A 3-phase AC induction motor (20 kW capacity) is used for pumping operation.

Electrical
parameter such as current, volt and power factor were measured with power analyzer. Find
energy consumption of motor in one hour? (line volts. = 440 V, line current = 25 amps and
PF = 0.90).

A three phase,10 kW motor has the name plate details as 415 V, 18.2 amps and 0.9 PF.
Actual input measurement shows 415 V, 12 amps and 0.7 PF which was measured with
power analyzer during motor running.

A 400 Watt mercury vapor lamp was switched on for 10 hours per day. The supply volt is
230 V. Find the power consumption per day? (Volt = 230 V, Current = 2 amps, PF = 0.8)

10 kg of steam at 100oC with latent heat of vapourisation 2260 kJ is cooled to 50oC.

If the specific heat of water is 4200 J/kgoC, find the quantity of heat given out?

Skim milk is prepared by the removal of some of the fat from whole milk. This skim milk
is found to contain 90.5% water, 3.5% protein, 5.1% carbohydrate,
0.1% fat and 0.8%
ash. If the original milk contained 4.5% fat, calculate its composition
assuming that fat
only was removed to make the skim milk and that there are no losses
in processing.

A solution of common salt in water is prepared by adding 20 kg of salt to 100 kg of

water, to make a liquid of density 1323 kg/m3. Calculate the concentration of salt in this
solution as a (a) weight fraction, (b) weight/volume fraction, (c) mole fraction, (d) molal
concentration.

If air consists of 77% by weight of nitrogen and 23% by weight of

oxygen calculate:
(a) the mean molecular weight of air,
(b) the mole fraction of oxygen,
(c) the concentration of oxygen in mole/m3 and kg/m3 if the total pressure is 1.5
atmospheres and the temperature is 25 oC.

In the carbonation of a soft drink, the total quantity of carbon dioxide

required is the
equivalent of 3 volumes of gas to one volume of water at 0 oC and
atmospheric pressure.
Calculate (a) the mass fraction and (b) the mole fraction of the CO 2 in
the drink, ignoring
all components other than CO2 and water.

If 35,000kg of whole milk containing 4% fat is to be separated in a 6

hour period into
skim milk with 0.45% fat and cream with 45% fat, what are the flow
rates of the two
output streams from a continuous centrifuge which accomplishes this
separation?
Basis 1 hour's flow of whole milk

Potatoes are dried from 14% total solids to 93% total solids. What is the product yield
from each 1000 kg of raw potatoes assuming that 8% by weight of the original potatoes is
lost in peeling.
Basis 1 000kg potato entering
As 8% of potatoes are lost in peeling, potatoes to drying are 920 kg, solids 129 kg

A textile dryer is found to consume 4 m3/hr of natural gas with a

calorific value of 800
kJ/mole. If the throughput of the dryer is 60 kg of wet cloth per hour,
drying it from 55%
moisture to 10% moisture, estimate the overall thermal efficiency of
the dryer taking into
account the latent heat of evaporation only.

An autoclave contains 1000 cans of pea soup. It is heated to an overall temperature of

100 oC. If the cans are to be cooled to 40 oC before leaving the autoclave, how much
cooling water is required if it enters at 15 oC and leaves at 35 oC?
The specific heats of the pea soup and the can metal are respectively 4.1 kJ/ kg oC and
0.50 kJ/ kg oC. The weight of each can is 60g and it contains 0.45 kg of pea soup. Assume
that the heat content of the autoclave walls above 40 oC is 1.6 x 104 kJ and that there is no
heat loss through the walls.
Let w = the weight of cooling water required; and the datum temperature be 40oC, the
temperature of the cans leaving the autoclave.

It is desired to freeze 10,000 loaves of bread each weighing 0.75 kg from an initial room
temperature of 18oC to a final temperature of –18oC. The bread-freezing operation is to
be carried out in an air-blast freezing tunnel. It is found that the fan motors are rated at a
total of 80 horsepower and measurements suggest that they are operating at around 90%
of their rating, under which conditions their manufacturer's data claims a motor
efficiency of 86%. If 1 ton of refrigeration is 3.52 kW, estimate the maximum
refrigeration load imposed by this freezing installation assuming (a) that fans and motors
are all within the freezing tunnel insulation and (b) the fans but not their motors are in
the tunnel. The heat-loss rate from the tunnel to the ambient air has been found to be 6.3
kW.

During an air pollution monitoring study, the inlet gas stream to a bag filter is 1,69,920
m3/hr and the dust loading is 4577 mg/m3. The outlet gas stream from the bag filter is
1,85,040 m3/hr and the dust loading is 57 mg/m3.
What is the maximum quantity of ash that will have to be removed per hour from the bag
filter hopper based on these test results?

A scrubber is used to remove the fine material or dust from the inlet
gas stream with a spray of liquid (typically water) so that outlet gas
stream meets the required process or emission standards. How much
water must be continually added to wet scrubber shown in Figure
below in order to keep the unit running? Each of the streams is
identified by a number located in a diamond symbol. Stream 1 is the
recirculation liquid flow stream back to the scrubber and it is 4.54
m3/hr. The liquid being withdraw for treatment and disposal (stream 4)
is 0.454 kg m3/hr.
Assume that inlet gas stream (number 2) is completely dry and the
outlet stream (number 6) has 272.16 kg/hr of moisture evaporated in
the scrubber. The water being added to the
scrubber is stream number 5.

Biscuits are to be baked in a continuous oven. The inlet moisture

content is
25%. The outlet moisture is 1%. The production is 2 tonnes /hour on a
dry
basis. Make a material balance and find out how much quantity of
moisture is
removed per hour.

A furnace is loaded with materials at 5 T/hr. The scale losses are 2%.
Find
out the material output?

In a heat exchanger, inlet and outlet temperatures of cooling water are 28oC &
33 oC. The cooling water circulation is 200 litres/hr. The process fluid enters
the heat exchangers at 60 oC and leaves at 45 oC. Find out the flow rate of the
process fluid?
(Cp of process fluid =0.95)

Steam output of boiler is measured by measuring feed water. The tank level
reading from 8.00 a.m. to 8.00 p.m. was 600 m3. Continuous blow down was
given at 1% of the boiler feed rate during the above period. Find out the
average actual steam delivered per hour?

The following are the cooling water requirements for a process industry:
Heat exchanger 1: 300 m3 /hr. at 3 kg/cm2
Heat exchanger 2: 150 m3 /hr. at 2.5 kg/cm2
Heat exchanger 3: 200 m3 /hr. at 1 kg/cm2
Find out the total cooling water requirement per hour for the plant?
(all heat exchangers are in parallel)

In a dryer, the condensate was measured to be 80 kg/hr. The flash

steam was
calculated to be 12 kg/hr. Find out the actual steam consumption of
the dryer?

Simple payback period for a continuous Deodorizer that costs Rs.60 lakhs to
purchase and
install, Rs.1.5 lakhs per year on an average to operate and maintain and is expected
to save
Rs. 20 lakhs by reducing steam consumption (as compared to batch deodorizers),
may be
calculated as follows:

Calculate the internal rate of return for a economizer that will cost Rs.500,000, will
last 10
years, and will result in fuel savings of Rs.150,000 each year.
Find the i that will equate the following:

Cost of an heat exchanger is Rs.1.00 lakhs .Calculate simple pay back period
considering annual saving potential of Rs.60,000/- and annual operating cost
of Rs.15,000/-

Calculate simple pay back period for a boiler that cost Rs.75.00 lakhs to
purchase and Rs.5 lakhs per year on an average to operate and maintain and is
expected to annually save Rs.30 lakhs.

Investment for an energy proposal is Rs.10.00 lakhs. Annual savings for the
first three years is 150,000, 200,000 & 300,000. Considering cost of capital as
10%, what is the net present value of the proposal?
An industry is having contract demand of 1000 kVA. The minimum billing demand is
75% of the contract demand. The connected load of the plant is 2000 kVA. The
recorded demand and power factor for the month of March 2003 is 1200 kVA and 0.8.
The monthly consumption is 2.0 lakh units. The average load and maximum load of
the industry is 700 kW and 900 kW respectively. Calculate 1. Minimum billing
demand of the industry 2. Load factor of the plant3. Demand factor of the plant

The contract demand of plant is 1000 kVA. The minimum billing demand is 75% of
the contract demand. The basic tariff structure is as follows:
Demand charges : Rs. 180 per kVA / month
Unit charges :Rs. 3.75 for the first one lakh units / month
Rs. 3.50 above one lakh units / month
Fuel surcharge :Rs. 0.20 per unit / month
Service Tax :Rs. 0.25 per unit / month
Meter rent :Rs 500 / month

The energy consumption is 3,15,000 units and the maximum demand recorded is
600 kVA. Calculate the cost of monthly electricity consumption?

A plant is using 4 tonnes / day of coal for its boiler. The calorific value of the coal is
4000 kcal / kg. The cost of coal is Rs.2,000/ tonne. It is interested to use rice husk
in the calorific value of rice husk is 3000 kcal / kg. The cost of rice husk is
Rs.700/tonne. Find out the annual savings at 300 days of operation and assuming
that the boiler efficiency does not change.

The plant has four heat exchangers and cooling water is circulated through these
exchangers. The details are given below.
Heat exchanger Water flow, m3/h Temperature raise, °C
1 200 7
2 300 8
3 400 3
4 500 2
Evaluate heat rejection (kCal/h) of each heat exchanger and total heat rejected to
cooling water

In a textile mill, an evaporator concentrates a liquor containing solids of 6% by w/w

(weight by weight) to produce an output containing 30% solids w/w. Calculate the
evaporation of water per 100 kg of feed to the evaporator.

A boiler is fed with soft water containing 120 mg/l dissolved solids. As per IS
standards the maximum dissolved solids in the boiler should not exceed 3500 mg/l
for boilers, operating up to 2 MPa. In order to maintain the specified level, a
continuous blow down system is adopted. Find the percentage of feed water which
will be blown down.
Production rate from a paper machine is 340 tonnes per day (TPD). Inlet and outlet
dryness to paper machine is 40% and 95% respectively. Evaporated moisture
temperature is 80 °C. To evaporate moisture, the steam is supplied at 3.5 kg/cm2
(a). Latent heat of steam at 3.5 kg/cm2(a) is 513 kCal/kg. Assume 24 hours/day
operation. i) Estimate the quantity of moisture to be evaporatedii) Input steam
quantity required for evaporation (per hour)Note: Consider enthalpy of evaporated
moisture as 632 kcal/kg

Steam generation Tonnes per day

a) Make-up water quantity 52.00
b) Condensate return
Brew house 42.48
Bottling 2.47
c) Total steam generation 96.95
Steam utilisation
Brew house
a. Mash Tank 10.89
b. Work kettle 27.45
c. Raw water heating 3.90
d. Process water heating 3.62
Bottling section
e. Pasteurisation machines 28.99
f. Washing machines 18.68

G Miscellaneous (blow down, yeast drying, keg filling) 3.42

i) What will be the condensate return as % of steam generation?
ii) Which equipment consumes more steam?
iii) What will be the percentage of bottling section steam load?

In a particular drying operation, it is necessary to hold the moisture content of feed to a

calciner to 15% (W/W) to prevent lumping and sticking. This is accomplishing by mixing
the feed having 30% moisture (w/w) with recycle steam of dried material having 3%
moisture (w/w). The dryer operation is shown in fig below. What fraction of the dried
product must be recycled.
 Water (W)
Fresh feed (F)

70% solids
30% moisture
Mixer Calciner Dryer
Mixed feed

85% solids
15% moisture
Product (P)
97% solids
Recycle (R) 3% moisture

97% solids, 3% moisture

In a foundry the following are the energy consumption areas. Induction furnace of 5 TPH
with a specific energy consumption of 620 kWh / tonne of liquid metal. The yield of the
foundry is 60%. Further the castings are heat treated in oil fire furnace which consumes
75 kgs / tonne. Find out the energy consumption per tonne of finished product in terms
of tones of oil equivalent.(CV of oil = 10,000 kcal / kg.)

In a pumping system the following are the efficiencies. Motor efficiency = 90% Pump
efficiency = 80% . Losses in throttle valve and pipe fittings is 20% and 28%
respectively. If the motor is drawing 34 kW, find out the power transmitted to water in
kW at the end use.

Calculate net present value for an investment towards a Compact Fluorescent Lamp
(CFL). The following table gives investment and cash flow. (Assume discount rate is
10% and life of the CFL is 2 years). Investment Rs.400/-
Savings in year Cash flow, Rs
Year # 1 1000
Year # 2 1000

An energy auditor recommended to replace an old air fan and incompetently designed air
delivery duct system causing Rs 23 lakh a year in electricity cost by changing the system
with a modern backward curved fan with adequately designed duct system for total
investment costs of Rs 2.2 lakh. Expected electricity cost reduction is 5%. Considering
over 15 years sustained savings, calculate 'IRR'
Annual savings after replacement of boiler for three years is Rs. 5, 00,000, Rs. 5, 50,000,
Rs. 6, 50,000. Total project cost is Rs 13.5 lakh. Considering cost of capital as 12%, what
is the net present value of the proposal?

An investment of Rs.1,00,000 is made for a variable speed drive of a compressor. The

savings expected over the next 4 years as given below:
End of year Net cash flow
1 Rs.30,000
2 Rs.30,000
3 Rs.40,000
4 Rs.45,000 Find out the internal rate of return.

Find out the critical path of the following network.

What is the minimum time period required for the completion of the project?

4 E=1
C=2
A=2
B=5
1 2 3 6

D=7 5 F=2

Construct a PERT chart for the example below.

Activ Prece Time
A - 10
B A 9
C A 3
D B 8
E C 2
F E 3
G C 3
H G 4
Plot electricity consumption Vs production for the months given in table below and
explain trend of Specific Energy Consumption (SEC).

Month kWh Cons kVAh cons Prod(MT) kVA demand

April 4,85,000 5,30,000 565 1285
May 4,30,000 4,80,000 498 1000
June 4,48,000 4,90,000 501 960
July 4,80,000 5,30,000 550 1300

Use CUSUM technique and calculate energy savings for 6 months period of 2003. For
calculating total energy savings, average production can be taken as 4000MT/Month. Refer
data given in table below
Month Actual –SEC( kWh/MT) Predicted SEC(kWh/MT)
Jan 242 265
Feb 238 265
Mar 287 265
Apr 237 265
May 295 265
Jun 246 265

During an air pollution monitoring study, the inlet gas stream to a bag filter was
200,000 m3 per hour. The outlet gas stream from the bag filter was a little bit
higher at 210,000 m3 per hour. Dust load at the inlet was 6 gram/ m3 , and at the
outlet 0.1 gram/ m3 . How much dust in kg/hour was collected in the bag filter bin?

A company consumes 1.3 x 105 kWh of electricity and 11.18 x 107 kCal of furnace
oil per month. Draw the pie chart of percentage share of fuels based on
consumption in kCal. (1 kWh = 860 kcal)

The company "Save Electricity the Smart Way" sells a gadget that lowers voltage of
your electric water storage heater by 20% and saves electricity by 20%. The heater
is rated 2 kW at 230 V. Do you agree with the claim of the company? Support your
opinion.
The following table shows the import bill of fossil fuels in million metric tonnes
(MMT) and its cost in Crores Rupees over the last eight years.
(i) calculate the average annual percentage increase of fossil fuel imports
(ii) calculate the average annual percentage increase of the import bill
(iii) calculate the average costs for the last eight years, in Rs. Per metric ton of
imported fossil fuels.

Import bill of fossil fuels

Year Quantity (MMT) Value (Rs.Crore)
1996-97 33.90 18,337
1997-98 34.49 15,872
1998-99 39.81 19,907
1999-00 57.80 40,028
2000-01 74.10 65,932
2001-02 84.90 80,116
2002-03 90.00 85,042
2003-04 95.00 93,159

An energy manager or energy auditor is trying to establish the power factor of a 15 HP

induction motor. The instrument to measure electric parameters displays the three numbers 5
kW and 2 kVAr and PF = 92.8%. Do you fully agree with the instrument display and its
correctness?

Fuel substitution from a high cost fuel to a low cost fuel in boilers is common to reduce energy
bill. For the following situations calculate:

(i) annual reduction in energy costs in Crore Rs.

(ii) annual change in energy consumption in %. (Calorific value of fuels not required
for calculations)
Before substitution:

Steam output = 6 tons/hour

Fuel consumption = 1 ton oil per 13 tons of steam.
Operating hours = 6400 / Year
Fuel costs = Rs.13,000 /ton of oil
Boiler thermal efficiency (yearly average)= 82%

After Substitution:

Steam output = 6 tons/hour

Fuel consumption = 3 tons of waste wood per 13 tons of steam
 Fuel costs = Rs.2,000 / ton of waste wood
Boiler thermal efficiency (yearly average) = 74%

A company invests Rs.10 lakhs and completes an energy efficiency project at the beginning of
year 1. The firm is investing its own money and expects an internal rate of return, IRR, of at
least 26% on constant positive annual net cash flow of Rs.2 lakhs, over a period of 10 years,
starting with year 1.

(i) Will the project meet the firm's expectations?

(ii) What is the IRR of this measure?

(i)
Construct a CPM diagram for the data given below
(ii) Identify the critical path. Also compute the earliest start, earliest finish, latest
start & latest finish of all activities

Acti Prect Time, weeks

A Start 3
B A 4
C A 1
D C 3
E Start 2
F B 2
Finish D, E, F --

During a ESP performance evaluation study, the inlet gas stream to ESP is 289920NM3/hr and
the dust loading is 5500 mg/ NM3. The outlet gas stream from ESP is 301100M3/hr and the
dust loading is 110 mg/NM3. How much fly ash is collected in the system?

Calculate fixed energy consumption for a rolling mill consuming 3,00,000 units electricity to
produce 500 MT product per month and having specific energy consumption of 500 Kwh/MT.

In a chlora-alkali plant, the inlet brine concentration to cell house is 300 gpl and the outlet
concentration is 260 gpl. If 3 MT Salt is added per hour, find out the brine flow rate to the
Cell House