Technological University of the Philippines

College of Engineering
Mechanical Engineering Department

Industrial Plant Engineering (Laboratory)

Laboratory No. 1
“Industrial Steam Processes”

Submitted by:
Eusebio, Brant Ivan R.
Macdon, John Paulo B.

Submitted to:
Engr. Sandra E. Abancio

Due: June 7, 2020

 One of the main issues that the author had considered was the ever changing of

renewable energy source forecast. These forecasts will define how a renewable energy

source will behave so that the power plant might take actions to cope with every kind of

situations. Though these forecasts are most of the time lacking, Electric Energy Storage

(EES) were introduced so that they could generate enough electricity to cover up at

times when the renewable energy source (RES) were insufficient. These EES has the

capability to store excess energy produced for it to be utilized whenever the supply runs

insufficiently. Furthermore, the author stated that Compressed Air Energy Storage

(CAES) is an interesting option for it can absorb excess energy from the grid to

compress the stored air in a reservoir during off-peak periods so it to be utilized for later

needs. This CAES has a current progressing technology that run in diabatic process.

This is then named Diabatic Compressed Air Energy Storage (D-CAES) and uses an

external heat source to expand the stored air from the reservoir and therefore provide

extra energy source which is then resulted as the drawback for using the excess energy

from the grid to compress the reservoir.

For this type of plants, it should have a location where underground reservoirs

can be excavated for this technology to work, otherwise, artificial storage tanks must be

addressed. For a further knowledge mizzle, this type of plant, a D-CAES plant is mostly

applicable for plants that utilizes combustion, like the use of Gas Turbines. Fuels are

used to produce combustion and run the turbines. By these, hot exhausts are utilized to

transfer heat to the compressed air on the D-CAES reservoir for expansion. Though

these might seem quite simple, a crucial part in the feasibility was the concern about the

availability of an efficient and economical air expander that is why the author put
considerations by reducing development economy using the common steam turbine

engineering practice as a reference.

For the project, the author relies on manufacturing industrial steam turbines.

These types of application have a vast range of parameters considering the conditions

of input steam, input mass flow, etc. They also recommended to utilized standardized

pre-designed building blocks for the assembly of the machine from major steam turbine

manufacturers to condense the design process and deliveries, and to acquire cost

reduction from manufacturing labors.

The research discussed the first step of evaluating the steam turbine’s air

performance by implementing a model that can do the same behavior of the machine

under the normal use condition. Technically, it is the best way of assessing the

performance of the case study by using the existing design as reference. The article

also includes the composition of turbine. Theoretically speaking, based on mechanical

engineering principles that A steam turbine consists of a rotor resting on bearings and

bounded in a cylindrical casing. The rotor is turned by steam imposing against attached

vanes or blades on which it exerts a force in the tangential direction. Thus, a steam

turbine could be viewed as a complex series of windmill-like arrangements, all

assembled on the same shaft. Therefore, the researchers have a correct information

because it satisfies the theoretical principles, components and applications of a steam

turbine.

The process in getting the air performance of existing industrial steam turbine

has its own criterion to be complied. According to Catherine Rastovski, A steam turbine

performance testing system including: an exhaust bypass conduit arranged for selective
fluid communication with an exhaust of the steam turbine, the exhaust bypass conduit

being arranged to receive a portion of an exhaust of the steam turbine as an exhaust

bypass flow; an inlet bypass conduit arranged for selective fluid communication with an

inlet of the steam turbine, the inlet bypass conduit being arranged to receive a portion of

an inlet steam flow of the steam turbine as an inlet bypass flow; and a mixed flow

conduit having a mixing point at one end in fluid communication with the exhaust

bypass conduit and the inlet bypass conduit, the mixing point and the mixed flow

conduit being arranged to form a mixed flow responsive to the exhaust bypass flow and

the inlet bypass flow entering the mixed flow conduit through the mixing point.

In addition, a steam turbine comprising: a turbine having an inlet and an exhaust,

the inlet being arranged for connection to a steam supply; an inlet measurement station

arranged to measure a characteristic in the inlet; an exhaust measurement station

arranged to measure a characteristic in the exhaust; an inlet bypass port at an inlet end

of the turbine; an inlet bypass conduit in fluid communication with the inlet bypass port

and arranged to selectively allow inlet steam to enter the inlet bypass conduit to form an

inlet bypass flow; an inlet bypass measurement station arranged to measure a

characteristic in the inlet bypass conduit; an exhaust bypass port at an exhaust end of

the turbine; an exhaust bypass conduit in selective fluid communication with the exhaust

bypass port and arranged to selectively allow exhaust steam to pass from the exhaust

into the exhaust bypass conduit to form an exhaust bypass flow; a mixed flow conduit in

fluid communication with the inlet bypass conduit and the exhaust bypass conduit at a

mixing point of the mixed flow conduit, the mixed flow conduit thereby being arranged to

receive and allow mixing of an inlet bypass flow and an exhaust bypass flow to form a
mixed flow; a mixed flow measurement station arranged to measure a characteristic in

the mixed flow conduit; and a computing device in communication with and receiving

measurements from at least the inlet bypass measurement station and the mixed flow

measurement station, the computing device being arranged to determine an exhaust

enthalpy of the steam turbine based at least in part on measurements received from the

measurement stations. Meaning that all the basis and criterion for doing the study are

observed by the researchers. The study concludes that the Air expander for CAES

performance results of a loss of act in terms of efficiency in respect to steam operation

but the performance level in wide range of operations can be considered more than

satisfactory. The researchers case study obtained a satisfactory result that can be also

improved and developed for the purpose of other intended applications.

 Technological University of the Philippines
College of Engineering
Mechanical Engineering Department

Industrial Plant Engineering (Laboratory)

Laboratory No. 2
“Industrial Wastewater Treatment”

Submitted by:
Eusebio, Brant Ivan R.
Macdon, John Paulo B.

Submitted to:
Engr. Sandra E. Abancio

Due: June 14, 2020

 The author introduces different ways on how to utilize biogases from biomasses

in different states. It is implied there that in order to gain effective business, efficient

utilization of waste should be considered to take an up step towards the circulation of

economy and at the same time, reducing the greenhouse gas emissions. Information

was given that biogas is generated through a variety of possible ways; landfill,

wastewater, etc. Biogases are products of anaerobic digestion of biomasses which

mainly consists of CH4 and CO2.

The researchers provided a history of energy production via biogas utilization in

Europe with comparison to the net unit of biogas utilization throughout the continent

therefore, giving emphasis on how Europe depend on the utilization of biomass. It is

also stated that industrial plants are the leading producer of biomass which gathers

roughly about 74% of Europe’s total biomass resources.

Accordingly, the design for anaerobic digestors are commonly tied to

conventional gas-fired engines for the power and heat source. With these design,

efficiency of waste management system is greatly affected as the industrial waste could

be manipulated to provide electrical energy. Though these designs may consist of great

advantages, disadvantages are also at stake especially in the exhaust which carries

pollution that are discharged to the environment. In further studies, innovations are

widely sought by engineers until the development of fuel cells which are used for

converting biogas into electricity. This fuel cell is still under detailed development and

some conducted investigation towards how much this machinery could reduce the

emission of biogas combustion like Lombardi and Gandiglio with their respective

companies.
 For the further advancement of the fuel cell technology, solid oxide fuel cell

(SOFC) is produced and are being fueled with biogases from landfills according to

Hagen. Several studies branch out from this SOFC like the use of pre-mixed dry biogas

with cleaning unit and pre-reformer by Papurello, review of fuel contaminants in the

SOFC’s and molten carbonate fuel cells (MCFC) by Lanzini, etc. By these branch-out

studies of fuel cells, the researcher discovers that SOFC have the advantages in fuel

flexibility granting it the capability of working directly with hydrocarbon fuels.

Additionally, the researcher explained how robust a SOFC can be because of its high

working temperature. One study tested a commercial fuel cell system at a landfill gas

site using a phosphoric acid fuel cell (PAFC) and was reported by Spiegel.

The researcher’s study branches when the first installation of fuel cell system for

converting biogas from a wastewater plant into electricity and heat was demonstrated

by Germany. The system installed was a PAFC system that runs on 200kW. Biogas

were pre-cleaned by two-phase purification system, an adsorption process using

activated carbon filter and utilizes a reformer unit for converting the biogas into H 2 rich

gas.

The researchers conducted a demo project and analyzes two industrial sized

Convion C50 SOFC systems installed at the same wastewater plant. The data gathered

from both technologies merely shows great difference and the test gave information that

the efficiencies were independent of the CH 4 content of the biogas. The study

enlightened the researchers that the SOFC technology’s high efficiency runs stable at

varying CH4 content and electric net power. Also, the study performed has concluded

that fuel cells shows far more capability over other converters like micro turbines and
combustion engines. Additionally, this shows that fuel cell systems can perform power

modulation according to the power demand.

 Technological University of the Philippines
College of Engineering
Mechanical Engineering Department

Industrial Plant Engineering (Laboratory)

Laboratory No. 3
“Air Pollution Control Systems for
Industrial Application”

Submitted by:
Eusebio, Brant Ivan R.
Macdon, John Paulo B.

Submitted to:
Engr. Sandra E. Abancio

Due: June 21, 2020

 The researchers conducted a study in order to measure the inhaled dust by

workers of metal casting industry. Based on reliable resources that in Metal casting

industry, certain hazards occurred during the production process. Because of the nature

of work and environment, metal casting industry is often pressurized for polluting the

environment. Some of the environmental issues associated with the industry are

emission of harmful and poisonous gases, dust and particles and generation of waste

pollutants. he government and metal casting industry associations have setup several

norms and guidelines to help the industry fight pollution by controlling emissions and

proper disposal of pollutants. Several environmental legislations have been presented

by the government that now have a significant impact on the way that foundries conduct

their business. It is crucial for the companies to be aware of different legislations that

apply to their business and the actions that are required to ensure compliance.

The researchers stated the different air pollution on their paper, and it is parallel

to what is being said on a reliable source. The metals casting industry produces

hazardous air pollutants that includes gases, which are generated when molds

containing carbon materials are subjected to high temperatures as happens in the

pouring of cast metals. It includes both chemically bonded as well as green sand molds.

Of all the hazardous air pollutants released from poured castings, benzene is the

largest. The study also stated the importance of ergonomics to the efficiency of workers.

Based on mechanical engineering safety, Ergonomics is doing a job to fit the workers,

so the work is safer and more efficient. The paper must include these definitions so that

the reader can easily comprehend the purpose of the research. In addition, they must

state some basic importance of ergonomics in which it is important because

Ergonomics is important because when you’re doing a job and your body is stressed by

an awkward posture, extreme temperature, or repeated movement your

musculoskeletal system is affected. Your body may begin to have symptoms such as

fatigue, discomfort, and pain, which can be the first signs of different disorders including

Lung problems because of the dust inhaled in the production site.

The researchers assessed or gather data with the use of certain devices to

measure the amount of inhaled dust. It is called the Personal Dust Sampler. Based on

reliable mechanical engineering theory and organization of safety and health, it is a

device in order to measure the worker’s exposure. The method is the air sample is

collected within the breathing zone of worker. The breathing zone is defined as being

within a 30 cm radius of nose and mouth. All of that are stated in the research, so that

information is true and valuable. The other monitoring device of the researchers used in

experimental time and condition is the Real-Time Dust Monitor. This device enables the

researchers to determine the mass concentration of the dust.

The Real-Time Dust Monitor measures the Total Indoor Suspended Dust.

Particulate matter (also referred to as PM or particle pollution) is a complex mixture of

solid and/or liquid particles suspended in air. These particles can vary in size, shape

and composition. EPA is especially concerned about particles that are 10 micrometers

in diameter or smaller because these particles are inhalable. Once inhaled, particles

can affect the heart and lungs, and in some cases cause serious health effects. The

human health effects of outdoor PM are well-established and are used to set health-

based standards for outdoor air (National Ambient Air Quality Standards, NAAQS). PM

is also found in all indoor environments. Indoor PM levels have the potential to exceed
outdoor PM levels and the NAAQS. However, less is known about the specific impacts

of indoor PM on health.

Thus, the researchers stated that air pollution is deemed to put human health in

danger. Environment pollutant cause various disease such as cardiopulmonary and

lungs cancer. These particle size and chemical composition of the dust particle itself

give alteration on body biological responses, and that means all these statements are

true. It also stated that working environment highly affects research variables. Sample

collection with different working environment will be indicator of working method or

system change applied in the industry. The same production floor condition from the

first period or until the last period of measurement is a form of working completion

consistency. Therefore, inhaled dust and total indoor suspended dust data can be seen

and compared in each research period. There’s a weakness of the research in which

examination of workers lungs condition that has not yet performed. Therefore, it is

needed to be perfected in the further research.

The researchers stated recommendation for the study, and it is to add data

parameters on the average value of company suspended dust and the average value of

workers’ inhaled dust as a requirement to issue operational permits. The study is

beneficial in terms of the quality of work for the workers and the efficiency that affects

the profit of the metal casting industry. This research must be applied and developed,

so that the air pollution will be minimized and lessen the harm or hazardous effects to

the workers.
 Technological University of the Philippines
College of Engineering
Mechanical Engineering Department

Industrial Plant Engineering (Laboratory)

Laboratory No. 4
“Fire Protection System”

Submitted by:
Eusebio, Brant Ivan R.
Macdon, John Paulo B.

Submitted to:
Engr. Sandra E. Abancio

Due: June 28, 2020

 The issue that is being tackled in this research is about the assessment of Fire

Assessment of an Industrial Building using Probabilistic Methods. But first, they need to

tackle the basics of fire risk assessment in which it is  a process involving the

systematic evaluation of the factors that determine the hazard from fire, the likelihood

that there will be a fire and the consequences if one were to occur. On the other hand,

they will use the probabilistic method and it is stated that this method is

a nonconstructive method, primarily used in combinatorics and pioneered by Paul

Erdős, for proving the existence of a prescribed kind of mathematical object.

In addition based from a reliable sources, that Probabilistic method works by

showing that if one randomly chooses objects from a specified class, the probability that

the result is of the prescribed kind is strictly greater than zero. Although the proof uses

probability, the conclusion is determined for certain, without any possible error.

Hence, we can agree to what the researchers talked about the probabilistic

method because it is stated that adopting it will be useful in the decision making

process, in order to reduce the cost and to compare the risk reduction associated with

different types of fire protection measures, taken for controlling the fire development and

spread within an industrial building. The probabilistic approach considered the most

suitable method to gauge the risk of fire occurrence in site and the reliability of the

protection systems. This method is very beneficial because it provides less cost.

Regarding the different types of fire protection that includes automatic fire detection;

Automatic fire suppression – Sprinkler System reliability; Manual Fire Suppression; Fire

spread outside the compartment boundary. All these terminologies parallel to what the

researchers stated to the mechanical engineering theory and principles.

 Based on the researchers’ data gathering and results, it is found out that the use

of probabilistic method in fire risk assessment of an industrial building is a variable tool

to identify the different factors affecting the life of an industrial building like strain and

deflection etc. This probabilistic approach is valuable and reliable to assess risk

because it represents numerical value of risk, which enables to quantify the probability

of unlikely events associated with unadorned consequences. In addition, this also

impact the field of business by providing data for the cost benefit analysis and that will

be useful for the optimization strategy cost.

 Technological University of the Philippines
College of Engineering
Mechanical Engineering Department

Industrial Plant Engineering (Laboratory)

Laboratory No. 5
“Common Industrial Processes”

Submitted by:
Eusebio, Brant Ivan R.
Macdon, John Paulo B.

Submitted to:
Engr. Sandra E. Abancio

Due: June 21, 2020

 The authors of this article about a methodology for the selection of industrial

robots in food handling discussed how the population are rapidly growing together with

the growth of different allergies and intolerances. In todays problem, it is not just about

the supplication of food, in fact, there are several factors to consider in food

manufacturing due to human needs. Special diets are commonly observed to people

with such handicaps especially to the swift increase in cases of diabetes, kidney

diseases, and more. That is why health is the number one factor that affects food

industries, therefore, industrial robots (IR) proposed a great purpose in hygienic,

precisive, and effective food handling. They have stated that many intellectuals have

agreed that IR facilitates hygiene, flexibility, reconfigurability, and improved efficiency

and productivity. This is because IR induce precise control over the food product and

has the capability to be positioned portably and programmed with certain set of

commands.

With accordance to the data provided by the author in table 1, it is truly unerring

that industrial robots decrease several ties in terms with cost. Also, it is true that utilizing

innovative robots could greatly impose an improved productivity on industrial production

lines. Safety is somewhat considerable as favorable due to the robot’s automation and

time aligned actions. It grants workers or operators decent aid without much needed live

interactions but with a somehow more precise job. In table 2, it states the possible or

common effects of different food characteristics to an automation. While this part has

the negative sides of automations efficiency, sometimes it is just recommended to use

manpower to minimize machine errors or damage to products that lead to rejections.

 Figure 1 provides a clear methodology on how industrial robots should be

designed, positioned, operated, and programmed to match the standard requirements

provided as per the figure shows. Table 3 lay out some category to consider when

acting upon such materials’ characteristics. A flow chart of decision making was

provided in figure 2. This address a technical schematic of determining what category

should the product being handled be accounted. Figure 3 pictures the classification of

operations maneuvered per station of food handling. Steps to specify food operation

types are also discussed, stating that during material handling, it is a key to remember

that foodstuff in this operation are unpacked and uncovered, therefore restricting the

handling system to be in direct contact with the material for transporting from point A to

point B of the stations. Also, it is included in material handling operation that at this point

of operation, foodstuff being transferred must be decided whether to be handled as a

whole or segmented. Assembly is where parts of the foodstuff are adjoined together to

either undergo another process for food requirement or most commonly to be prepared

for packaging. Third step was the packaging and palletizing of the assembled product.

This is where the pick and place operations are performed. Last step to specifying food

operation types is the identification of IR parameters. Provided within this article a table

in figure 5 that lists the common parameters used for IR configuration. This is indeed an

assistive table furnished by the author to elaborate the IR automations solution based

on foodstuff variety together with its operation type.

The conclusions yielded by the author impart a summary of effects of industrial

robot utilization and supplied a methodology for the selection of appropriate IR in

assisting a largescale adoption of flexile automation within the scope of food

manufacturing sector.