the capitalized cost, the value is given by:
Capitalized cost = (Total investment) + (Salvage value)
The data for the capitalized cost are as follows:
 Total investment = ₱559,758,628.69
Annual interest rate = 5%
Annual maintenance cost = ₱8,664,000.00
For the estimated salvage value, ESV, it is estimated to be equal to 10% of the machineries and
equipment cost. Therefore:
ESV = (10%) (₱500,000,000) = ₱50,000,000
With this, the capitalized cost is:
Capitalized cost = ₱559,758,628.69 + ₱50,000,000
Capitalized cost = ₱609,758,628.70
An additional 10% to 20% of the total cost should be made to care for contingencies which
may arise from unforeseen complications. We assumed 13% of the total cost. The adjusted
capitalized cost, ACC, therefore is:
ACC = (1.13) (₱609,758,628.70) = ₱609,758,628.70
The equivalent annuity of total capitalized cost, X, is:
X = 0.05 (₱609,758,628.70) = ₱34,451,362.00
For the break-even analysis by present worth method:

( )
−n
1−(1+i)
P = A i

n = 1.9872 years
For the rate of return, ROR:
N et annual prof it AIP − X
ROR = Capital investment
= Capital investment

ROR = 36.77%
Costing analysis summary:

Real Estate Cost 20,000,000.00

Building Cost 30,000,000.00
Energy selling cost: 8050 kW-hr
Income of the Plant (Annual): 224,233,847.00
Capitalized Cost: 609,758,628.70
Equivalent annuity: 34,451,362.00
Total Investment: 559,758,628.69
Break-even point (years): 1.9872 years
Rate of Return: 36.67%
Table 10. ​Summary of cost analysis of the design
References:
● Cruz C., Geron A., Garcia J., and Ramos F., 2018 “Water Quality Assessment of Agno
River Tributaries in Eastern Pangasinan for Irrigation Purposes” Journal of Natural and
Allied Sciences
● Naing I., 2016 “18-MW hydroelectric power plant design” DBTC
● NAPOCOR., 2015. “​San Roque dam elevation still above the normal high water level,
spilling operations continue”
https://www.napocor.gov.ph/index.php/35-press-release/419-san-roque-dam-elevation-sti
ll-above-the-normal-high-water-level-spilling-operations-continue-napocor
● DENR., 2020 “Agno River Basin”​ ​https://riverbasin.denr.gov.ph/river/agno
● National Geographic Society., 2019 “Hydroelectric Energy”
https://www.nationalgeographic.org/encyclopedia/hydroelectric-energy/
● Lewis B., 2013 “Small Dams Planning, Construction and Maintenance”
● Capote R.S., and Madawe J.A., “Powerplant Engineering”
● Estoperez N., “Country Report on Small Hydro PowerPlant”
http://www.hrcshp.org/en/world/db/philippines.pdf
● Aboitiz Power., “Hydro PowerPlant”
https://aboitizpower.com/generation/run-of-river-hydro/#hedcor
● Muise S., “HydroPower” ​https://www.studentenergy.org/topics/hydro-power
● U.S. Department of the Interior, Bureau of Reclamation, Power Resources office,
“HydroElectric Power” ​https://www.usbr.gov/power/edu/pamphlet.pdf
● Austria H.,“10-hour power outage to hit parts of Pangasinan - 2020” “11-hour
poweroutage to hit 7 towns, city in Pangasinan - 2019”
https://www.pna.gov.ph/articles/1096778​ & ​https://www.pna.gov.ph/articles/1082486