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13th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY AUDITORS – September, 2012

PAPER – 4: Energy Performance Assessment for Equipment and Utility

Systems

Date: 16.9.2012 Timings: 14:00-16:00 HRS Duration: 2 HRS Max. Marks: 100

Section - I: BRIEF QUESTIONS Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark

S-1 In a vapour compression refrigeration system, why the heat rejected in the
condenser is more than the heat absorbed in the evaporator ?

Ans Because heat of compression is also added to it

S-2 If the unit heat rate is 3120 kcal/kWh and the turbine heat rate is 2808
kCal/kWh what is the boiler efficiency ?

Ans (2808/3120) x 100 = 90 %

S-3 A rise in conductivity of boiler feed water indicates ____ .

Rise in the TDS level of feed water

Ans

S-4 Why is it preferable to measure the flow at the inlet side of the fan?

Ans Less turbulence

S-5 The critical point of steam occurs at ____bar and _______ oC

Ans 221.2 bar and 374.15oC

S-6 In a heat exchanger _______ is the ratio of actual heat transfer rate to the
maximum heat transfer rate.

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Ans Effectiveness

S-7 In an integrated steel plant pig iron is produced from _________furnace?

Ans Blast furnace

S-8
If the PLF of a 210 MW power plant is 80% , what is the annual gross generation in
MWh

Ans 1,471,680 MWH

S-9 A pump operates on water with a total head of 12 m. If water is replaced by

brine with a specific gravity of 1.2 what will be the total head developed by the
pump ?

Ans 12 m or same

S-10 A draft system in a boiler which uses both FD and ID fan is called…….

Ans Balanced Draft

. End of Section - I .

Section - II: SHORT NUMERICAL QUESTIONS Marks: 2 x 5 = 10

(i) Answer all Two questions

(ii) Each question carries Five marks

L-1 Calculate pressure drop in meters when pipe diameter is increased from
250 mm to 300 mm for a length of 600 meters. Water velocity is 2 m/s in
the 250 mm diameter pipe and friction factor is 0.005.

Ans Pressure drop = 4fLV2

--------------
2gD

Velocity of water in pipe of 300 mm diameter = (0.25 x 0.25 x 2) /(0.3 x 0.3)

= 1.39 m/s

Pressure drop with 300 mm = 4 x 0.005 x 600 x 1.392 / (2 x 9.81 x 0.300)

= 3.94 m

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L-2 A three phase 37 kW four pole induction motor operating at 49.8 Hz is rated for 415
V, 50 Hz and 1440 RPM. The actual measured speed is 1460 RPM. Find out the
percentage loading of the motor if the voltage applied is 410 V.
Ans

% Loading = Slip x 100%

(Ss – Sr) x (Vr / V)2

Synchronous speed = 120 x 49.8 / 4 = 1494 rpm

Slip = Synchronous Speed – Measured speed in rpm.

= 1494 – 1460 = 34 rpm.

% Loading = 34 x 100% = 61.45%

(1494 - 1440) x (415/410)2

. End of Section - II .

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Section - III: LONG NUMERICAL QUESTIONS Marks: 4 x 20 = 80

(i) Answer all Four questions

• Refer Original question paper for questions

N1 Key

a) Theoretical air required for complete combustion

   O  
(11.6 x C ) + 34.8 x  H 2 −  2    + (4.35 x S )
   8  
=
100
   32.52  
(11.6 x 33.95) + 34.8 x  5.01 −    + (4.35 x 0.09)
=    8   = 4.27 kg / kg of paddy husk
100

 77 
4.27 ×  
 100   0.0091 
Moles of N2 = +  = 0.1178
28  28 

Moles of C
% CO2 theoretical =
Moles of N 2 + Moles of C + Moles of S

 0.3395 
 
=  12 
 0.3395   0.0009 
0.1178 +   +  
 12   32 

Max theoretical ( CO2 )t = 19.36 %

Actual CO2 measured in flue gas = 14.0%

7900 x [( CO 2 ) t − (CO 2 ) a
b) % Excess air supplied = = 37.5 %
(CO 2 ) a x [100 − ( CO 2 ) t ]

c) Actual mass of air supplied = {1 + EA/100} x theoretical air

= {1 + 37.5/100} x 4.27
= 5.87 kg/kg of coal

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0 .3395 × 44 5 .87 × 77 (5 .87 − 4 .27 ) × 23

Mass of dry flue gas = + 0 .0091 + +
12 100 100

= 6.15 kg / kg of coal

(or)
(actual mass of air supplied + 1) – mass of H20

(5.87 + 1) – (9H + M) = 6.87 – (9x.05 + 0.1079)= 6.87 – 0.5579 = 6.31 kg/kg of coal

m x C P x ( Tf − Ta )
% Heat loss in dry flue gas = x 100
GCV of fuel
6.15 x 0.23 x (160 − 32 )
= x 100
3568
= 5.07 %

Loss due to CO =

= 0.35 x 0.3395 x 5654

(0.35+14) x 3568

L2 = 1.31 %

Heat Loss in ash

% heat loss due to unburnt flyash

% ash in paddy husk = 16.73

Ratio of bottom ash to flyash = 10:90
GCV of flyash = 450 kcal/kg
Amount of flyash in 1 kg of husk = 0.9 x 0.1673
= 0.15 kg
Heat loss in flyash = 0.15 x 450
= 67.5 kcal/kg of husk
GCV of bottom ash = 800 kcal/kg

Amount of bottom ash in 1 kg of husk = 0.1 x 0.1673

= 0.01673 kg
Heat loss in bottom ash = 0.01673 x 800
= 13.4 kcal/kg of husk

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Total heat loss in ash = 67.5 + 13.4

= 80.9 kcal/kg
% loss in ash = 80.9/3568
= 2.26 %

Total losses = 100 – (5.07 + 1.31 +2.26) – (15.4)

Boiler efficiency = 100 – 8.64 – 15.4 = 75.96 %

N-2 KEY

Hot Water use per day : 20,000 L/day

Water in = 200C
Water out = 600C
Temp. diff. = 400C
Total Heat required = mCpdt
= 20000 x 1 x 40 = 8,00,000 kcal/day

1. Energy Requirement for 20KL/day of water for a temperature differential of 40

deg.C in an Electric Boiler/Geyser

Energy Requirement (for 20 KL/day)

= Total heat required (800000)
860 kcal/kWh x 0.99 ( efficiency of electric heating))
= 939.6 kWh/day

2. For 20 KL/day, of water flow with 400C Temperature Diff. Energy to be drawn by
Heat Pump

= 8,00,000 = 391.68 Kwh/day

860x0.95x2.5

Energy drawn by circulation pump = 3.74 x 24 hr = 89.76 kWh/day

Energy drawn by evaporator fan = 1.4 kW x 16 hr = 22.4 kWh/day

Total Energy drawn by heat pump system = 391.68 +89.76+22.4

= 503.8 kWh /day

SAVINGS IN COMPARISON TO ELECTRIC WATER HEATER

= 939.6 – 503.8 = 435.75 Kwh/day

= 1,52,516 kWh/year ( @ 350 days/year)
= 12.20 lakhs ( @ Rs8.0 per kWh)

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3. SIMPLE PAY BACK PERIOD = Rs.16.0 LAKHS Investment/ Rs.12.20 lakhs per
year savings
= 1.30 years or 16 months

N-3 KEY

Ans
Power generation from cogen plant = 5000X 0.9 X 8000 = 360 lac Kwh/yr

Auxiliary power = 1%
Net power generation = 0.99 X 360 = 356.4 lac Kwh

Natural gas requirement for = 360 X 3050 / 9500 = 115.57 lac sm3
power generation

Cost of fuel per annum = 115.57 X 8 = Rs.924.56 lacs

Annual expenditure for interest, = 500 + 200 = 700 lacs

depreciation and O&M

Total cost of generation = Rs.1624.56 lacs.

Cost of cogeneration power = 1624.56 X 105 / 356.4 X 105

= Rs.4.56 / Kwh.

Gas consumption in existing gas = [10000 (665 – 85) / (0.86 X 9500)]

fired boiler = 710 Sm3/hr
= 710 x 24 = 17040 sm3/day

Cost of steam from existing boiler = 710*Rs. 8 x8000

= Rs. 454.4 Lacs /yr

Cost of power generation after giving = 1624.56 – 454.4 = Rs.1170.16 lacs

credit for steam generation

Cost of power generation after accounting = 1170.16 X 105 / 356.4 X 105

for steam cost
= Rs. 3.28 / Kwh

Grid power cost = Rs. 4.5 / Kwh

Cost advantage for cogen plant = 4.5 – 3.28 = Rs.1.22 / Kwh

generation

Daily gas requirement for operating = 5000 X 0.9 X 3050 X 24

GT cogen plant 9500
= 34673.68 Sm3 / day
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Additional gas requirement for = 34673.68 – 17040 = 17633.68 Sm3/day

co-gen plant

N-4 To attempt ANY ONE OF THE FOLLOWING among A, B, C and D

N4 A KEY

Ans i) Turbine power output kW =

Steam flow to turbine kg/hr x enthalpy drop across the turbine kcal/kg
-------------------------------------------------------------------------------------------------------
860

Inlet enthalpy of steam =794.4 kcal/kg

Enthalpy of exhaust steam is calculated as given below

exhaust steam dryness fraction = 90%
enthalpy of exhaust steam = (45.9 + 0.9 x 572.5) = 561 kcal/kg
turbine out put = ((120 x 1000 kg/hr x (794.4 – 561) kcal/kg) /860
turbine output = 32567.4 kW

ii) generator output kW = turbine output x combined efficiency of mechanical, gear

transmission & generator
= 32567.4 x 0.92
=29962 kW

iii) turbine heat rate = heat input in to the turbine/ generator out put
=q x (h1 – hw)/generator out put

Where q = steam inflow to turbine kg/hr

h1= enthalpy of turbine inlet steam =794.4 kcal/kg
hw= enthalpy of feed water to boiler = 100 kcal/kg

Turbine heat rate = ((120 x 1000 kg/hr) x (794.4 – 100) kcal/kg))/ 29962 kw
= 2781 kcal/kwh

iv) unit heat rate = turbine heat rate /boiler efficiency

= 2781 / 0.88 = 3160 kcal/ kwh

v) turbine cycle efficiency = (860 / turbine heat rate) x 100

= 860 /2781 =0.309
=0.309 x 100 = 30.9%

vi) condenser heat load = m x cp x dt

Where m = cooling water flow through condenser, kg/hr

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note: density of water is given as 0.95 g /cubic centimetre = 950 kg/ cubic meter
cp = specific heat of cooling water, kcal/ kg. oC = 0.98 kcal /kg. oC
dt = cooling water temperature rise, oC = 10

Condenser heat load =6318 x 950 x 0.98 x 10 = 5,88,20,580 kcal /hr

vii) specific steam consumption of turbine = 860 / (enthalpy drop x combined efficiency)
= 860/ ((794.4 – 561) x 0.92))
=860 / (233.4 x 0.92) =4.0 kg/kwh
= 4.0 kg / kwh

N4-B KEY
Ans
Volumetric flow rate of PH gas at NTP = 1.47 x 125 x 1000 = 183750 [Nm3/hr]

Mass flow rate of PH gas = 183750 x 1.42 = 260925 [kg/hr]

Calculation for 4 stage pre-heater kiln

Heat loss in PH Gas = m x cp x T [kcal/hr]

= 260925 x 0.244 x 370 = 23556309 [kcal/hr]
Equivalent coal wasted = 23556309 = 4.252 [tons of coal/hr]
5540 Χ 1000

Electrical Energy consumption of PH Fan

Volumetric flow rate of PH Gas at 370 oC temperature and -400 mm WC static pressure:

V = 183750 Χ ( 273 + 370) Χ 10333 = 450216 [m3/hr]

273 Χ (10333 − 400 )
or V = 450216/3600 = 125 [m3/sec]

Pressure difference across PH fan = 50 – (- 400) = 450 [mm WC]

Power consumption of PH fan
125 Χ 450 = 806.24 [kW]
P=
102 Χ 0.72 Χ 0 .95

Calculation for 6 stage pre-heater kiln

Heat loss in PH Gas = m x cp x T [kcal/hr]

= 260925 x 0.244 x 295 = 18781381 [kcal/hr]

Equivalent coal wasted = 18781381 = 3.39 [tons of coal/hr]

5540 Χ 1000

Electrical Energy consumption of PH Fan

Volumetric flow rate of PH Gas at 295 oC temperature and -600 mm WC static pressure:
V = 183750 Χ ( 273 + 295) Χ 10333 = 405875 [m3/hr]
273 Χ (10333 − 600)

Or V = 405875/3600 = 112.75 [m3/sec]

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Pressure difference across PH fan = 50 – (- 600) = 650 [mm WC]

Power consumption of PH fan
P = 112.75 Χ 650 = 1050.4 [kW]
102 Χ 0.72 Χ 0.95

The above kilns can be compared as follows:

Item 6 Stage PH Kiln 4 stage PH kiln
PH Gas heat loss (kcal/hr) 18781381 23556309
Equivalent coal wasted (tons of coal) 3.39 4.252
Power consumption in PH Gas (kW) 1050 806.24

Calculation for annual Monetary savings

Coal savings in 6 stage PH Kiln = 4.252 – 3.39 = 0.862 [ton of coal/hr]

Annual monetary savings (Thermal) = 0.862 x 8000 x 6150 = 4,24,10,400 [Rs.]

Additional Electrical energy requirement for 6 stage PH Kiln = 1050.4 – 806.24 = 244.16 [kW]

Annual additional electrical cost = 244.16 x 8000 x 5 = 97,66,400 [Rs.]

It is obvious that in monetary terms, thermal energy saving in 6 stage pre-heater kiln is higher than the additional
electrical energy cost in 4 stage kiln. Therefore, 6 stage pre-heater kiln is better option than 4 stage pre-heater
kiln.

So the net annual monetary saving in case of 6 stage pre-heater kiln is

= 4,24,10,400 – 97,66,400 = 3,26,44,000 [Rs.]

N4-C KEY

Ans a)
Before insulation
Surface heat loss, S = [ 10 + (TS-Ta)/20] x (Ts –Ta)
Total heat Loss =SxA where A= Surface area, m2
Surface heat loss , S = [ 10 + ( 110-25)/20] x (110-25) = 1211.25 K.Cal/m2/hr
Total heat loss = 1211.25 x 20 m2 = 24225 kCal/hr

After insulation
Surface heat loss ,S = [ 10 + (55-25)/20] x (55-25) =345 K.Cal/m2/hr
Total heat loss = 345 x 20 m2 = 6900 kCal/hr
Heat reduction per hour after proper insulation = 24225- 6900 = 17325 kCal/hr
Annual heat loss reduction = 17325 x 8000 = 138600000
= 138.6 million kCal/year

Steam distribution loss = 20%

Heat loss = 138.6 million kCal/ 0.8 = 173.25 million kcal/year
Boiler efficiency = 70%

Equivalent coal consumption reduction = 173.25 x106 /0.7 x 4800 = 51.56 Ton /year
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Monetary Cost savings per year = 51.5 x 5000 = Rs 2.575 lacs

Investment @ Rs 1000 per M2 = 20 x 1000 = Rs 20000

Condensate recovery
Reduction in coal consumption through
heat recovered from condensate return = 2000 x 1 x (80 – 40) / 0.7 x 4800
= 23.8 kg of coal per hour
Annual coal savings = 23.8 x 8000/1000
= 190.4 ton / year
Annual savings = 23.8 x 8000 x Rs.5/kg coal
= Rs. 9.52 lacs

b)Simple payback period

Total savings from both the measures = 2.575 + 9.52 = 12.1 lakhs
Total investment = Rs. 20,000 + Rs 2 lakhs = Rs.2.2 lakhs
Simple payback period (combined) = 2.2/12.1= 2.2 months

c)GHG emission reduction

Carbon content in the coal = 40% by weight
Total Coal saving /year = 51.5 + 190.4 = 241.9 Ton per year
CO2 reduction = 241.9 x 0.4 x 44/12 = 355 Ton of CO2/year

N4-D KEY

Ans Theoretical air required for complete combustion

=[(11.6x85.9)x(34.8x(12-0.7/8))+4.35x0.5]/100
=996.44+414.12+2.175/100
=14.1 kg/kg of oil

Existing oxygen % in flue gas =6%

% excess air supplied =6 x100/(21-6) =40%

Actual mass of air supplied =(1+Excess air/100)x Theoretical air
=(1+40/100)x 14.1
=19.74 kg/kg of oil

After modification, oxygen % in flue gas =3%

% excess air supplied =3 x100/(21-3) =16.67%

Actual mass of air supplied =(1+Excess air/100)x Theoretical air

=(1+16.67/100)x 14.1
=16.45 kg/kg of oil

a) Heat loss reduction through actual mass of air supplied

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Actual mass of air supplied before WHR =19.74 kg/kg of oil

Actual mass of air supplied AFTER WHR =16.45 kg/kg of oil

Existing oil consumption per hour = 25 ton/hr x 60kg/ton = 1500 kg of oil /hr

Flue gas loss before WHR = [1500 kg oil + (1500 x 19.74 kg air)] x 0.24 x (600-30)
= 4255848 kcal/hr

Flue gas loss after WHR = [1500 kg oil + (1500 x 16.45 kg air)] x 0.24 x (300-30)
= 1696140 kcal/hr

Flue gas heat loss reduction after WHR implementation = 4255848-1696140

= 2559708 kcal/hr

Reduction in fuel oil consumption after installing

Waste heat recovery and reduction in excess air = 256 kg/hr

Furnace efficiency after WHR = 25000 x 0.12 x (1200-40) x 100

[(1500-256) x10000)]
= 28 %

b) Calculate fuel oil reduction after charging hot ingot in reheating furnace

Ingot charging temperature is increased from 40 oC to 500 oC

Fuel oil reduction due to increased charge temperature =

= 25 x 1000 x 0.12 x(500-40)/0.28 x10,000
= 492.86 kg/hr = 493 kg/hr

c ) Specific oil and power consumption after implementing both the above measure

Fuel oil reduction after implementation of both measures

= 256 + 493 = 749 kg oil/hr

Fuel oil consumption after implementation of both measures

= 1500 – 749 = 751 kg oil/hr

Yield improvement = 3%
Production after implementation = 25 x 1.03 = 25.75 ton/hr
of both measures

Specific oil consumption = 751/ 25.75 = 29.2 kg/Ton

Specific power consumption = 25x90 / 25.75 = 87.37 kWh/ton

-------- End of Section - III ---------

12
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14th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY AUDITORS – August, 2013

PAPER – 4: Energy Performance Assessment for Equipment and Utility Systems

Date: 25.8.2013 Timings: 14:00-16:00 Hrs Duration: 2 Hrs Max. Marks: 100

Section - I: BRIEF QUESTIONS Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark

S-1 If EER of a 1.5 TR window airconditioner is 2.5 what will be the power input?

Ans 1.5 x 3.516/2.5 = 2.11 kW

What is the significance of monitoring dew point of compressed air for

S-2
pneumatic instruments application?

Ans To check the moisture level/dryness in instrument air

For a thermal power plant, the percentage auxiliary consumption of a 500 MW

S-3
unit is ____than that of a 110 MW unit.

Ans Less

Between one litre of ‘liquid hydrogen’ and one litre of ‘liquid gasoline’ which
S-4
will have a higher heat content?

Ans Liquid gasoline

Why is the COP of a vapour absorption refrigeration system always less than
S-5
one?

COP is given by (heat taken by evaporator/ heat given to generator). The heat given
Ans to generator of VAR is always more than heat taken away in the evaporator
(refrigeration effect)

S-6 Regenerators utilising waste heat are widely used in _________furnaces

Ans Glass melting or Open hearth furnaces

S-7 Why small bypass lines are provided in a centrifugal pump?

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Ans To avoid pump running at zero flow

If the speed of a reciprocating pump is reduced by 50 %, what will be its effect

S-8
on the head?

Ans The head will remain the same

As the ‘approach’ increases, the other parameters remaining constant, the

S-9
effectiveness of cooling tower will _____________

Ans Decrease

In a DG set, waste heat is used for steam generation. This type of

S-10
cogeneration is called _________cycle.

Ans Topping

…………. End of Section - I ………….

Section - II: SHORT NUMERICAL QUESTIONS Marks: 2 x 5 = 10

(i) Answer all Two questions

(ii) Each question carries Five marks

L-1 An automobile plant has a maximum demand of 5000 kVA at a PF of 0.95. The
plant has shifted its electric annealing furnace with a steady resistive load of
600 kW to its foundry unit in a nearby location after suitable modifications.
What will be the new PF of the automobile plant without the electric annealing
furnace?

Ans
Existing maximum demand in kW, 5000 x 0.95 = 4750 KW
Existing reactive power load in the plant

(KVAR)2 = KVA2 – KW 2 = (5000)2 – (4750)2

KVAR = 1561

Electrical load after shifting 600 KW annealing furnace = 4750 – 600 = 4150 KW

However, KVAR load will remain same as 600 kW annealing furnace did not impose
any kVAr loading.

KVA = SQRT [(4150)2 + (1561)2] = 4434

PF = 4150 / 4434 = 0.936

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L-2 In a medium sized engineering industry a 340 m3/hr reciprocating compressor

is operated to meet compressed air requirement at 7 bar. The compressor is in
loaded condition for 80% of the time. The compressor draws 32 kW during
load and 7 kW during unload cycle.
After arresting the system leakages the loading time of the compressor came
down to 60%.
Calculate the annual energy savings at 6000 hours of operation per year.

Ans
Average power consumption with 80% loading =
= [0.8 x 32 + 0.2 x 7] = 27 KW

Average power consumption with 60% loading after leakage reduction =

= [0.6 x 32 + 0.4 x 7] = 22 KW

Saving in electrical power = 5 KW

Yearly savings = 5 x 6000
= 30,000 kWH

…………. End of Section - II ………….

Section - III: LONG NUMERICAL QUESTIONS Marks: 4 x 20 = 80

(i) Answer all Four questions

N1 A multi-product chemical plant has an oil fired boiler for meeting its steam requirements for
process heating. The average fuel oil consumption for the boiler was found to be 950 litres per
hour. Calculate the cost of steam per tonne considering only the fuel cost.

The performance and other associated data are given below:

O2 in the flue gas (dry) at boiler exit = 6%

Temperature of the flue gas at boiler exit = 200oC
Enthalpy of steam = 665 kcal/kg
Enthalpy of feed water = 80 kcal/kg
Steam is dry saturated.

Fuel analysis data:

Carbon (C) = 85% Hydrogen (H2) = 12% Nitrogen (N2) = 0.5%
Oxygen (O2) = 1% Sulfur (S) = 1.5%

Gross calorific value of fuel oil = 10,000 kcal/kg

Specific gravity of fuel oil = 0.95
Cost of fuel oil per KL = Rs.40,850/-

Specific heat of flue gas = 0.262 kcal/kgoC

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Specific heat of superheated vapour in flue gas = 0.43 kcal/kgoC

Humidity in combustion air = 0.025 kg/kg dry air
Ambient air temperature = 30oC
Radiation & convection loss from boiler = 1.8%

ANS
Calculate boiler efficiency by indirect method

Calculate evaporation ratio Kg steam / Kg fuel oil

And then compute fuel cost of steam

Boiler efficiency by indirect method:

Theoretical air required for complete combustion of fuel oil

= {11.6. C + [34.8 (H2 – O2/8)] + 4.35 S} / 100

= {11.6 x 85 [34.8 (12 – 1/8)] + 4.35 x 1.5} / 100
= 14.05 Kg/Kg fuel oil

% O2 in fuel gas = 6
% Excess air = [%O2 / (21 - % O2)] x 100
= [6 / (21 – 6)] x 100
= 40%

Actual Air Supplied (ASS) = (1 + 0.4) x 14.05 = 19.67 Kg/Kg fuel oil

Mass of dry flue gas = mdfg

Mass of dry flue gas = mass of combustion gases due to presence C, S, O2, N2
+ mass of N2 in air supplied

Mdfg = 0.85 x (44 / 12) + 0.015 x (64 / 32) + .005 + [(19.67 – 14.05) x (23 / 100)] + 19.67 x (77/100)
Mdfg = 19.59 Kg/Kg fuel oil

Alternatively Mdfg = (AAS+1) – (9xH2) = (19.67+1) – (9 x 0.12) = 19.59 kg/kg fuel oil

% heat loss in dry flue gas = mdfg x Cpf x (Tg – Ta) / GCV of fuel
Tg = flue gas temperature = 200oC
Ta = ambient temperature = 30oC
Cp = SP ht of flue gas = 0.26 Kcal/KgoC
GCV = Gross Calorific Value of fuel oil = 10,000 Kcal/kg

L1 = % heat loss in dry flue gases = [(19.59 x 0.262 x (200-30))/10,000] X 100 = 8.73 %

Heat loss due to evaporation of water due to H2 in fuel

= {9 x H2 [584 + CPS (Tg – Ta)]} / GCV
CPS = Specific heat of superheated steam
= 0.43 Kcal/KgoC

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L2 = {9 x 0.12 [ 584 + 0.43 (200 – 30)] / 10000} x 100 = 7.09%

L3 = % heat loss due to moisture in fuel = 0
As % moisture in fuel is nil (not given)

% heat loss due to moisture in air

L4 = AAS x humidity factor x CPS x (Tg – Ta) / GCV

Humidity factor = 0.025 Kg/Kg dry air

L4 = {[19.67 x 0.025 x 0.43 (200-30)] / 10000} x 100 = 0.36%

L5 = Radiation and convection loss from the boiler = 1.8% (given data)

Total losses in the boiler in % = L1 + L2 + L3 + L4 + L5

= 8.73 + 7.09 + 0 + 0.36 + 1.8
= 17.98 say 18 %
Efficiency of boiler by indirect method = 100 - % total loss = 100 – 18 = 82%

Boiler n = E.R. (hs – hw) / GCV x 100

ER = Evaporation Ratio = Kg steam / Kg fuel oil
hs = Enthalpy of Steam = 665 Kcal/Kg
hw = feed water enthalpy = 80 Kcal/Kg
Boiler Efficiency = 82%

ER = 0.82 x 10000 / (665-80) = 14.02 = Say 14 Kg steam / Kg fuel oil

Cost of fuel oil per KL = Rs.40,850/-

S.G. of fuel oil = 0.95
Cost of fuel oil per tonne = 40,850 / 0.95 = Rs.43,000/-

Fuel cost of steam per tonne = 43000 / 14 = Rs.3071.45

N2 In a food processing unit, 24,000 litres of water per day is to be heated from 25oC to 55oC.
Presently this requirement is met by an electrical heater. The management is planning to install a
vapour compression heat pump system having a COP of 2.3 which includes the compressor motor
losses. The schematic of the heat pump hot water system is given below:

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Hours of operation of water circulation pump = 24 hours/day

Evaporator fan operation = 20 hours/day
Energy consumption of water circulation pump
and evaporator fan per day = 50 kWh
Compressor motor efficiency = 88 %
Annual operating days of heat pump = 330 days
Cost of electrical energy = Rs.10/kWh
Heat loss in the condenser and hot water tank
in addition to the heat load = 5%
Investment for heat pump = Rs.15 Lakhs
The compressor and evaporator fan are interlocked in operation.

Find out
i) Heat pump capacity in TR in terms of heat delivered
ii) The payback period of investment towards heat pump
iii) Evaporator capacity in TR
i)
Hot water requirement per day = 24000 litres = 24000 kgs.
ANS
Inlet water temperature = 25oC
Outlet water temperature = 55oC

Energy required for electrical heating per day = 24000 (55 – 25) / 860 = 837.2 Kwh

Heat load on the condenser per day = 24000 (55 – 25) x 1.05
including 5% loss (in the condenser & hot water tank)
= 756000 Kcals/day
Heat pump capacity based on delivered heat =756000/(24 x 3024)
= 10.4 TR
Electrical energy equivalent of heat delivered = 756000 / 860 = 879.07 Kwh

Daily energy consumption in the heat pump with a COP of 2.3 = 879.07 / 2.3
= 382.2 Kwh

Daily energy consumption in the circulating = 50 Kwh (given data)

water pump and evaporator fan

Total energy consumption for operation of = 432.2 Kwh

heat pump per day

Energy saving with heat pump compared = 837.2 – 432.2 = 405 Kwh
to electrical heating per day

Cost of electricity per kwh = Rs.10

Monetary saving per day = 405 x 10 = Rs.4,050/-

Annual savings with 330 days operation = 4050 x 330 = Rs.13,36,500/-

= Rs.13.365 lacs

Investment for heat pump = Rs.15 lacs

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Simple pay back period = 15 / 13.365 = 13 months

The investment is attractive and justifiable.

Evaporator capacity in tonne refrigeration

= Heat delivered at the condenser – Input energy to the compressor
= [{879 – (382.17 x 0.88)} x 860] / (3024 x 20)
= 7.72 TR

N-3 In an organic chemical industry 10 tonne per hour of hot oil is to be cooled from 210 oC to 105oC by
DM water. The DM water enters the heat exchanger at 25oC and exits at 85oC after which it is fed to
the feed water storage tank of the boiler.

i. Depict the heat exchanger process on a schematic for the parallel and counter flow
indicating the hot and cold stream temperatures along with terminal temperature difference.
ii. Find out the LMTD for parallel and counter flow heat exchange and justify the choice of the
heat exchanger.
iii. Estimate the DM water flow rate through the heat exchanger. The specific heat of oil is 0.5
kcal/kgoC.

Ans I)

ii)
Δ t1 - Δ t2
LMTD parallel flow = -----------------
Ln Δt1 / Δt2

= (185 – 20) / ln (185 / 20) = 74.19oC

LMTD Counter flow = (125 – 80) / ln (125/80) = 100.9oC

Counter flow heat exchange will yield higher LMTD and hence heat exchanger area will be less and hence
preferred.
iii)
mc = mass flow rate of DM water
mc x 1 x (85 – 25) = mh x 0.5 x (210 – 105)
mc x 1 x (85 – 25) = 10000 x 0.5 x (210 – 105)
mc = 8750 kg/hour

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N-4 To attempt ANY ONE OF THE FOLLOWING among A, B, C and D

A An energy audit was conducted on a 110 MW thermal power generating unit. The details of
design parameters and operating parameters observed during the audit are given below.
Parameters Design Operating
Generator output 110 MW 110 MW
Boiler outlet superheated steam temperature 540oC 520oC
Boiler outlet steam pressure 140 kg/cm2(a) 130 kg/cm2(a)
Feed water inlet temperature to Boiler 120 oC 120 oC
Feed water enthalpy 120 kcal/kg 120 kcal/kg
Boiler efficiency 87% 87%
GCV of coal 3650 kcal/Kg 3650 kcal/Kg
Turbine exhaust steam pressure 0.09 kg/cm2(a) 0.12 kg/cm2(a)
Dryness fraction of exhaust steam 88% 88%
Unit gross heat rate 2815 kcal/kWh ?
Efficiency of turbine & generator (including gear box) - 90 %

Steam properties are as under:

Enthalpy of steam at 520oC and 130 kg/cm2(a) is 808.4 kcal/kg

Enthalpy of Exhaust steam at 0.12 kg/cm2(a) is 550 kcal/kg

For the changed current operating parameters calculate the following..

I. Steam flow rate to the Turbine

II. Specific steam consumption of Turbine

III. Specific coal consumption and unit gross heat rate

IV. Additional quantity of coal required based on 8000 hours/year of operation of the plant

V. Increase in annual coal cost due to increase in coal consumption at a cost of Rs. 3400 per
tonne of coal.

Ans
(i) Calculation of Steam flow rate to Turbine

Turbine output, KW = m x (Hs – Hf)/ 860

Where, m = steam flow to turbine, Kg/hr

Hs = Enthalpy of steam at 520 Deg.C& 130 Kg/cm2 = 808.4 Kcal/Kg

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Hf = Enthalpy of turbine exhaust steam =550 Kcal/kg

Turbine output = Generator output/ Efficiency of Turbine & Generator

= 110 / 0.9 =122.2 MW
122.2 x 1000 = (m x (808.4 – 550))/860
Steam flow rate to Turbine, m = 406.7 Tonnes/hr

(ii) Calculation of specific steam consumption of Turbine, kg/kwh

Specific steam consumption = Steam flow to turbine, Kg/hr / Generator output, Kw

= 406.7 x 1000/( 110 x 1000)
= 3.697 Kg/Kwh
(OR)

ALTERNATE PROCEDURE

Specific steam consumption = 860/((Hs – Hf) x Efficiency of Turbine & Generator)

= 860/(( 808.4 – 550) x 0.9)
= 3.697 Kg/Kwh

(iii) Calculation of specific coal consumption, Kg/kWh

Boiler efficiency = m kg/hr ( Hs – Hw) Kcal/kg / ( Q x GCV)------------(2)
0.87 = (406.7 x1000 ( 808.4 – 120 ))/ ( Q X 3650 )
Coal consumption Q = 88166 Kg/hr

Specific coal consumption = Coal consumption, Kg/hr / Generator output, Kw

Specific coal consumption = 88166/ (110 x 1000)= 0.801 Kg /Kwh
Unit gross Heat rate= 0.801x3650=2923.6 kcal/kWh

( iv) Additional quantity of coal required

Specific coal consumption at design conditions = unit heat rate / GCV of coal
2815/3650 =0.771 kg/kwh
Additional coal consumption/year = (0.801 – 0.771) x 110 x 1000 x 8000 =26400000 kg
Additional quantity of coal required /year = 26400 Tonnes

(v) Annual increase in coal cost

Additional cost of coal = 26400Tonnes x 3400 Rs/Tonne
=Rs. 8,97,60,000
B

During the conduct of heat balance of a 5 stage inline calciner Kiln of a cement plant , the following data
were measured at preheater outlet using pitot tube and flue gas analyser.

Temp Static Pressure Avg. Dynamic Pressure Oxygen CO2 CO Duct Area
o
C (Ps) mm WC (Pd) mm WC % (v/v) dry % (v/v) dry % (v/v) dry m2
350 -435 16.9 6.0 19.2 0.06 3.098

Note: take Pitot tube constant as 0.85, reference temperature as 20 oC and atmospheric pressure same
as at sea level i.e. 10334 mm WC.
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Other Data obtained

Kiln Clinker Return Dust in PH NCV of Cost of Annual Operation
Feed Production gas Coal coal
TPH TPH % of Kiln Feed kcal/kg INR hrs
(Rs)/tonne
88.5 55 6.8 5356 6950 8000

Cp of PH gas = 0.25 kcal/kg oC) , (Cp of return dust = 0.23 kcal/kg oC)

Calculate the following:

a. Specific volume of Preheater gas (Nm3/kg clinker)

b. Heat loss in pre-heater exit gas (kcal/kg clinker)

c. Heat loss in pre-heater return dust (kcal/kg clinker)

d. Heat loss due to CO formation (kcal/kg clinker)

e. Reduction in above mentioned heat losses (kcal/kg clinker) and the annual thermal monitory
savings if the Preheater exit gas temperature is reduced to 330 oC and there is no CO formation in
the system.

Ans :
a. Density of Pre-heater gas at STP:

(O2 %  MWO2 )  (CO2 %  MWCO2 )  ((N 2  CO)%  MWCO )

 STP 
22.4 100
(6.0  32)  (19.2 44)  ((74.74 0.06)  28)
 STP  = 1.398 kg/Nm3
22.4 100

273 (10334 PS )
T , P   STP 
(273 T ) 10334
273 (10334 435)
T , P 1.393 = 0.587 kg/m3
(273 350) 10334

Velocity of Preheater gas

2 g Pd
v  Pt
T , P
2  9.8 16.9
v  0.85 = 20.19 m/sec
0.585
Volumetric flow rate of PH gas = velocity x duct cross-sectional area
= 20.22 x 3.098
= 62.55 m3/sec
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= 62.55 x 3600
= 225180 m3/hr
= 225180 x 0.587/1.398
= 94550 Nm3/hr
Specific volume of PH gas = 94550/55000 = 1.72 Nm3/kg clinker

b. Heat loss in pre-heater exit gas

Q1 = m ph c p T (Cp of PH gas = 0.25 kcal/kg oC)

Q1= 1.72 x 1.398 x 0.25 (350-20)
= 198.37 kcal/kg clinker

c. Heat loss in return dust

Q2 = mdust c p T (Cp of return dust = 0.23 kcal/kg oC)

mdust = clinker factor x % return dust/100
= (88.5/55) x (6.8/100)
= 1.609 x 0.068
= 0.1094 kg dust/ kg clinker
Q2= 0.1094 x 0.23 x (350-20)
= 8.3 kcal/kg clinker

d. Heat Loss due to CO Formation

Q3= mco X 67636

CO%
mco= X sp. volum eof PH Gas
22.4 X 100
= [0.06/(22.4 x100)] x 1.72
Q3= 2.68 x 10-5 x 1.72 x 67636
= 3.12 kcal/kg clinker

e. At exit temperature 330 oC the above losses would be

Q1’= 1.72 x 1.398 x 0.25 x (330-20)

= 186.35 kcal/clinker
Thermal saving = Q1- Q1’= 197.95 – 186.35 = 12.02 kcal/kg clinker

Q2’= 0.1094 x 0.23 x (330-20)

= 7.8 kcal/kg clinker
Thermal Saving = Q2 – Q2’ = 8.3 – 7.8 = 0.5 kcal/kg clinker
Overall Thermal Savings = 12.02 + 0.5 + 3.12
= 15.64 kcal/kg clinker

Equivalent coal saving = 14.56/5356 = 0.0029 kg coal/kg clinker

Coal saving in one hour = 0.0029 x 55 = 0.1595 TPH
Annual Coal Saving = 0.1595 x 8000= 1276 tons of coal
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Annual Monitory Saving = 1276 x 6950 = INR 88,68,200

or

C In a textile process house a new stenter is being installed with a feed rate of 1000 kg/hr of wet
cloth having a moisture content of 55%. The outlet (final) moisture of the dried cloth is 7%. The
inlet and outlet temperature of the cloth is 25oC and 75oC respectively. The drying efficiency of the
stenter is 50%. It is proposed to connect the stenter to the existing thermic fluid heater of
10,00,000 kcal/hr capacity, which is already loaded to 60% of its capacity. The thermic fluid heater
has an efficiency of 75%. Check whether the thermic fluid heater will be able to cater to the input
heat requirements of the stenter.

Ans Feed rate of wet cloth to the stenter = 1000 Kg/hr

Initial moisture = 55%
Quantity of moisture at inlet = 0.55 x 1000 = 550 Kg/hr
Wt of bone dry cloth = 1000 – 550 = 450 Kg/hr
Final moisture in outlet cloth = 7%
Quantity of moisture (final) at outlet = (450 / 0.93)– 450 = 483.87 – 450 = 33.87 Kg/hr
mi = inlet moisture in bone dry cloth = 550 / 450 = 1.22 kg moisture / kg cloth
mo = Outlet (final) moisture in bone dry cloth = 33.87 / 450 = 0.0753 Kg moisture/Kg cloth

Heat load of the stenter for drying process = W x (mi – mo) x [(Tin – Tout) + 540]
W = Wt of bone dry cloth Kg/hr
Tin = Inlet temperature of cloth to stenter
Tout = Outlet temperature of cloth from stenter
Latent heat of evaporation of water = 540 Kcal/Kg

Heat load of the stenter for drying = 450 (1.22 – 0.0753) x [(75 – 25) + 540]
= 303917.85 Kcal/hr.

Input heat requirement of the stenter = 303917.85 / 0.5 = 607835.7 Kcal/hr.

with 50% efficiency for drying
(heat to be supplied)

Capacity of the thermic flue heater = 1000000 Kcal/hr

Existing load = 60% x 1000000 = 600000 Kcal/hr
Balance capacity = 400000 Kcal/hr.

The thermic fluid heater capacity is not sufficient to cater to the input heat requirement of the new stenter.

D In a steel plant, daily sponge iron production is 500 tons. The sponge iron is further processed in a steel
melting shop for production of ingots. The yield from converting sponge iron into ingots is 88%. The plant
has a coal fired captive power station to meet the entire power demand of the steel plant.

The base year (2011) and current year (2012) energy consumption data are given below:

Parameters Base Year (2011) Current Year (2012)

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Sponge iron production 500 T/day 500 T/day

Specific coal consumption for sponge 1.2 T/ T of Sponge Iron 1.1 T/T of Sponge Iron
iron production
Specific power consumption for sponge 120 kWh/ T of Sponge 100 kWh/ T of Sponge
iron production Iron Iron
Yield ,in converting sponge iron into 88% 88%
ingot in steel melting shop
Specific power consumption in steel 950 kWh / T of Ingot 900 kWh / T of Ingot
melting shop to produce ingots
Captive power station heat rate 3500 kcal/ kWh 3200 kcal / kWh
GCV of coal 5000 kcal /kg 5000 kcal /kg

i) Calculate the specific energy consumption of the plant in Million kcals / Ton of finished product
(Ingot) for the base year as well as for the current year

ii) Reduction in Coal consumption per day in current year compared to base year for the plant

Ans i) specific energy consumption of the plant

For Base Year

Specific energy consumption for sponge iron = 1200 kgx 5000 + 120 Kwhx 3500
= 6.42 million K Cal/ Ton of SI
Total energy consumption for sponge iron /day 6.42 X 500 = 3210 million kCal
Actual production considering 88% yield from sponge = 500 Tons x 0.88 = 440 Tons / day
iron to ingot conversion
Specific energy consumption for ingot = 950 kWhx 3500
= 3.325 million Kcal/ ton of ingot
Total energy consumption for ingot production per day 3.325X 440=1463 million kCal
Plant specific energy consumption for production of (3210+1463)/440
finished product ( ingot) during base year = 10.62 million kCal/ ton

For Current Year

Specific energy consumption for sponge iron = 1100 kgx 5000 + 100 Kwhx 3200
= 5.82 million K Cal Ton of SI
Total energy consumption for sponge iron /day 5.82 X 500 = 2910 million kCal
Actual production considering 88% yield from sponge = 500 T X 0.88 = 440 Tons / day
iron to ingot conversion
Specific energy consumption for ingot = 900Kwh x 3200 = 2.88 million
Kcal/ ton of ingot
Total energy consumption for ingot production per day 2.88 X 440 = 1267.2 million kCal
Plant specific energy consumption for production of = (2910+1267.2)/440
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finished product ( ingot) during current year = 9.49 million Kcal/ ton

ii) Reduction in coal consumption

Energy saving in sponge iron plant = (6.42-5.82) x500 = 300 million Kcals/day
Energy saving in steel melting plant = ( 3.325-2.88) x 440 = 195.8 million Kcal/day
Total energy saving = 300 + 195.8 = 495.8 million Kcals/day
Equivalent coal reduction(saving) = 495.8 x 106 /5000 = 99.16 Tons per day

-------- End of Section - III ---------

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15th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY AUDITORS – August, 2014

PAPER – 4: Energy Performance Assessment for Equipment and Utility Systems

Date: 24.8.2013 Timings: 14:00-16:00 Hrs Duration: 2 Hrs Max. Marks: 100

Section - I: BRIEF QUESTIONS Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark

S-1 Which loss is not considered while evaluating boiler efficiency by “Indirect Method”?

Ans Blow down loss

S-2 What will be the synchronous speed of a VFD driven 4-pole induction motor
operating at 40 Hz ?
Ns = 120 x f/P
Ans
= 120 x 40/4= 1200 RPM
What is the refrigerant used in a vapour absorption system with lithium bromide as
S-3
an absorbent?
Ans Water
Other than rated kW of motor and the actual power drawn, what other parameter is
S-4
required to determine the percentage loading of the motor ?
Ans Motor Efficiency or rated motor efficiency
Inclined tube manometer is used for measuring gas flow in a duct when the air
S-5
velocity is very high: True or False?
False.
Ans
A pump will cavitate if the NPSHrequired is _________ than the NPSHavailable.
S-6
More
Ans
To determine the effectiveness of the cooling tower, it is required to measure cooling
S-7
water inlet, outlet and _____temperatures.

Ambient Wet bulb

Ans

S-8 The ratio of actual heat transfer to the heat that could be transferred by heat
exchanger of infinite size is termed as ………

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Ans Effectiveness

S-9 If the unit heat rate of a power plant is 3070 kcal/kWh ,what is the power plant
efficiency ?

Ans (860/3070) x 100 = 28 %

S-10
The difference between GCV and NCV of hydrogen fuel is Zero: True or False
False
Ans

…………. End of Section - I ………….

Section - II: SHORT NUMERICAL QUESTIONS Marks: 2 x 5 = 10

(i) Answer all Two questions

(ii) Each question carries Five marks

Hot water at 80 OC is used for room heating in a 5 Star hotel for 4 months in a year.
L-1
About 200 litres per minute of hot water is maintained in circulation with the return
temperature at 50 OC. The hot water is generated using a „hot waste stream‟,
through a Plate Heat Exchanger (PHE). The hot stream enters the PHE in
counterflow direction at 95 OC and leaves at 60 OC. The area of the heat exchanger
is 20 m2.

Calculate the LMTD and the overall heat transfer coefficient.

Heat load, Q = 200 * 60 * (80 – 50) = 360000 Kcals/hr (or) 418.7 kW

Ans
(95 – 80)/(60 – 50)
LMTD (for counter flow) = ------------------------ = 3.7 OC
ln (15/10)

Overall Heat Transfer Coefficient, U = Q/( AxLMTD)

= 418.7/(20 x 3.7) = 5.66 kW/m2.OC

(OR)
= 4864.8 kcal/hr.m2.OC

A gas turbine generator is delivering an output of 20 MW in an open cycle with a

L-2
heat rate of 3440 kcal/kWh. It is converted to combined cycle plant by adding heat
recovery steam generator and a steam turbine raising the power generation output
to 28 MW. However, with this retrofitting and increased auxiliary consumption, the
fuel consumption increases by 5% in the gas turbine.

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Calculate the combined cycle gross heat rate and efficiency.

Gas turbine output = 20 MW

Ans
Combined cycle output = 28 MW

Heat rate in GT open cycle for 20 MW = 3440 kcal/kwh

Increase in fuel consumption in = 5%

combined cycle operation

Combined cycle heat rate = (3440 X 1.05) X( 20 / 28)

= 2580 kcal/kwh

Combined cycle plant efficiency = (860 / 2580) X 100

= 33.33%

…………. End of Section - II ………….

Section - III: LONG NUMERICAL QUESTIONS Marks: 4 x 20 = 80

(i) Answer all Four questions

N-1 The steam requirement of an export oriented unit is met by a 6 TPH oil fired package
boiler generating steam at 10 kg/cm2. The monthly steam consumption of the unit is
3000 tonnes.
Other data are given below:

Fuel oil composition:

Carbon = 86%; Hydrogen = 12%; Oxygen= 0.5%; Sulphur =1.5%

Specific heat of flue gases, Cp = 0.27 kcal/kgoC

G.C.V. of fuel oil = 10,000 kcal/kg
Sp.heat of super heated water vapour = 0.45 kcal/kgoC
Enthalpy of steam at 10 kg/cm2 = 665kcal/kg
Feed water temperature = 85 oC
% O2 in dry flue gas = 6%
Flue gas temperature at boiler outlet = 240 oC
Ambient temperature = 30oC
Cost of fuel oil = Rs.43 per kg.
Radiation and other unaccounted losses = 2.45%

The export oriented unit is costing its steam cost based on the fuel consumption cost
with additional 15% to account for the auxiliary and consumables.

A neighbouring continuous process plant now offers to supply the required steam at 10
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kg/cm2 to the export oriented unit at a cost of Rs 3300 per tonne with a condition that
all the condensate will be returned back.

Calculate the following:

a) Boiler efficiency
b) Cost advantage per tonne of availing steam from neighbouring plant in place of
in-house generation and also monthly monetary saving.

Ans
First calculate the efficiency of Boiler (in EOU)

Theoretical air required =

= 11.6 C + 34.8 (H – O/8) + 4.35 S
= [11.6 X 86 + 34.8 (12 – 0.5/8) + 4.35 X 1.5] x 1/100
= 14.195 = Say 14.2

% Excess Air = [% O2 / (21 - % O2)] X 100

= [6 / (21 – 6)] X 100 = 40%

AAS = Actual amount of air supplied = 14.2 X 1.4

= 19.88 kg per kg. of fuel oil

Mass of dry flue gas mdfg = Mass of combustion gases due to presence of C,H,S
+Mass of N2 supplied
= (0.86 X 44/12) + (0.015 X 64 / 32) + [(19.88 – 14.2) X 23 / 100] + (19.88 X 77/100)
= 19.797
Mass dry flue gas ,say = 19.8 Kg / kg fuel
Or
Alternatively mass of dry flue gas = (AAS + 1) – 9 H
= (19.88 + 1) – 9 X 0.12 = 19.8 Kg./Kg. fuel

L1 = % heat loss in dry flue gas = [mdfg x Cp x (Tq – Ta) / GCV] x 100

19.8 X 0.27 x (240 – 30)

= --------------------------------- x 100
10,000
L1 = 11.23%
L2 = Loss due to presence of hydrogen forming water vapour
9 x H [584 + Cps (Tg – Ta)]
= ------------------------------------------ x 100
GCV
9 X 0.12 [584 + 0.45 (240 – 30)]
= ------------------------------------------- x 100
10000
L2 = 7.33%
L3 = Radiation and other unaccounted losses = 2.45%
Total losses = L1 + L2 + L3

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= 11.23 + 7.33 + 2.45 = 21.05 %

Efficiency of the EOU boiler by indirect method
= 100 – 21.05 =78.99 %
= Say 79 %

Secondly calculate the cost of steam in the EOU plant

Evaporation Ratio = [(n X GCV) / (hg – hf)] X 100
= [(0.79 X 10000) / (665 – 85)] X 100
= 13.62 kg Steam / kg. Fuel

Fuel oil consumption = 1000 / 13.62 kg. per tonne of steam

Fuel oil consumption = 73.42 kg./tonne of steam gen

Cost of fuel oil. = Rs. 43 per kg

Cost of steam in EOU = Fuel cost + 15% fuel cost
= 73.42 x 1.15 x 43
= Rs.3,599 per tonne
Say = Rs 3600 per tonne

Selling cost of steam from neighboring plant = Rs 3300 per tonne

Cost advantage = 3600 – 3300 = Rs.300 per tonne

Annual Savings = Rs.300 per tonne x 3000tonne/month X 12 month

= Rs.108 Lacs
N-2
a) The operating parameters of a Vapour Compression Refrigeration system are
indicated below.

Parameter Chiller side Condenser side

Water Flow (m3/hr) 89 87
Inlet Temperature (OC) 10.1 32.3
Outlet Temperature (OC) 6.8 36.6
Density (kg/m3) 1000 990

Find the COP of the Refrigeration system ignoring heat losses.

b) A 6 pole, 415 volt, 3 , 50 Hz induction motor delivers 22 kW power at rotor shaft

at a speed of 950 rpm with PF of 0.88. The total loss in the stator including core,
copper and other losses, is 2 kW. Calculate the following.
i) i) Slip
ii) ii) Rotor Copper Loss
iii) iii) Total Input to motor
iv) ivi) Line current at 415 V and motor pf of 0.88
v) v) Motor operating efficiency

a) Refrigeration Effect = 89 x 1000 x (10.1 – 6.8)

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Ans = 293700 kcal/hr

Condenser load = 87 x 990 x (36.6 – 32.3)
= 370359 kcal/hr
Compressor work = Condenser load – Refrigeration effect
= 370359 – 293700
= 76659 Kcal/hr
C.O.P. = Refrigeration Effect/ Compressor work
= 293700/76659 = 3.83

b) Synchronous Speed = (120 x 50 / 6 ) = 1000 rpm

Motor Speed = 950 rpm
(i) Slip = (1000 – 950 ) / 1000 = 5 %
Power input to rotor = { ( 22 / ( 1 – 0.05 ) } = 23.16 kW

(ii) Rotor Copper Loss = ( 0.05 x 23.16 ) = 1 . 1 5 8 k W

Or = 23.16-22 =1.16 kW

(iii) Total Input to motor = ( 23.16 + 2 ) = 25.16 kW

(iv) Line Current = ( 25.16 x 1000) /( 3 x 415 x0.88 )

= 39.75 Amps

(v) Motor Efficiency = ( 22 / 25.16 ) = 87.44 %

N-3 A common plant facility is installed to provide steam and power to textile and paper
plant with a co-generation system. The details and operating parameters are given
below:
60 T/hr.80 bar at 5000C

Enthalpy- 810 kcal/kg

To paper
Boiler industry
Turbine G
Coal
Alternator To textile
Boiler efficiency- 80% industry
GCV of Coal-5000 kcal/kg
Boiler feed water temp.- 800C
Steam 60T/hr. at 10 bar
Enthalpy- 660 kcal/kg

Steam 20 T/hr Steam Header Steam 40 T/hr

To textile industry To paper industry

Other data:
- Turbine, alternator and other losses = 8%
- Specific steam consumption in paper industry= 5 Tons/Ton of paper
- Specific power consumption in paper industry= 600 kWh/Ton of paper
Calculate:

6
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Bureau of Energy Efficiency
 Paper 4 – SET A

i. Coal consumption in boiler per hour or per day.

ii. Power generation from co-generation plant
iii. If 10% is auxiliary power consumption in co-generation plant, how much power
is consumed by the textile industry per hour?
iv. What is the gross heat rate of turbine?

Ans
i. i) Boiler efficiency = Steam production ( steam enthalpy- Feed water enthalpy) /
Quantity of coal x G.C.V. of coal
Quantity of coal = 60,000 (810-80)/ 0.8 x 5000
= 10.95 tons/hr.

ii) Gross power generation from co-generation plant

Total enthalpy input to turbine = 60,000 x 810 = 48.6 Million kcal.

Total enthalpy out put through back pressure= 60,000* 660 = 39.6 Million kcal
Enthalpy difference = 48.6- 39.6 = 9 Million kcal/hr
Turbine,alternator and other losses =8% or 9x0.08 = 0.72 Million kcal/hr
Useful energy for power generation = 9- 0.72 = 8.28 Million kcal/hr
6
Power generation from co-generation plant = 8.28 x 10 /860 = 9628kWh

iii) If 10% is auxiliary power consumption in co-generation plant, power consumed by

textile industry

10% of total power generation = 9628 x 0.10 = 962.8kWh

Total power consumed by industries = 9628 – 962.8 = 8665.2kWh

Total steam consumption in paper plant 40 tons/hr. and specific steam consumption
5 ton/ton of paper. So Paper production per hour is 8 tons.

Specific power consumption = 600kWh/ton.

Total power consumption in paper industry = 8 x 600 = 4800kWh
Total power consumption in textile industry = 8665.2- 4800 = 3865.2 kWh

iv) Gross heat rate= Input enthalpy – output enthalpy/ gross generation
=( 48.6- 39.6) 106/ 9628 = 934.7 kCal/kWh

N-4 To attempt ANY ONE OF THE FOLLOWING among A, B, C and D

A A captive thermal plant is delivering an output of 29 MW at the generator terminal. The

generator efficiency is 96%. The steam generated in a utility boiler with an efficiency of
86% at 105 ata and 485oC is fed to the turbine. The turbine exhausts steam to
condenser maintained at 0.1 ata and 45.5oC. The feed water temperature at inlet to the
boiler is 105oC.

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Bureau of Energy Efficiency
 Paper 4 – SET A

The other data pertaining to captive power plant are,

Enthalpy of steam at 105 ata 485oC = 795 kcal/kg.

Dryness fraction of steam at inlet to condenser = 0.9
Enthalpy of dry saturated steam at 0.1ata =618 kcal/Kg.
o
Enthalpy of water at 0.1 ata & at 45.5 C = 45.5 kcal/Kg.
Loss in the gear box connecting turbine and generator = 1100 kW
Enthalpy of feed water at inlet to the boiler , = 105 kcal/Kg.

Based on the above data determine:

i. Output of the steam turbine in kW
ii. Steam flow through the turbine
iii. Turbine heat rate
iv. Unit heat rate

Ans
Enthalpy of steam at turbine exhaust = 45.5 +0.9 (618 – 45.5)
i.e. h3 = 560.75 Kcal/Kg.

Generator electric output = 29000 KW

Generator input = 29000 / 0.96 = 30208.33 KW

Loss in gear box = 1100 KW

Output of steam turbine = Generator input + Gear box loss
= 30208.33 + 1100
= 31308.33 KW

i) Output of the steam turbine Say = 31308 KW

ms = Steam flow through turbine

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Bureau of Energy Efficiency
 Paper 4 – SET A

= (Turbine output x 860)

(h2 – h3) Turbine enthalpy drop

h2 = Enthalpy at turbine inlet = 795 kcal/kg

h3 = Enthalpy at turbine exhaust = 560.75 kcal/Kg.
ms = 31308 x 860 / 795 – 560.75) = 114940.78 kg/Hr.
= 114.94 TPH
ii) Steam flow through the turbine Say = 115 TPH

iii) Turbine heat rate = Heat input to turbine / Generator output

= [ms (h2 – h1)] / 29000
= 115000 (795 – 105) / 29000
= 2736.2 kcal/ kWh

iv)Unit heat rate = Turbine heat rate / Efficiency of boiler

Unit heat rate = 2736.2 / 0.86 = 3181.63 kcal/ kWh

Or
B In a textile unit a stenter is delivering 80 meters/min of dried cloth at 5%
moisture. The moisture of wet cloth at inlet is 50%. The stenter is heated by
steam at 7 kg/cm2 with inlet enthalpy of 660 kcal/kg. and condensate exits the
stenter at 135 kcal/kg.

Other data
Latent heat of water evaporated from the wet cloth = 540 kcal/kg
Weight of 10 meters of dried cloth = 1 kg
Inlet temperature of wet cloth = 27oC
Outlet temperature of dried cloth at stenter outlet = 80oC.

i) Estimate the steam consumption in the stenter considering a dryer

efficiency of 48%.
ii) Determine the specific steam consumption kg/kg of dried cloth

Ans Output of stenter = 80 mts/min.

= 80 x 60 /10 = 480 Kg/hr.

Moisture in the dried output cloth = 5%

Wt of bone dry cloth = 480 X (1 – 0.05)
i.e. W = 456 Kg/hr.

mo =moisture in outlet cloth

=(480 – 456)/456 =0.0526 Kg./Kg. of bone dried cloth
Inlet moisture = 50%
Wt of inlet cloth = 456 / (1 – 0.50) = 912 Kg./hr.
mi = moisture in inlet cloth
= 912 X 0.5 / 456 = 1.00 Kg./Kg. bone dried cloth
Inlet temperature of cloth = 27oC
9
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Bureau of Energy Efficiency
 Paper 4 – SET A

Final temperature of cloth = 80oC

Heat load on the dryer = w x (mi – mo) X [(Tout – Tin) + 540] Kcal/hr.
.
Heat load on the dryer = 456 (1 – 0.0526) X [(80 – 27) + 540]
= 2,56,184.5 Kcal/hr

Efficiency of the dryer = 48%

Heat input to the stenter = 2,56,184.5 / 0.48 = 5,33,717.71 Kcal/hr

Steam consumption in
the stenter = 5,33,717.71 / (660 – 135)
= 1016.61 Kg/hr

Steam consumption per Kg. of dried at stenter outlet cloth

= 1016.61 / 480
= 2.12 Kg./Kg. dried cloth

Or

C Determine the cooling load of a commercial building for the following given data.
Outdoor conditions :
DBT = 35 C ; WBT = 25 C; Humidity = 18 g of water / kg of dry air
Desired indoor conditions :
DBT = 25.6 C ; RH = 50 %; Humidity = 10 g of water / kg of dry air
Total area of wall = 40 m2
Total area of window = 20m2
U – Factor ( Wall ) = 0.33 W / m2K
U – Factor ( Roof ) = 0.323 W / m2K
U – factor [ fixed windows with aluminum frames and a thermal break ] = 3.56 W / m2K
15 m x 25 m roof constructed of 100 mm concrete with 90 mm insulation & steel
decking.
CLTD at 17:00 h :Details : Wall = 12 C Roof = 44 C Glass Window = 7 C
SCL at 17 : 00 h :Details : Glass Window = 605 W/ m2
Shading coefficient of Window = 0.74
Space is occupied from 8:00 to 17:00 h by 25 people doing moderately active work.
Sensible heat gain / person = 75 W ; Latent heat gain / person = 55 W ; CLF for
people = 0.9

10
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Bureau of Energy Efficiency
 Paper 4 – SET A

Fluorescent light in space = 21.5 W/m2 FLF for lighting = 0.9

Ballast factor details = 1.2 for fluorescent lights & 1.0 for incandescent lights
Computers and office equipment in space produces 5.4 W/m2 of sensible heat
One coffee maker produces 1050 W of sensible heat and 450 W of latent heat.
Air changes / hr of infiltration = 0.3
Height of building = 3.6 m

Ans
I External Heat Gain

(i) Conduction heat gain through the wall =U – factor x net area of wall x CLTD
=[ 0.33 x 40 x 12 ] = 158.4 W
(ii) Conduction heat gain through the roof =U – factor x net area of roof x CLTD
=0.323 x ( 15 x 25 ) x 44 = 5 329.5 W
(iii) Conduction heat gain through the windows =U – factor x net area of windows x CLTD
= (3.56 x 20 x 7) = 498.4 W
(i) Solar radiation through glass = Surface area c Shading coefficient x SCL

=(20 x 0.74 x 605) = 8 954 W

II Internal Heat Gain

(i) Heat gain from people =Sensible heat gain + Latent heat gain

Sensible heat gain =(No.of people x Sensible heat gain / person x CLF)
=(25 x 75 x 0.9) = 1 687.5 W
Latent heat gain =No.of people x Latent heat gain / person
=(25 x 55 ) = 1 375 W
Therefore, Heat gain from people=(1687.5 + 1375 ) = 3 062.5 W

(ii) Heat gain from lighting =( Energy input x Ballast factor x CLF )

Energy input =( Amount of lighting in space / unit area ) x Floor area

=21.5 x ( 15 x 25 ) =8 062.5 W
Therefore, heat gain from lighting =( 8062.5 x 1.2 x 0.9 ) =8 707.5 W

11
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Bureau of Energy Efficiency
 Paper 4 – SET A

(iii) Heat generated by equipment :

Sensible heat generated by coffee maker =1050 W

Latent heat generated by coffee maker =450 W
Sensible heat gain by computers and office equipment = 5.4 x 375 = 2025 W
Therefore, Heat generated by equipment = 3 525 h

(iv) Heat gain through air infiltration =( Sensible heat gain + Latent heat gain )

Sensible heat gain =(1210 x airflow x T )

Airflow =( Volume of space x air change rate ) / 3600
={ (15 x 25 x 3.6 ) x 0.3 } / 3600
=0.1125 m3 / s
Therefore, sensible heat gain =1210 x 0.1125 x ( 35 – 25.6 ) = 1 279.58 W
Latent heat gain =3010 x 0.1125 x ( 18 – 10 ) = 2 709 W

No Space Load Components Sensible Heat Load (W) Latent Heat Load (W)

1 Conduction through exterior wall 158.4 ------

2 Conduction through roof 5 329.5 ------

3 Conduction through windows 498.4 ------

4 Solar radiation through windows 8954 ------

5 Heat gained from people 1 687.5 1 375

6 Heat gained from lighting 8 707.5 ------

7 Heat gained from equipment 3 075 450

8 Heat gained by air infiltration 1 279.58 2 709

Total space cooling load 29 689.88 4 534

Or
D During heat balance of a 5 stage preheater Kiln in a cement plant, the following data
was measured at Preheater (PH) Fan Inlet and clinker cooler vent air fan inlet:

12
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Bureau of Energy Efficiency
 Paper 4 – SET A

Parameter Temperature Static Avg. Specific Gas Duct

measured Pressure Dynamic heat Density Area
Pressure at STP
o
Unit C (Ps) mm (Pd) mm kcal/kg kg/m3 m2
o
WC WC C
PH Exit Gas 316 -650 28.6 0.248 1.4 2.27
at PH fan Inlet
Clinker cooler 268 -56 9.7 0.24 1.29 2.01
vent air at
cooler Stack
Fan Inlet

Note: take Pitot tube constant as 0.85, reference temperature 20 oC and atmospheric pressure
9908 mm WC.

Other Data
Clinker Designed specific NCV of Cost of Annual
Production volume of PH gas Coal coal Operation
TPH Nm3/kg clinker kcal/kg Rs./ton hrs
45.16 1.75 5500 6500 8000

Calculate the following:

i. Specific volume of PH gas as well as cooler vent air (Nm3/kg clinker)

ii. Heat loss in pre-heater exit gas (kcal/kg clinker)

iii. Heat loss in cooler vent air (kcal/kg clinker)

iv. If the measured specific volume of PH gas (Nm3/kg clinker) exceeds the design value,
calculate the heat loss (kcal/kg clinker) and annual monetary loss due to excessive
specific volume of PH gas.

Ans i. Density of Pre-heater gas at PH Fan Inlet at prevailing temp., pressure

conditions:

273 (9908 PS )
T,P STP
(273 T ) 10334
273 (9908 650)
T,P 1.40 = 0.581 kg/m3
(273 316) 10334
Velocity of PH gas
2 g Pd
v Pt
T,P

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Bureau of Energy Efficiency
 Paper 4 – SET A

2 9.8 28.6
v 0.85 = 26.4 m/sec
0.581
Volumetric flow rate of PH gas = velocity X duct cross-sectional area
= 26.4 X 2.27
= 59.9 m3/sec
= 59.9 X 3600
= 215640 m3/hr
Specific volume of PH gas = 215640 X 0.58/1.4
= 89491 Nm3/hr
= 89491/45160 = 1.98 Nm3/kg clinker

Similarly density of cooler vent air at cooler vent air fan Inlet at prevailing temp.,
pressure conditions:
273 (9908 PS )
T,P STP
(273 T ) 10334
273 (9908 56)
T,P 1.29 = 0.62 kg/m3
(273 268) 10334
Velocity of cooler vent air in the fan inlet duct
2 g Pd
v Pt
T,P

2 9.8 9.7
v 0.85 = 14.88 m/sec
0.62
Volumetric flow rate of PH gas = velocity X duct cross-sectional area
= 14.88 X 2.01
= 29.9 m3/sec
= 29.9 X 3600
= 107640 m3/hr
Specific volume of cooler vent air = 107640 X 0.62/1.29
= 51734 Nm3/hr
= 51734/45160 = 1.15 Nm3/kg clinker

ii)Heat loss in PH exit gas

Q1 = m ph c p T (Cp of PH gas = 0.248 kcal/kg oC)

Q1= 1.98 X 1.4 X 0.248 x (316-20)
= 203.5 kcal/kg clinker

iii) Heat loss in cooler vent air

Q2 = mCA c p T (Cp of cooler vent air = 0.24 kcal/kg oC)

Q2= 1.15 x 1.29 x 0.24 x (268-20)
= 88.3 kcal/kg clinker
14
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Bureau of Energy Efficiency
 Paper 4 – SET A

iv) Heat Loss due to excess specific volume of PH gas

Vexcess =1.98 – 1.75 = 0.23 Nm3/kg clinker

Heat loss Q = 0.23 x 1.4 x 0.248 x (316-20) = 23.6 kcal/kg clinker

Equivalent coal saving = 23.6/5500 = 0.0043 kg coal/kg clinker or ton of coal/ton of

clinker
Coal saving in one hour = 0.0043 x 45.16 = 0.194 TPH
Annual Coal Saving = 0.194 x 8000= 1552 tons of coal per annum
Annual Monitory Saving = 1552 x 6500 = Rs. 100.88 lakhs

-------- End of Section - III ---------

15
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Bureau of Energy Efficiency
 REGULAR Paper 4 – Set A

MODEL SOLUTIONS

16th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS – September, 2015

PAPER – 4:Energy Performance Assessment for Equipment and Utility

Systems

Date: 20.09.2015 Timings: 14:00-16:00 HRS Duration: 2 HRS

Max. Marks: 100

Section - I: BRIEF QUESTIONS Marks: 10

x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark

S-1 Why is the exhaust temperature of furnace oil fired systems limited to
about 1700C?
Ans Acid dew point due to presence of sulphur
S-2 The net present value of a energy conservation project is Rs.48,784/- and
the initial capital investment Rs,2,00,000/- calculate the profitability
index of the project.
Ans PI = 48784 = 0.244
2,00,000

S-3 The dry bulb and wet bulb temperatures of air entering an air washer are
35 and 28 0C respectively. If the saturation efficiency is 90 %, calculate
the air temperature leaving the air washer.

Ans 90% = 35 -Tout

35-28
 REGULAR Paper 4 – Set A

Tout = 28.7oC

S-4 Other than exhaust gas what is the major source of waste heat recovery
in a water cooled DG set?
Ans Engine jacket cooling water
S-5 In poorly loaded motor, current measurements are not a right indicator
of motor loading. Why?
Ans PF will be low.
S-6 If the condenser back pressure is 76 mm Hg, calculate the condenser
vacuum. if the atmospheric pressure is 745 mmHg.

Ans Condenser vacuum, mmHg = (Atmospheric pressure, mmHg –

Condenser back
pressure, mmHg)
= (745 - 76) = 669 mmHg.

S-7 If the coal GCV is 4000 kcal/kg and specific coal consumption is 0.65
kg/kWh, what is the power station gross efficiency?
(860 /(4000 x 0.65)) x100 = 33.07%

S-8 For a process requiring indirect heating to 200oC, thermic fluid is

preferred to steam as a heat carrier. Why?
Ans Because for steam to be heated to high temperatures, the pressure
required will be very high.
S-9 Between a natural gas fired boiler and oil fired boiler which will have a
higher percentage of hydrogen loss in flue gas? Why ?
Ans Gas fired boiler. Because the hydrogen percentage is more in natural gas
compared to oil.
S-10 After cleaning of choked AHU filter, AHU fan power increased. Why?

Ans Due to less resistance, the air flow increased.

…………. End of Section - I ………….

 REGULAR Paper 4 – Set A

Section - II: SHORT NUMERICAL QUESTIONS Marks: 2 x 5 =

10

(i) Answer all Two questions

(ii) Each question carries Five marks

L-1 A pump is drawing water through a 150 mm diameter pipe with a

suction head of 3.5 m below the pump centre line. Find out the pump
efficiency if the actual power input the motor is 17.6 kW at a motor
efficiency of 90 %. The discharge pressure is 4.5 kg/cm2 and the velocity
of water through the pipe as measured by an ultrasonic flow meter is 1
m/s.

Ans Discharge Head, kg/cm2 = 4.5

Suction Head, m = - 3.5
Total Head = 45 - (-3.5)
48.5 m
Flow rate = (22/7 x D2/4) x 1 m/s
= (22/7 x 0.152 / 4) x 1 m/s
= 0.0177 m3/sec

Hydraulic Power = 0.0177 x 1000 x 9.81 x

48.5/1000

= 8.42 kW

Pump Efficiency 8.42/(17.6x0.9)

= 53.2 %
 REGULAR Paper 4 – Set A

L-2 A luxury hotel is using a diesel fired heater with an efficiency of 70% for
supplying hot water at 55oC from an initial temperature of 20oC. The hot
water requirement is 24,000 litres per day.

The management is considering to install a specially designed electric

heat pump for the specific high hot water temperature requirement
with a heat pump coefficient of performance (C. O. P.) of 2. Find out the
reduction in daily operating cost with heat pump in place of diesel fired
heater ignoring auxiliary energy consumption. The following data are
given.

Electricity cost = Rs.10/kWh

Diesel cost = Rs.50/litre
G.C.V. of diesel = 9100 kcal/litre
Ans Solution:

Diesel required
For hot water heater = [24000 LitHotwater/ day ) x (55-20oC) x (1
kcal/LitoC)]
(0.7 Effy x 9100 kcal/Lit diesel )

= 131.9 Litdiesel /day

Diesel cost / day = 131.9 x 50 = 6595 Rs./day

COP = Heat pump refrigeration effect / Input electrical energy

Or

Input electrical energy, kW = Heat pump refrigeration effect, kcal

COP x 1 kW
Or

Input electrical energy, kW = Heat pump refrigeration effect, kcal

COP x 860 kcal/hr
 REGULAR Paper 4 – Set A

Electrical energy required with heat = 24000 x 1 x (55 – 20)

(2 x 860)
pump of COP = 2

Energy input with heat pump = 488.372 kWh/day

Operating cost with heat pump = 488.372 x 10

= 4883.72 Rs./day

Reduction in operating cost = 6595 – 4883.72

= Rs.1711.28 /day

…………. End of Section - II ………….

Section - III: LONG NUMERICAL QUESTIONS Marks: 4 x 20 = 80

(i) Answer all Four questions

(ii) Each question carries Twenty marks

N-1 In an organic chemical industry 10 Tonne per hour steam is generated at 10

Kgf/cm2 in a 12 TPH natural gas fired smoke tube boiler. The % oxygen in
the exit flue gas was 3.5% and the flue gas temperature was 190oC. The
following data have been provided.

Ultimate analysis of natural gas per kg ,

Carbon = 0.72 kg/kg; Hydrogen = 0.236 kg/kg; Nitrogen = 0.03
kg/kg; Oxygen = 0.011 kg/kg;

Specific heat of flue gas = 0.297 Kcal/kgoC

Specific heat of superheated water vapor = 0.45 Kcal/kgoC
G.C.V. of natural gas = 9100 Kcal/m3
Density of natural gas = 0.7
Density of air = 1.12 kg/m3
Enthalpy of steam at 10 kg/cm2 = 665 Kcal/kg
 REGULAR Paper 4 – Set A

Temperature of feed water at inlet to boiler = 95oC

Yearly hours of operation = 6000 hours

a. Find out the S/F (steam to fuel) ratio in kg steam/m3 gas

b. Estimate the annual reduction in carbon dioxide emission in
tones/year compared to the furnace oil fired boiler of 83%
efficiency on G.C.V. which was earlier used for delivering the
same steam load. Assume G.C.V. of furnace oil as 10300 Kcal/kg
and 0.86 carbon per kg. furnace oil.

Ans Ultimate analysis of natural gas per kg. of gas

Carbon = 0.72 kg/kg; Hydrogen = 0.236 kg/kg; Nitrogen = 0.03

kg/kg; Oxygen = 0.011 kg/kg;

Theoretical air required

= 11.6C + [34.8 (H2 – O2/8)] + 4.35S,
= 11.6 X 0.72 + [34.8 (0.236 – 0.011/8)]
(note S= sulfur in above composition is nil)
= 16.524 kg air/kg gas

% Excess Air = [% O2 / (21 - % O2)] x 100

= [3.5 / (21 – 3.5)] x 100 = 20%

Actual Air Supplied (AAS) = [1 + 0.2] x 16.524 = 19.83kg air / kg

gas

Mass of dry flue gas; mdfg = mass of combustion gases due to

presence C, N2,S in the fuel+mass of residual O2 in flue gas + mass
of N2 supplied with air

= 0.72 X 44/12 + 0.03 + (19.83 – 16.524) x 0.23 + 19.83 x 0.77

= 18.70 kg dfg / kg gas

L1 = % heat loss due to dry flue gases

REGULAR Paper 4 – Set A

mdfg x cpfg x (Tg – Ta)

= ------------------------------ X 100
G.C.V. of gas

Kcal / m3 9100
G.C.V. of gas = ----------- = --------- = 13000 Kcal/kg
Density 0.7

18.69 x 0.297 x (190 – 30)

= -------------------------------- X 100 = 6.84 %
13000

L2 = Loss due to presence of hydrogen forming water vapor

9H [584 + Cps x (Tg – Ta)

= ---------------------------------- X 100
G.C.V.

9 x 0.236 [584 + 0.45 (190 – 30)

= --------------------------------------------- x 100
13000
L2 = 10.72 %

Radiation and unaccounted losses in the boiler (given) = 1.45%

Total losses = 6.84 + 10.72 + 1.45 = 19%

Efficiency of natural gas fired boiler on = 100 – 19 = 81%

G.C.V. by indicated method

Steam to fuel ratio in kg steam/m3 gas= 0.81 x 9100 / (665 – 95) =

12.93

Amount of gas required for generation = (10,000 / 12.93) x 0.7

10 tonne/hr of steam
= 541.38 kg/hour
 REGULAR Paper 4 – Set A

CO2 emission with natural gas firing = 0.72 x 3.67 x 541.38

(1 kg carbon gives 44/12 i.e. 3.67 kg CO2)

= 1430.54 kg/hr

Furnace oil required for 10000 kg steam = (10,000 x 570) / (0.83

x 10,300)
= 666.74 kg/hr

CO2 emission with furnace oil firing = 0.86 x 3.67 x 666.74

= 2104.36 kg/hr

Net reduction in CO2 emission with = 2104.36 – 1430.54

natural gas compared to furnace
oil firing
= 673.82 kg/hr

Annual reduction in CO2 for 6000 hrs. = 673.82 x 6000

operation

= 4042.920 Tonnes

N-2 A gas engine-based trigeneration plant operates in two modes:

• Power and heating mode (10 hours per day) :

Pel= 650 kW of electricity and 325 kg/h of steam with enthalpy addition of
530 kcal/kg of steam & EUFheat = 0.85

• Power and cooling mode (14 hours per day) :

Pel = 650 kW of electricity and chilling load of 213 TR for absorption chillers
&
EUFcool = 0.73

• Calorific value of natural gas = 8500 kcal/Sm3

 REGULAR Paper 4 – Set A

• Average operating days/year = 330

• Alternator efficiency = 0.95
• The energy loss in the flue gas and that in the cooling water is same as
engine power output and other losses are negligible

Answer the following:

a. What is the average plant energy utilization factor

b. Calculate the useful energy produced daily by the trigeneration plant in
Gcal
c. Determine the daily plant natural gas requirements based on average
energy utilization factor
d. The plant proposes to install a 60 TR hot water driven Vapour
absorption chiller with a COP of 0.5 using waste heat from jacket cooling
water. Check if it is feasible with supporting calculations.

Ans 1) Plant average energy utilization factor

Plant average energy utilization

= (0.85 x 10 + 0.73 x 14)/24
factor
= 0.78

2) The useful energy produced daily by the trigeneration plant in

Gcal

PElect = 650 KW
QHeat = 325 x 530
= 172250 kcal/h
QCool = 213 x 3024
= 644112 kcal/h

Total daily useful energy (650 x 860 x 24 +172250 x 10

=
production of the plant + 644112 x 14)
13416000 + 1722500 +
=
9017568
REGULAR Paper 4 – Set A

The useful energy produced daily = 24156068 kcal/day

The useful energy produced in 24156068x 330 / 106
=
Gcal
= 7971.5 Gcal

3)The daily plant natural gas requirements

Input heat = 24156068 / 0.78

= 3096931795 kcal/day
Natural gas requirements = 3096931795 / 8500

= 3643 Sm3/day

4) Justification for a 60 TR Vapour Absorption chiller from waste

heat of the jacket cooling water

Heat required for operating 60 TR = 60 x 3024/0.5

at COP of 0.5 = 362880 Kcal/hr

650 /0.95
Power output of the engine =
684.2 KW

= 684.2 x 860
Heat in the jacket cooling water
= 588412 kcal/hr

Since the heat requirement (362880 kcal/hr) is much less than heat
available (588412 kcal/hr) the proposal is feasible.
 REGULAR Paper 4 – Set A

N-3 Hot effluent having a flow rate of 63450 Kg/hr at 80OC from the process is
sent to a heat exchanger for cooling. The outlet temperature of effluent in
the heat exchanger is 38 OC. Air having a flow rate of 370057 Kg/hr enters
the heat exchanger at a temperature of 30OC and leaves at 60 OC. Power
drawn by the fan is 30 KW. The plant works for 16 hours a day for 330 days
per year.

Now plant has decided to replace air cooled heat exchanger with a water
cooled counter current Heat Exchanger.

Given that Pump Efficiency = 75%, Motor efficiency = 90 %, Effectiveness

of water cooled heat exchanger is 0.4, water is available at 25 OC &
Pressure drop in plate heat exchanger is 1.2 kg/cm2 , Over all heat transfer
coefficient of heat exchanger is 22300 Kcal/m2/OC.

1. Calculate the savings due to replacement by water cooled heat

exchanger

2. Calculate the heat transfer area of heat exchanger.

Ans Solution:

Heat Duty
Heat duty in hot fluid = M x Cph x (Ti - To)
= 63450 x 1 x (80 - 38)
= 2664900 kcal / Kg

Heat duty in cold Air = M x Cpair x (to – ti)

= 370057 x 0.24 x (60 – 30)
= 2664410 Kcal / Kg

In heat exchanger, Heat duty in hot fluid = Heat duty in cold Air

Effectiveness of water cooled heat exchanger = 0.4

Cold Water outlet – Cold water inlet

Effectiveness = Hot effluent inlet – Cold water inlet
REGULAR Paper 4 – Set A

Cold Water Outlet = (0.4 x (80 – 25)) + 25

= 47 OC

Mass flow rate of cooling water (M) = Heat duty in hot fluid

Cp x (Cold water outlet – Cold water inlet)

= ___2664900
1 x (47 – 25) x 1000

= 121.13 m3 /hr

Pressure drop in Plate Heat exchanger = 12 m

Hydraulic Power Requirement for one Cooling Water Pump:

= (Flow in m3/Hr x Head in m x Density in Kg/m3 x g in m/s2)

(1000 x 3600)

= (121.13 x 12 x 1000 x 9.81)

(1000 x 3600)

= 3.96 KW

Pump Power Requirement at 75% pump efficiency = 3.96 KW

0.75
= 5.28 KW

Motor Input Power Required at 90% Efficiency = 5.28

0.9
= 5.87 KW

Savings = Power consumption by fans – Water Pumping Power

 REGULAR Paper 4 – Set A

= 30 – 5.87
= 24.13 KW

Annual Saving in kWh = 24.13 KW x 16 Hrs x 330 Days = 127406

KWh/Annum

Calculations for LMTD for Proposed HEx:

LMTD for counter current flow in HEx

= {(80-47) – (38-25)} / ln {(80-47) / (38-25)}

= 21.5 Deg C

Considering overall heat transfer coefficient (U) = 22300 kcal/m2/0C

Heat transfer Area = Q

(U x ∆Tlm)

= 2664900
(22300 x 21.5)

= 5.6 m2 (Say 6 m2)

N-4 Answer ANY ONE OF THE FOLLOWING among A, B, C and D

A) A steam power plant consisting of high pressure Turbine (HP Turbine) and
low pressure Turbine (LP Turbine) is operating on Reheat cycle(schematic
of power plant is represented below).Steam from Boiler at a pressure of
150 bar(a) and a temperature of 5500C expands through the HP Turbine.
The exhaust steam from HP Turbine is reheated in a Reheater at a constant
pressure of 40 bar (a) to 5500C and then expanded through the LP Turbine.
The exhaust steam from LP Turbine is condensed in a condenser at a
pressure of 0.1 bar (a).The isentropic efficiency of HP Turbine and LP
Turbine is same and is 90%. Generator efficiency is 95%
REGULAR Paper 4 – Set A

The other data of the power plant is as given below:

Main steam flow rate : 228 TPH

Enthalpy of main steam : 3450 KJ/kg
Enthalpy of feed water : 990.3KJ/kg
Isentropic Enthalpy of cold reheat steam : 3050 KJ/kg
Enthalpy of hot reheat steam : 3560 KJ/kg
Condenser pressure and temperature : 0.1 bar(a) and 45.80C
Isentropic enthalpy of LP Turbine exhaust steam : 2300 KJ/kg
Enthalpy of dry saturated steam at 0.1 bar(a) and 45.80C : 2584.9KJ/kg
Enthalpy of water at 0.1 bar(a) and 45.80C:191.9 KJ/kg

Based on the above data calculate the following parameters

(a) Power developed by the Generator
(b) Turbine heat rate
(c) Turbine cycle efficiency
(d)Dryness fraction of LP Turbine Exhaust steam
(e) Specific steam consumption of turbine cycle.
 REGULAR Paper 4 – Set A

Ans SOLUTION:

(A) Power developed by the Generator: Turbine output x Generator

efficiency--(1)

Turbine output = Q1 (H1 – h2) + Q2(H3 – h4)/860 MW ----------- (2)

Where, Q1= main steam flow rate =228 TPH
H1=main steam enthalpy=3450 KJ/Kg
h2=actual enthalpy at HP Turbine outlet (cold reheat enthalpy)
Q2=steam flow through reheater = 228TPH
H3=enthalpy of hot reheat steam = 3560 KJ/kg
h4= actual enthalpy of LP turbine exhaust steam

HP Turbine isentropic efficiency= Actual enthalpy drop/isentropic enthalpy

drop
0.9 = (H1- h2) / (H1-h2is)

h2is = isentropic enthalpy of cold reheat steam = 3050KJ/kg

0.9 = (3450 – h2) / (3450 - 3050)
h2= 3090 KJ/kg

LP Turbine isentropic efficiency= (H3—h4)/(H3—h4is),

h4is = isentropic enthalpy of LP Turbine Exhaust steam = 2300 KJ/kg

0.9 = (3560 - h4) / (3560 - 2300)
h4 = 2426 KJ/kg

Substituting the values in equation-2,we get

Turbine output = 228 x (3450 - 3090) + 228 x (3560 - 2426) / 860 = 75.73
MW
Generator output = 75.73 x 0.95 = 71.5 MW

(B) Turbine heat rate = Q1(H1- hfw) + Q2(H3 - h2)/Generator output

 REGULAR Paper 4 – Set A

=KJ/kWhr---(3)

hfw = enthalpy of feed water = 990.3KJ/kg

Substituting the values in the above equation-3, we get

Turbine heat rate = 228 (3450 - 990.3) + 228(3560 - 3090) / 71.5

= 9342 KJ/kWhr

(C) Turbine cycle efficiency = 860/Turbine heat rate

= 860x 4.18 / 9342 = 38.5%
(D) Dryness fraction of steam at 0.1 bar(a) and 45.8 oC

Actual enthalpy of LP Exhaust steam = enthalpy of water + dryness fraction

of steam x L.H of vaporisation of
steam
2426 = 191.9 + dryness fraction of steam x (2584.9 - 191.9)

Dryness fraction of steam = 93.35%

(E) Specific steam consumption of cycle = Steam flow / generator output

= 228 / 71.5 = 3.19 tons/MWhr

Or
B) Stenter operations in a textile process were significantly improved to
reduce inlet moisture from 60% to 55% in wet cloth while maintaining the
same outlet moisture of 7% in the dried cloth. The Stenter was operated at
80 meters/min in both the cases. The dried cloth weighs 0.1 kg /meter.
Further steps were taken to improve the efficiency of the fuel oil fired
thermic fluid heater from 80% to 82%, which was supplying heat energy to
the dryer. The other data and particulars are

Latent heat of water evaporated = 540kcal/kg,

Inlet temperature of wet cloth = 28oC ,
Outlet temperature of dried cloth = 80oC,
Dryer efficiency = 50% ,
G.C.V of fuel oil = 10,300 kcal/kg,
REGULAR Paper 4 – Set A

Yearly operation of the stenter = 5000 hours

a) Find out the % reduction in Dryer heat load ,

b) Estimate the overall yearly fuel savings in tonnes by reducing
moisture and efficiency improvement compared to the initial case.
Assume only energy for moisture evaporation for dryer heat load

Solution:

Initial case: Inlet moisture, 60%, outlet moisture 7%, dryer efficiency
50%, thermic fluid heater efficiency 80%

Output of stenter = 80 mts/min x 0.1 x 60

= 480 Kg/hr

Moisture in the dried output cloth = 7%

Wt. of bone- dry cloth = 480 X (1 – 0.07)

i.e. W = 446.4 Kg/hr.

mo= moisture in outlet cloth = (480–446.4) /446.4

= 0.0753 Kg/Kg. bone-dry cloth

Inlet moisture = 60%

Wt. of inlet cloth = 446.4 / (1 – 0.60) = 1116.00 Kg./hr.

mi = moisture in inlet cloth

= ((60/40) x 446.4)/446.4 = 1.5 Kg./Kg.
bone-dry cloth

Inlet temperature of cloth Tin = 28oC

Final temperature of clothTout = 80oC

Heat load on the dryer = w x (mi – mo) X [(Tout – Tin) + 540]

Kcal/hr.
.
. . Heat load on the dryer = 446.4 (1.5 – 0.0753) X [(80 –
REGULAR Paper 4 – Set A

28) + 540]
= 3,76,503.76 Kcal/hr

Efficiency of the dryer is 50%, Efficiency of the thermic fluid heater is

80%

Fuel oil consumption in the thermic fluid heater

= 3,76503.76/( 0.5x 0.8x10300) = 91.40 kg/hr

Improved case: Inlet moisture, 55%, outlet moisture 7%, dryer efficiency
50%, thermic fluid heater efficiency 82%

Inlet moisture = 55%

Wt of inlet cloth = 446.4 / (1 – 0.55) = 992.00 Kg./hr.

mi = moisture in inlet cloth

= ((55/45) x 446.4)) / 446.4
= 1.22 Kg./Kg. bone-dry cloth

Heat load on the dryer = w x (mi – mo) X [(Tout – Tin) + 540] Kcal/hr.
.
. . Heat load on the dryer = 446.4 (1.22 – 0.0753) X [(80 – 28) +
540]
= 3,02508.00 Kcal/hr

Efficiency of the dryer is 50%, Efficiency of the thermic fluid heater is

82%

Fuel oil consumption in the thermic fluid heater in impoved case

= 3,02,508.00/( 0.5x 0.82x10300) = 71.63

kg/hr
 REGULAR Paper 4 – Set A

(a) % reduction in dryer load due to reduction inlet moisture

(3,76,504 - 3,02,508) x 100

= -----------------------------------------
(3,76,504)

= 19.65%

(b) Saving in fuel oil consumption in improved case

= 91.4 - 71.63
= 19.77 kg/hr

Yearly fuel oil savings = 19.77x 5000 x 1/1000

= 98.85 tonnes

or
C) In a steel industry, the composition of blast furnace gas by volume is as
follows
CO – 27%, H2 - 2%, CO2 – 11%, N2 - 60%.

i) Calculate the stoichiometric air for combustion

ii) Calculate the gross calorific value of gas in kcal/Nm3
iii) Calculate the net calorific value of gas in kcal/Nm3
iv) If 3,00,000 Nm3/hr of gas is available and is to be co-fired in a coal
fired boiler. How much coal it can replace if the GCV of coal is 4000
kcal/kg.

Ans (i) Stoichiometric air for combustion:

C + O2 ------ CO2 + 8,084 kcal/kg Carbon

2C + O2 ------ 2 CO + 2,430 kcal/kg Carbon
H2 + ½O2 -------H2O + 28,922 kcal/kg Hydrogen
CO + ½ O2 -------CO2 + 5,654 kcal/kg Carbon
REGULAR Paper 4 – Set A

1 mole CO + 0.5 mole O2 ------ 1 mole CO2 + 5654 kCal/kg

For 27% CO, O2 required is (0.5/1) x 0.27 = 0.135 O2

1 mole H2 + 0.5 mole O2 ------ 1 mole H2O + 28922 Kcal/kg

For 2 % of H2, O2 required is (0.5/1) x 0.02 = 0.01 O2

Total stoichiometric oxygen required = 0.135 + 0.01 = 0.145 O2

Stoichiometric air required = 100 x 0.145 = 0.690 m3 air / m3 blast furnace

gas 21

(ii) Gross calorific value of gas:

1 kg mole of any gas at STP occupies 22.4 m3 of volume.

Therefore,

((5654 x 12) / 22.4) x 0.27 = 817,83 kCal/m3 (molecular weight of Carbon =

12)

((28922 x 2) / 22.4) x 0.02 = 51.64 kCal/m3 (molecular weight of Hydrogen =

2)

Gross Calorific Value = 817.83 + 51.64 = 869.5 kcal/m3

(iii) Replacement of coal by blast furnace gas:

Gross calorific value of coal = 4000 kcal/kg (given)

Blast furnace gas available = 3,00,000 m3/hr (given)
 REGULAR Paper 4 – Set A

Heat content available from gas = 3,00,000 m3/hr x 869.5 kcal/m3

= 2608.5 x 105 kcal/hr

If X is the coal quantity to be replaced, then

4000 kcal/kg x X = 2608.5 x 105 kcal/hr
X = 65212 kg/hr of coal can be replaced by gas of 3,00,000 m3/hr.

or
D) As an energy auditor, auditing a cement plant, it is essential to assess the
specific coal consumption for the production of the clinker. With the
following data available, calculate the specific coal consumption (kgCoal/
KgClinker).

S.No Parameter Value

1. Reference temperature 20Oc

2. Barometric pressure 10329

mmWC

3. Density of the Pre-heater at NTP 1.436kg/m3

4. Density of Air 1.293Kg/m3

5. Pitot Tube Constant 0.85

6. Clinker production rate 4127 TPD

7. Static Pressure of the Pre-heater gas in the pre- 640mmWC

heater duct
8. Dynamic pressure of the pre-heater gas in the duct 15.8mmWC

9. Temperature of the Pre-heater gas 320OC

 REGULAR Paper 4 – Set A

10. Specific heat of the Pre-heater gas 0.247kCal/kg

0
C

11. Area of the Pre-heater Duct 8.5 m2

12. Temperature of the exit clinker 128OC

13. Specific heat of the clinker 0.193

kCal/kg 0C

14. Static Pressure of the Cooler Exhaust gas in the duct 42mmWC

15. Dynamic pressure of the Cooler Exhaust gas in the 15.5mmWC

duct
16. Temperature of the Cooler Exhaust gas gas 290

17. Specific heat of the Cooler Exhaust gas 0.247kCal/kg

0
C

18. Area of the Cooler exhaust duct 7.1m2

19. Heat of Formation of Clinker 405

Kcal/KgClinker

20. All other heat loss except heat loss through Pre- 84.3 Kcal/Kg
heater gas, exiting clinker and cooler exhaust gases Clinker

21. All heat inputs except heat due to Combustion of fuel 29 Kcal/Kg
(Coal) Clinker

22. GCV of the Coal 5500Kcal/Kg

Ans Heat Lost in the along with the Exiting pre-heater gases:
REGULAR Paper 4 – Set A

QPH Gas = mphgas × Cpphgas × (tephgas-tr)

mphgas = VphgasX  Phgas
Vphgas = vph gas X A

Corrected density of the pre-heater gas:

10329  640 273
 Phgas = 1.436  
10334 273  320

= 0.6198 kg/ m3

Velocity (v) = Pt × [(2g(ΔPdynamic)avg /  Phgas)]0.5 m/sec

2  9.81  15.8
= 0.85  m/sec
0.6198
= 19.0 m/sec

VPH gas = 19.0m3/s X 8.5 m2

= 161.5 m3/sec
= 5,81,400m3/hr

Mph gas = 581400 m3/hr X 0.6198 kg/m3

=3,60,351/72 Kg/hr

mphgas = 3,60,351 kg/hr / 1,71,958 kg/hr = 2.095Kgph gas/ Kg clinker

QPH Gas = 2.095 X 0.247 X (320 -20)

= 155.24Kcal/KgClinker

Heat Lost in the along with the Exiting Hot Clinker:

QHot clinker = mclinker× Cpclinker× ( tclinker- tr)

= 1 x 0.193 x (128 – 20),
= 20.84 kCal/kgClinker
REGULAR Paper 4 – Set A

---- (2 marks)
Heat Lost in the along with the Exiting Cooler Exhaust gases:

QCooler Exhaust Gas = mCooler Exhaust Gas × CpCooler Exhaust Gas × (tCooler Exhaust Gas-tr)
mCooler Exhaust Gas = VCooler Exhaust Gas X  Cooler Exhaust Gas
VCooler Exhaust Gas = vCooler Exhaust Gas X A

Corrected density of the pre-heater gas:

10329  42 273
 Cooler Exhaust gas = 1.293  
10334 273  290
= 0.624 kg/ m3

Velocity (v) =Pt × √(2g(ΔPdynamic)avg /  Cooler Exhausts) m/sec

2  9.81  15.5
= 0.85  m/sec
0.624
= 18.76 m/sec

VcoolerExhaustgas = 18.76m/s X 7.1 m2

= 133.196 m3/sec
= 4,79,505m3/hr

McoolerExhaustgas = 479505 m3/hr X 0.624 kg/m3

=2,99,211 Kg/hr

mcoolerExhaustgas = 2,99,211 kg/hr / 1,71,958 kg/hr =1.74 KgcoolerExhaustgas/

Kg clinker

QcoolerExhaustgas = 1.74 X 0.244 X (290 -20)

= 114.63Kcal/KgClinker
REGULAR Paper 4 – Set A

Heat Input = Heat output

Heat Inputcoal + Heat inputothers = HeatClinker formation + HeatPH gas +

HeatClinker+ Heatcooler exhaust gas + Heatothers

GCVcoalX mcoal + 29 = 405 + 155.24 + 20.84 +114.63 + 84.3

mcoal = 751 / 5500

= 0.137 Kgcoal/Kgclinker

-------- End of Section - III ---------

Regular set A

Regn No: __________________

Name : __________________
(To be written by the candidate)

17th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS – September, 2016

PAPER – 4:Energy Performance Assessment for Equipment and Utility Systems

Date: 25.09.2016 Timings: 14:00-16:00 HRS Duration: 2 HRS

General instructions:
o Please check that this question paper contains 6 printed pages
o Please check that this question paper contains 16 questions
o The question paper is divided into three sections
o All questions in all three sections are compulsory
o All parts of a question should be answered at one place

Section - I: BRIEF QUESTIONS

S-1 An air washer cools the water and a cooling tower cools the air. True or False.
Ans False.
S-2 A 11 kW induction motor has an efficiency of 90% what will be its maximum delivered
output?
Ans 11 kW.
S-3 The COP of a vapour absorption refrigeration system is lower than the COP of a
vapour compression refrigeration system-True /false.
Ans True.
S-4 An industrial electrical system is operating at unity power factor. Addition of further
capacitors will reduce the maximum demand (kVA). True or False.
Ans False.
S-5 Which parameter in the proximate analysis of coal is an index of ease of ignition?
Ans Volatile matter.
S-6 The major source of heat loss in a coal fired thermal power plant is through flue gas
losses in the boiler. True or false.
Ans False.
S-7 With evaporative cooling, it is possible to attain water temperatures below the
atmospheric wet bulb temperature. True or False
Ans False
S-8 A pump is retrofitted with a VFD and operated at full speed. Will the power
consumption increase or decrease or remain the same?
Ans Increase
S-9 De-aeration in boiler refers to removal of dissolved gases. True or false

Ans True
Regular set A

S-10 In a compressed air system, the function of the after cooler is to reduce the work of
compression. True or False

Ans False
…………. End of Section - I ………….
Section - II: SHORT NUMERICAL QUESTIONS

L-1 In a petrochemical industry the LP & HP boilers have the same evaporation ratio
of 14 using the same fuel oil. The operating details of LP & HP boiler are given
below:
Particulars LP Boiler HP Boiler
Pressure 10 Kg./cm2a 32 Kg./cm2a
Temperature Saturated Steam 400oC
Enthalpy of steam 665 Kcal/kg 732 Kcal/kg
Enthalpy of feed water 80oC 105oC
Evaporation Ratio 14 14

Find out the efficiency of HP boiler if the LP boiler efficiency is 80%.

Ans Effy ᶯ = ER. (hg – hf) / GCV
EffyL.P ᶯ1 = 0.8 = 14 x(665 – 80) / GCV
EffyH.P ᶯ2 = 14 x(732 – 105) / GCV
EffyH.P ᶯ2 / EffyL.P ᶯ1 = (732 – 105)0.8 / (665 – 80) = 0. 8574 =85.74%

Or

EffyL.P ᶯ1= 0.8 = 14 x(665 – 80) / GCV

GCV= 14x(665-80) / 0.8 = 10237.5kcal/kg
EffyH.P ᶯ2 = 14 x(732 – 105) / GCV
= 14 x(732 – 105) / 10237.5 = 0.8574 = 85.74%

L-2 While carrying out an energy audit of a pumping system, the treated water flow
(in open channel) was measured by the tracer method. 20% salt solution was
used as the tracer which was dosed @ 2 lts/min. The water analysis about 500
mtrs away revealed salt concentration of 0.5%. Assuming complete mixing and
no losses, calculate the water flow rate.
Ans 20% salt solution = 200 gms of salt in 1 Litre of water
0.5% salt solution = 5 gms of salt in 1 litre of water
Dosing rate = 2 lts/min
Salt added in water = 2 x 200 = 400 gms/min
Total flow = 400/5 = 80 lts/min
Water flow rate = 80 – 2 = 78 lts/min
Or

C1V1 = C2V2
V2 = C1V1/C2 = 0.2x2/0.005 =80 lts/min
Actual flow = total flow – dosage flow = 80-2 =78 lts/min

…………. End of Section - II ………….

Regular set A

Section - III: LONG NUMERICAL QUESTIONS

N-1 In a chemical plant, a 3000 Million Cal/hr cooling tower with one CW pump caters to the
cooling water requirements. The management had decided to refurbish the cooling tower
as its performance is felt to be low. The operating parameters of the CW system before
and after refurbishment are presented below.

S.No Parameter Before After

refurbishment refurbishment
1 CW inlet temp to CT 35oC 35oC
2 Atmospheric air WbT -25 oC, WbT -25 oC,
conditions DbT - 38 oC DbT - 38 oC
3 COC 3.5 5
4 Suction head of CW -1m -1m
pump
5 Discharge pressure of 4kg/cm2(g) 4kg/cm2(g)
CW pump
6 Efficiency
CW Pump 54% 53%
CW Pump motor 89% 89%
CT fan 55% 54%
CT fan motor 90% 90%

7 Pressure developed by 20mmwc 20mmwc

CT fan
8 Effectiveness of CT 60 % 70%
9 L/G ratio 1.5 1.5
10 Density of air 1.29kg/m3 1.29kg/m3

As a result of cooling tower refurbishment the effectiveness has increased from 60% to 70
%. Also with improved water treatment the COC has increased to 5.

Find out
1. Reduction in power consumption of pump and fan due to improvements in cooling
tower.
2. Reduction in make up water consumption (ignoring drift losses) in KL/day
Regular set A

Ans

Paramet Equation / Before After refurbishment

er formulae refurbishment
Effectiven = (TCWi-TCW0)/(TCWi- 0.6=(35- TCWO)/(35- 0.7=(35- TCWO)/(35-
ess WbT) 25) 25)
TCWO = 29 oC TCWO = 28 oC
CW flow = heat load/( TCWi- =(3000x106/103) / ( =(3000x106/103)/(35-
rate Q TCW0) 35- 29) 28)
= 500000 kg/h = 428571 kg/h
= 500 m3/h = 429 m3/hr
Evaporati =1.8*.00085*CW 1.8x0.00085x500x 1.8x.00085x429x(35-
on loss flow x Range (35-29) 28) = 4.59 m3/h
= 4.59 m3/h
Blow = Evaporation = 4.59/(3.5-1) 4.59/(5-1)
down loss Loss/(COC-1) = 1.84 m3/h = 1.15 m3/h
Total = Eva loss+ Blow = 4.59+1.84 =4.59+1.15
water down loss =6.43 m3/h =5.74 m3/h
loss
Make-up = Total water loss = 6.43 x 24 = 5.74 x 24
water x 24hrs = 154.2 m3/day = 137.76m3/day
=154.2KL/day =137.76 KL/day
Total = discharge head- = 40-(-1) = 41 mWC = 40-(-1) = 41 mWC
head H suction head
Pump = = =
LKW ((Q*1000/3600)*(H* (500*1000/3600)*(41 (429*1000/3600)*(41
9.81))/1000 *9.81)/1000 *9.81)/1000
= 55.86KW = 47.9 kW
Pump = Pump =55.86/0.54 = 47.9/0.53
input LKW/Eff.Pump =103.4 kW =90.4 kW
Motor = Pump = 103.4/0.89 =90.4/0.89
input input/motor eff =116.2 kW = 101.6kW
Air flow in =[( CW flow)x1000]/ = =
CT fan [((L/G)]*1.29) (500x1000/(1.5x1.29) (429x1000/(1.5x1.29
Qf = 258398 m3/h )
= 221705m3/h
Hf Pressure developed = 20mmWC = 20mmWC
by fan Hf
Air KW = [(Qf in m3/h)*(Hf =(258398*20)/(3600* =(221705*20)/(3600*
in 102) 102)
mmWC)]/(3600*102 =14.07 kW = 12.08 kW
)
Fan =Air KW/(FanEffi x =14.07/(0.55*0.9) =12.058/(0.54*0.9)
motor Motor Eff) = 28.43kW = 24.9 kW
input

(1) Reduction in power of pump and motor = (116.2+28.43) - (101.6+24.9) = 18.13 kW

(2) Reduction in makeup water = 154.2-137.76 = 16.44 or 16.5 KL/day

Regular set A

N-2 In a beverages industry the product stream (liquid) flowing at a rate of 5000 kgs/hr at 90 oC
is first cooled in counter type cooling water (CW) heat exchanger to 55 oC and then by a
chilled water (ChW) heat exchanger, to reduce temperature of the product to 11oC. The
specific heat of the product is 0.9 kCal/kgoC. The other operating data and parameters are:

Cooling Water heat exchanger Chilled Water heat exchanger

Inlet temp Outlet temp Inlet temp Outlet temp
Product 90oC 55 oC Product 55oC 11 oC

Cooling 25 oC 32 oC Chilled 7 oC 12 oC
Water water

The chilled water is supplied by a reciprocating chiller, whose motor is drawing 60 KW with
a motor efficiency of 87%. The management decides to upgrade cooling water heat
exchanger by providing additional heat exchanger area to further enhance heat recovery
i.e. to reduce the temperature of product at its outlet to 40oC.
A. Depict the heat exchanger in existing and upgraded (improved) heat recovery case
in a simple block diagram
B. Calculate

i. The additional heat exchanger area (as a % of the existing area) for cooling water
heat exchanger, assuming there is no change in cooling water circulation rate and
the overall heat transfer coefficient.
ii. The COP of the chiller.
iii. Reduction in refrigeration /chiller load and yearly energy savings at 600 hours per
month operation, assuming energy consumption is proportional to load delivered.
Regular set A

Ans (A) Existing

mh = 5000 Kg/hr, 90oC product 55oC 11oC
Cooling water heat Chilled Water heat exchanger
Δ T1 exchanger area (A1) Δ T2

cw.out 32oC
ch.w out 12oC ch.w in 7oC

cw.in 25oC To chiller From chiller

Heat load on CW heat exchanger = heat gained by CW

Heat rejected by product stream
Q1 = mc X 1 X (Δ Tc) = 5000 X 0.9 X (90 – 55)
Q1 = 1,57,500 Kcal/hr
mc = Cooling Water flow rate = (5000X0.9 X 35)/(32 – 25)
= 22,500 Kg/hr.
Heat exchanger duty with increased heat = 5000 X 0.9 X (90 – 40)
recovery Q2 = 2,25,000 Kcal/hr
Cooling water temp. Rise with increased heat = 5000 X 0.9 X (90 – 40)
exchanger duty for cooling product stream to ------------------------------ = 10oC
40oC 22,500

Cooling water outlet temp with the above case = 25 + 10 = 35oC

(A) Upgraded
mh = 5000 Kg/hr, 90oC product 40oC 11oC
Upgraded Cooling water heat Chilled Water heat exchanger
Δ T1 exchanger area (A2) Δ T2

cw.out 35oC
ch.w out 12oC ch.w in 7oC

cw.in 25oC To chiller From chiller

…..2.5 marks
Δ T1 - Δ T2
LMTD1 with existing case = ----------------------
Ln Δ T1 / Δ T2

(90 – 32) –(55 – 25)

= -------------------------------- = 42.49oC
Ln (90 – 32) / (55 – 25)
Regular set A

(90 – 35) – (40 – 25)

LMTD2 with additional heat recovery = -------------------------------- = 30.77oC
Ln (90 – 35) / (40 – 25)

Q2 = U X A2 X LMTD2 Q1 = U X A1 X LMTD1
Q2 = 2,25,000 = U X A2 X 30.77 Q1 = 1,57,500 = U X A1 X 42.49

A2 / A1 = (2,25,000 /1,57,500) X (42.49 / 30.77) = 1.973

Additional area required = 97.3% of existing heat exchanger area of CW

heat exchanger
Refrigeration load in existing = 5000 X 0.9 X (55 – 11)
case
= 1,98,000 Kcal/hr
= 1,98,000 /3024
= 65.476 TR
Motor input power = 60 KW
Motor eff. = 87%
C.O.P. of refrigeration chiller = 198000 /( 60 X 0.87 X 860)
= 4.41
Input KW / TR = 60 / 65.476 = 0.916
Reduction in refrigeration load = 5000 X 0.9 X (55 – 40) / 3024
due to lower input temperature = 22.32 TR
of the product to chilled water
heat exchanger
= 22.32 X 0.916 X 600 X 12
Yearly energy savings at 600 1,47,204.86 Kwh
hrs. operation per month =

N-3 In a continuous process industry Steam and Power are supplied through a cogeneration
plant interconnected with grid. The design and actual operating parameters of the
cogeneration plant as represented in the schematic are given in the table below.

Double Extraction – Condensing Steam Turbine Cogeneration System

Regular set A

Design actual
B- Boiler 68.75tph,
75tph,64kg/cm2(a), 450oC @82%
64kg/cm2(a), 450oC
efficiency
@81% efficiency
T- Steam Turbine Double Extraction – Condensing type
G- Generator 10MW 7.2MW

Stream Steam flow location Steam Flow Steam Steam Steam

Ref (tph) Pressure Temp (oC) enthal
(kg/cm2) py
(kCal/k
g)
1 Steam input to 68.75 64 450 745
turbine
2 First extraction 18.75 17 270 697
3 Second extraction 31.25 9 200 673
Condenser in 18.75 0.1 - 550
4
Condenser out 18.75 - - 46

The industry is installing a 1200 TR double effect absorption chiller to meet the
refrigeration load due to product diversification. Additional steam will be generated by the
boiler, which will go into the turbine and be extracted at 9kg/cm 2(a) to meet the VAM
requirement. The additional power thus generated will reduce the imported grid power.

The following additional data has been provided:

Maximum allowable steam flow the extraction at 9
40 TPH
Kg/cm2a
Minimum allowable steam to condenser 9 TPH
Critical power requirement of the plant 3800 KW
Power import from grid 500 KW
Cost of grid power Rs.4.25 / Kwh
G.C.V. of coal 4000 Kcal/Kg.
Cost of coal Rs. 4000/ton
Feed Water temperature 105oC
Feed Water enthalpy 105 Kcal/Kg.
Combined efficiency of gear box and generator 96%
Steam requirement for double effect absorption chiller 4.5 Kg./TR hr at 9 Kg/cm2a
Annual hours of operation. 8000 hrs/y
Steam rate at 9 Kg/cm2a at 2nd extraction for 1 KW
12 (Kg/hr)/kW
turbine output
Ignore auxiliary power consumption and also return condensate from extracted steam to
process.

Calculate
(i) The Energy Utilization Factor (EUF) for the existing operating case
(ii) The net additional annual operating cost, after installation of VAM.
(iii) The Energy Utilization Factor (EUF) after installation of VAM.
Regular set A

Ans (i) Q thermal + P electrical

Energy Utilization Factor (EUF) = -----------------------------------
(before VAM installation) Fuel Consumption X G.C.V.

Q thermal = m2 h2 + m3h3 + m4h’4

m (h1 – hf)
Q in = -------------
 X G.C.V.

Q thermal = 18750 X 697 + 31250 X 673 + 18750 X 46

= (18.75 X 697 + 31.25 X 673 + 18.75 X 46) X 103 Kcal/hr
= (13068 X 21031 + 862.5) X 103 Kcal/hr
= 34962.5 X 103 Kcal/hr

Pe = 7200 X 860
= 6192 X 103 Kcal/hr

(745 – 105) X 68.750x1000

Fuel Consumption = -------------------------- = 13.58 TPH
0.81X 4000 X 1000

34962.5 X 103 + 6192 X 103

EUF = ---------------------------------- -x 100 = 75.76%
13.58 X 103 X 4000

(ii)
Refrigeration Load = 1200 TR

1TR requires 4.5 Kg./hr steam at 9 Kg./cm2a

Steam consumption in double effect absorption chiller = 1200 X 4.5
= 5400 Kg./hr.
Increase in steam extraction at 9 Kg./ cm2a = 5400Kg/hr

Every 12 Kg./hr extraction at 9 kg/ cm2a gives 1 KW output at turbine ,

efficiency of generator and gear box = 0.96

Additional power recovery due to increase in extraction = (5400 / 12) X 0.96

= 432 KW

Additional coal consumption due to increase in extraction

= (745 – 105)X 5400/(0.81x4000)
= 1066 kg/h
Additional cost of coal = 4000x1.066 = Rs 4266.6 /hr
…..2 marks
Monetary realisation by reducing import cost of purchased electricity = 4.25 Rs./unit
= 432 X 4.25
= 1836 Rs./hr
Regular set A

Net additional annual operating cost after VAM installation = (4266.6-1836)*8000

= Rs 1.94 crore/y

(iii)
Stream Steam flow Steam Steam Steam Steam
Ref location Flow Pressure Temp enthalpy
(tph) (kg/cm2) (oC) (kCal/kg)
1 Steam input to 68.75+5.4 64 450 745
turbine =74.15
2 First extraction 18.75 17 270 697
3 Second extraction 31.25+5.4 9 200 673
=36.65
Condenser in 18.75 0.1 - 550
4
Condenser out 18.75 - - 46

Q thermal + P electrical
Energy Utilization Factor (EUF)= -----------------------------------
(after VAM installation) Fuel Consumption X G.C.V.

Q thermal = m2 h2 + m3h3 + m4h’4

m (h1 – hf)
Q in = -------------
 X G.C.V.

Q thermal = 18750 X 697 + 36650 X 673 + 18750 X 46

=(18.75 X 697 + 36.65 X 673 + 18.75 X 46) X 103 Kcal/hr
= (13068 X 21031 + 862.5) X 103 Kcal/hr
= 38596.7 X 103 Kcal/hr

Pe = (7200+432) X 860
= 6563.5 X 103 Kcal/hr

Fuel Consumption = 13.58 TPH +1.066 TPH = 14.646TPH

38596.7 X 103 + 6563.5 X 103

EUF = ----------------------------------------x100 = 77.08%
14.646 X 103 X 4000

Answer ANY ONE OF THE FOLLOWING among A, B, C and D

N-4
A) The operating parameters observed w.r.t. design in a 110 MW power generation unit are
given below:
Regular set A

Parameters Design Operation

Generator output 110 MW 110 MW

Steam generator outlet super heat 540oC 525oC
temperature

Steam generator outlet pressure 140 Kg/cm2a 130 Kg/cm2a

Feed water inlet temperature 135oC 135oC
Boiler  87.5% 87.5%
GCV of Coal 3800 3800
Turbine exhaust pressure 0.09 0.11
Kg./cm2a Kg./cm2a
Dryness fraction of exhaust steam 0.87 0.89

Turbine heat rate 2362.5 Kcal ------

/Kwh

Efficiency generator 96% 96%

Energy loss in gear box 4420 KW 4420 KW
Enthalpy of steam at 520oC, 130 Kg/cm2a, 810
Kcal/Kg.
Enthalpy of steam at 0.11 Kg./cm2a 550
Kcal/Kg

Calculate the
I. Actual steam flow to the turbine
II. Specific steam consumption of turbine
III. % increase in gross unit heat rate compared to design
IV. Increase in monthly (720 hours/month) coal consumption due to deviation in
operation w.r.t. design at a plant load factor of 80%
Ans
Generator output = 110 MW
 of generator 96%
Generator input = 110 / 0.96
= 114.58 MW

Energy loss in gear box = 4420 KW

= 4.42 MW

Turbine output = Total input at gear box +

energy loss in gear box
Turbine out put = 114.58 + 4.42
= 119 MW

Turbine out put = ms (810 – 550) X (1 / 860)

Regular set A

ms (810 – 550) X (1 / 860) = 119 X 1000

Steam flow rate through the = 3,93,615 Kg /hr
turbine = 393.615 Tonne/hr

Specific steam consumption = (393.615 X 1000) / (110 X

1000)
= 3.58 Kg./kW
Boiler  = Ms (hg – hw)
--------------- X 100
GCV X mf
393615 (810 – 135)
Coal consumption mf -------------------------
0.875 X 3800
79906.8 Kg./hr

= 79906.8 / (110 X 1000)

Specific coal consumption = 0.726 Kg./Kwh

Actual unit heat rate = 0.726 X 3800

= 2758.8 Kcal/Kwh

Design turbine heat rate 2362.5 Kcal / KW

 of steam generator or boiler 87.5%
Design unit heat rate = 2362.5 / 0.875
= 2700 Kcal/Kwh
% increase in heat rate w.r.t. = [(2758.8 – 2700) / 2700] X 100
design = 2.17 %
Specific coal consumption for = 2700/3800
design heat rate = 0.71kg/kwh
= (0.726 – 0.71) X 110 X 1000 X 0.8 X 720
------------------------------------------------
Additional coal consumption per 1000
month with a PLF of 80% 1013.76 tonnes
=
Or
B) In a textile process house the production from the stenter machine is 72000 mtrs per day.
The effective operation of stenter is 20 hours per day. The percentage moisture in the
dried cloth (output) is 6% and its temperature is 75oC and wet cloth inlet is at 25oC . The
stenter is heated by steam at 8 kg/cm2a and the daily steam consumption for the stenter is
16.5 tonnes. The efficiency of the stenter dryer is 47%. Calculate the
(i) Linear speed of the stenter machine
(ii) Inlet moisture
(iii) Feed rate of the stenter.

The following data have been provided

Weight of 10 meter of dried cloth = 1 kg.
Enthalpy of the steam to the stenter = 665 kcal/kg.
Regular set A

Enthalpy of condensate at the exit of stenter = 130 kcal/kg.

Ignore losses in start-up and stoppage.

Ans Production per day = 72000 meters

Actual hours of operation = 20 hours/ day
Linear speed of the stenter = 72000 / (20x60) = 60 meters per min

Dried cloth output = 72000 / (20x10) = 360 kg/hr.

Moisture in dry cloth = 6%

Bone dry cloth = 360 x 0.94 = 338.4 kg/hr

Moisture in outlet cloth mo = (360 – 338.4) / 338.4

= 0.0638 Kg./Kg. bone dry cloth

Steam consumption per day = 16.5 tonnes

= 16500 / 20 = 825 Kg./hr.

Heat load on the dryer =Energy input in steam x Dryer Efficiency

= Steam flow rate x (Enthalpy steam – Enthalpy condensate) x Efficiency Dryer
= 825 x (665 – 130) x 0.47
= 207446.3 Kcal/hr.

Further Heat load on the dryer = w x (mi – mo) X [(Tout – Tin) + 540] Kcal/hr.
w =weight of bone dry cloth rate kg/hr
mi = weight of cloth inlet moisture Kg./Kg. bone dry cloth
Tout = dried cloth outlet temperature= 75oC
Tin = wet cloth inlet temperature = 25oC

338.4 x (mi – 0.0638) X [(75 – 25) + 540] = 207446.3 Kcal/hr

mi = 1.1028 Kg./Kg. bone dry cloth(1.1028) / (1.1028+1)x100
% inlet moisture in wet cloth = 52.44 %

total moisture in inlet cloth = 1.1028x338.4= 373.2 kg/hr

feed rate(inlet cloth rate), = total inlet moisture/hr +bone dry cloth/hr
= 373.2+338.4
= 711.6 Kg./hr.

or
C) The preheater exhaust gas from a cement kiln has the following composition on dry basis
:CO2 – 23.9%, O2 – 5.9%, CO – 0.2%, remaining is N2. The static pressure and
temperature measured in the duct are -730 mmWC and 3500C respectively. The velocity
pressure measured with a pitot tube is 19 mmWC in a duct of 2800 mm diameter ( Pitot
tube constant = 0.89 ). The atmospheric pressure at the site is 10350 mmWC and
universal gas constant is 847.84 mmWCm3/kg mol k. The specific heat capacity of
preheater exhaust gas is 0.25 kcals/kg0C.
Regular set A

The static pressure developed by PH exhaust fan is 630mmWC and power drawn is 1582
kW. Calculate the efficiency of fan given that the motor efficiency is 92%.

The management had decided to install a 1.3 MW power plant with a cycle efficiency of
15% by using this preheater exhaust gas. Calculate the exhaust gas temperature at the
outlet of waste heat recovery boiler of the power plant.
Ans Molecular weight exhaust gas (dry basis) M
= %CO2xMCO2 + %O2xMO2 + %COxMCO + %N2 x MN2
= {(23.9 x 44) + (5.9 x 32) + (0.2 x 28) + (70 x 28)}/100
= 32.06 kg/kg mole

Exhaust Gas density at operating temperature = γ = [ PM / RT ]

= [ (10350 – 730) x 32.06 ) / { 847.84 x (273+350) }
= 0.584 kg/m3

Duct Area = 3.14 x( 2.8/2) 2= 6.15 m2

Volume flow rate

=A Cp (2 x g x ∆P / γ)1/2 = 6.15 x 0.89 (2 x 9.81x 19 /0.584)1/2
= 138.3 m3/s
Volume flow rate= 497880 m3/ h

Fan efficiency = volumetric flow rate x pressure developed

(102 x power drawn x motor eff)

= 138.3 x 630 x100 = 58.69%

(102x1582x0.92)

Mass flow rate of preheater exhaust gas = Volume flow rate x density
= 497880*0.584 = 2,90,762 kg/hr

Heat equivalent of power generated from power plant =1.3MW =1300 x 860
= 1118000 kCals/hr

Heat given up to power plant by exhaust gas = 290762 x0.25 x(350-To)x0.15

To = 350 - (1118000/(290945x0.25x0.15)) = 247.50C

or
D) For a commercial building, using the following data,
(i) Determine the building cooling load in TR
(ii) Calculate the supply air quantity to the cooling space in m3/s

Outdoor conditions : DBT = 40C, WBT = 28C, Humidity = 19 g of water / kg of dry air
Desired indoor conditions : DBT = 25C, RH = 60 %, Humidity = 12 g of water / kg of dry
air
Regular set A

Total area of wall = 324 m2, out of which 50% is window area.

U – Factor ( Wall ) = 0.33 W/m2K

U – Factor ( Roof ) = 0.323 W/m2K
U – factor [ fixed windows with aluminium frames and a thermal break ] = 3.56 W/m2K
Other data:

 20 m x 25 m roof constructed of 100 mm concrete with 90 mm insulation & steel

decking.
 CLTD at 17:00 hr : Details : Wall = 12C; Roof = 44C; Glass Window = 7C
 SCL at 17 : 00 hr : Details : Glass Window = 605 W/ m2
 Shading coefficient of Window = 0.74
 Space is occupied from 8:00 to 17:00 hr by 30 people doing moderately active
work.
 Sensible heat gain / person = 75 W ; Latent heat gain / person = 55 W ; CLF for
people = 0.9
 Fluorescent light in space = 21.5 W/m2 ; CLF for lighting = 0.9
 Ballast factor details = 1.2 for fluorescent lights & 1.0 for incandescent lights
 Computers and office equipment in space produces 5.4 W/m2 of sensible heat
 One coffee maker produces 1050 W of sensible heat and 450 W of latent heat.
 Air changes/hr of infiltration = 0.3
 Height of building = 3.6 m
 Supply air dry bulb temperature is 150C
Ans (i) Cooling Load Determination:

I. External Heat Gain

(i) Conduction heat gain through the wall = U – factor x net area of wall x CLTD
= 0.33 x (324*0.5) x 12 ] = 641.5 W

(ii) Conduction heat gain through the roof = U – factor x net area of roof x CLTD
= 0.323 x ( 20 x 25 ) x 44
= 7106 W

(iii) Conduction heat gain through the windows = U – factor x net area of windows x CLTD
= (3.56 x 162 x 7) = 4037 W

(iv) Solar radiation through glass

= Surface area x Shading coefficient x SCL
= (162 x 0.74 x 605) = 72527 W

II. Internal Heat Gain

(i) Heat gain from people =Sensible heat gain + Latent heat gain
Regular set A

Sensible heat gain = (No. of people x Sensible heat gain / person x CLF)
=(30 x 75 x 0.9) = 2025 W

Latent heat gain = No. of people x Latent heat gain / person

= (30 x 55 ) = 1650 W
Therefore, Heat gain from people = (2025 + 1650 ) = 3675 W

(ii) Heat gain from lighting = (Energy input x Ballast factor x CLF)
Energy input = (Amount of lighting in space / unit area)x Floor area
= 21.5 x (20 x 25) = 10750 W

Therefore, heat gain from lighting = (10750 x 1.2 x 0.9) =11610 W

(iii) Heat generated by equipment :

Sensible heat generated by coffee maker =1050 W

Latent heat generated by coffee maker = 450 W
Sensible heat gain by computers and office equipment = 5.4 x 500 = 2700 W
Therefore, Heat generated by equipment = 4200 W

(iv)Heat gain through air infiltration = (Sensible heat gain + Latent heat gain)

Sensible heat gain =(1210 x airflow x ∆T )

Airflow = (Volume of space x air change rate ) / 3600
= { (20 x 25 x 3.6 ) x 0.3 } / 3600
= 0.15 m3 / s

Therefore, sensible heat gain =1210 x 0.15 x ( 40 – 25 ) =2722.5 W

Latent heat gain =3010 x 0.15 x ( 19 – 12 ) =3160.5 W

No. Space Load Components Sensible Heat Load Latent Heat

(W) Load (W)
1. Conduction through exterior wall 641.5 ---
2. Conduction through roof 7106 ---
3. Conduction through windows 4037.0 ---
4. Solar radiation through windows 72527 ---
5. Heat gained from people 2025 1650
6. Heat gained from lighting 11610 ---
7. Heat gained from equipment 3750 450
8. Heat gained by air infiltration 2722.5 3160.5
Total space cooling load 104419 5260.5
Total Cooling Load = 109679.5W/3516 =31.2 TR

(ii) Supply Air Quantity Calculation:

Supply air flow = Sensible heat gain / {1210 * (Room dry bulb temperature
– Supply dry bulb temperature)}
= 104419 W / {1210 J/m30K*(25 – 15)0C}
= 8.63 m3/s
Regular set A

-------- End of Section - III ---------

 Paper 4 – Set A with Solutions

Regn No: __________________

Name : __________________
(To be written by the candidate)

18th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS – September, 2017

PAPER – 4:Energy Performance Assessment for Equipment and Utility Systems

Date:24.09.2017Timings: 14:00-16:00 HRS Duration: 2 HRS Max. Marks: 100

General instructions:
o Please check that this question paper contains 7 printed pages
o Please check that this question paper contains 16 questions
o The question paper is divided into three sections
o All questions in all three sections are compulsory
o All parts of a question should be answered at one place

Section - I: BRIEF QUESTIONS Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark

S-1 A rise in conductivity of boiler feed water indicates a rise in ____ level of feed water.

Ans TDS

S-2 In a parallel flow heat exchanger the hot fluid inlet temperature is 150 °C . The cold
fluid inlet and outlet temperatures are 45 °C and 60 °C. Calculate the effectiveness.

Ans = 15/105 =0.14

S-3 Integrated Part Load Value (IPLV) in a vapour compression refrigeration refers to
average of ____with partial loads

Ans kW/TR

S-4 A pure resistive load in an alternating current (AC) circuit draws only reactive power
– True or False

Ans False (active power)

 Paper 4 – Set A with Solutions

S-5 In a reciprocating air compressor, if the speed is reduced to 80%, the power will
reduce by about 50% -True or False

Ans False

S-6 If slip of an induction motor increases, the shaft speed also increases – True or False

Ans False

S-7 The advantage of evaporative cooling is that it is possible to obtain water

temperatures below the wet bulb economically. True or false

Ans False

S-8 In a step down transformer for a given load the current in the primary will be more
than the current in the secondary. True or false

Ans False

S-9 For two pumps to be operated in parallel their ______heads should be the same

Ans Shut off (or ’closed discharge valve’ heads)

S-10 A fluid coupling changes the speed of the driven equipment without changing the
speed of the motor. True or false

Ans True

…………. End of Section - I ………….

Section - II: SHORT NUMERICAL QUESTIONS Marks: 2 x 5 = 10

(i) Answer all Twoquestions

(ii) Each question carries Five marks

L-1 In a Process Industry the L.P and H.P boilers have the same efficiency of
83%. The operating parameters and data are given below:

Boiler L.P. (Low Pressure) H.P. (High Pressure)

Efficiency on G.C.V. 83% 83%
Fuel Furnace Oil Furnace Oil
G.C.V. 10,000 Kcal/Kg. 10,000 Kcal/Kg.
Steam enthalpy 666 Kcal/Kg. 737 Kcal/Kg.
Feed water temperature 95oC 105oC
 Paper 4 – Set A with Solutions

The cost of steam fromL.Pboiler is Rs. 3000 per tonne. Find out the cost of
steam from H.P boiler.

Ans % Boiler Efficiency = (TPH of Stm) x 1000 x (Enth of Stm – Enth of FW) x 100
(Mass of Fuel x GCV Fuel)

Evaporation ratio of LP Boiler; ER LP =0.83 X 10000 = 14.53

(666 – 95)
………………..1.5 marks
Evaporation ratio of HP Boiler; ER HP = 0.83 X 10000= 13.13
(737 – 105)
………………..1.5 marks
ER HP is less than ER LP ;
Thus, the specific fuel consumption (kg fuel / kg steam) is more in the case
of the HP boiler than in the case of the LP boiler.
Therefore, the cost of steam from HP boiler is higher than the cost of steam
from LP boiler.
HP Steam Cost = 14.54x 3000 = Rs.3322 per tonne
13.13 ………2 marks

OR
1 T of FO – 14.54 T of LP steam
Cost of LP steam – Rs.3000/T
cost of 1 T of FO= Rs.3000 x 14.54 = Rs.43620/-
………………..1 mark
1 T of FO – 13.13 T of HP steam
cost of 1T of HP steam = Rs.43620/13.13 = Rs.3322/T

………………..1 mark
L-2 A shell-and-tube heat exchanger with 2-shell passes and 8-tube passes is
used to heat ethyl alcohol (cp= 2670 J/kgoC) in the tubes from 25 oC to 70oC
at a rate of 2.1 kg/s.
The heating is to be done by water (cp= 4190 J/kgoC) that enters the shell
side at 95oC and leaves at 45oC.
The LMTD correction factor for this heat exchanger is 0.82
If the overall heat transfer coefficient is 950 W/m2oC, determine the flow
rate of water in kg/s and surface area of the heat exchanger in m2.
Ans Heat duty
Cold fluid (ethyl alcohol)
Qcold= 2.1 x 2670 x (70-25) J/s
= 252315 Watts
 Paper 4 – Set A with Solutions

= 252.315 kW
………………..1 mark
Hot fluid (water)
Qhot= mw x 4190 x (95 -45)
= mw x 209500 J/s
= (209500 mw) Watts
= (209.5 mw) kW
………………..1 mark
Qcold= Qhot
252.315 kW = (209.5 mw) kW
mw=1.204 kg/s
LMTD = [(95-70) – (45-25)] / [ln (95-70) / (45-25)]
= 22.42oC
Corrected LMTD = 0.82 x 22.42
= 18.38oC
………………..2 marks
Q = U*A*LMTD
A = 252315 / (950x 18.38)
= 14.5m2
………………..1 mark

…………. End of Section - II …………

Section - III: LONG NUMERICAL QUESTIONS Marks: 4 x 20 = 80

(i) Answer all Four questions

(ii) Each question carries Twentymarks

N-1 A Process industry is operating a natural gas fired boiler of 10 tonnes/hr to cater
to a steam load of 8 tonnes/hr at 10.5 kg/cm2(g). The O2 in the flue gas is 4%
and the exit flue gas temperature is180oC. Due to increased cost of natural gas,
the management has decided to revert to operating the furnace oil fired boiler,
having an efficiency of 84% on G.C.V. for meeting the above load.

In keeping with its sustainability policy the management proposes to offset the
additional CO2 emissions due to the use of furnace oil by sourcinga part of its
total electrical energy consumption from green power (wind source).
 Paper 4 – Set A with Solutions

The following is the additional data.

COMPOSITION OF FUELS (% BY WEIGHT)

Constituents Natural gas Furnace oil

Carbon 73 84
Hydrogen 23 11
Nitrogen 3 0.5
Oxygen 1 0.5
Sulphur - 4

 G.C.V. of natural gas -13000 kcal/kg

 Enthalpy of steam at 10.5 kg/cm2(g) -665 kcal/kg.
o
 Inlet feed water temperature -90 C
 Heat loss due to Radiation and moisture in air -1.2%
o
 Specific heat of flue gases -0.29 kcal/kg C
o
 Specific heat of super heated water vapour -0.45 kcal/kg C
 G.C.V. of furnace oil - 10,000 kcal/kg
o
 Ambient temperature -30 C
,

Substitution by 1 kwh of green electrical energy in place of grid electricity,

reduces 0.80 kg. of CO2
Determine the monthly amount of green electrical energy from wind, (for 720
hours operation) required to be purchased to maintain the existing level of CO 2
emissions.

 Theoretical air required = 11.6 C + [34.8 (H2 – O2/8)] + 4.35 S

Ans = 11.6x0.73 + [34.8 (0.23 – 0.01/8)]
= 16.43 kg. air / kg. gas
 Excess Air % = % O2 / (21 - % O2) x100
= [(4 ) / (21 – 4)] x100
= 23.5 %
 Actual Air Supplied (AAS) = (1 + 0.235) x 16.43
= 20.29 kg.air / kg.gas

………………..3 marks
 Mass of dry flue gas mdfg = mass of combustion gases due
to PresenceofC,N,S + mass of
N2 in the fuel + mass of nitrogen
in air supplied + mass of excess
O2in flue gas
 Paper 4 – Set A with Solutions

=(0.73 x 44/12) + 0.03 + (20.29 x 0.77)

+ (20.29–16.43) x 0.23

= 19.22 kg. dry flue gas / kg. gas

………………..2. marks
 (Mair+Mfuel) ie (20.29+1) = 21.29 may also be considered.
 L1 = % heat loss due to dry flue gases
= MdfgxCpx (Tq – Ta)x 100
GCV of fuel(NG)
= 19.22 X 0.29 X (180 – 30)x 100
13000
= 6.43 %
………………..2 marks
 L2 = % Loss due to water vapour from hydrogen

= 9 H [584 + Cps (Tq – Ta)] x100

13000
= [9x0.23x[584+0.45x(180-30)]x100
13000
= 10.37 %

………………..2 marks
 Heat loss due to Radiation and
moisture in air= 1.2% (given)

 Efficiency of natural gas boiler

on GCV = 100 – [6.43 + 10.37 + 1.2]
= 82%

 Steam Load = 8 tonnes /hr.

 Amount of Gas required= 8000 (665 – 90)

0.82 X 13000 ,,

= 431.52 kg / hr
………………..2 marks
 Amount of CO2 emission with
natural gas = (431.52 X 0.73 X 3.67)
= 1156.1 Kg/hr.
 Amount of furnace oil required for
the same steam load =8000 (665 – 90)
0.84 X 10000
 Paper 4 – Set A with Solutions

= 547.62 kg / hr
………………..2 marks
 Amount of CO2 emission with F.O = (547.62 X 0.84 X 3.67)
= 1688.2kg CO2/hr

………………..2. marks
(Note: 1 Kg. Carbon Combustion emits 3.67 Kg. CO 2)

 Increase in CO2 emission due

to switchingfrom natural gas
to furnace oil= (1688.2 – 1156.1)
= 532.1 kg. CO2/hr.
………………..2.5 marks
[Substituting 1 kWh grid (Thermal) electrical energy by green electrical energy
reduces 0.80 Kg.of CO2)]
 Green energy to be purchased to
offset higher CO2 emissions per
month= [(532.1x 720)/ 0.8] =4,78,890 Kwh

………………..2.5 marks
N-2 The monthly energy consumption for 30 days operation in a 25 TPD (Tonneper day)
ice plant, producing block ice, is 37,950 kWh. The daily output of the ice plant is 15
Tonnes of block ice by freezing 16.5 m3 of water at 30oC. The higher water
consumption is due to loss of ice, while removing the block ice from ice cans, for
customer delivery. The following data has been given:
o
 Temperature of ice block = (-) 8 C
 Latent heat of freezing of ice = 80 kcal/kg.
o
 Specific heat of water = 1 kcal/kg C
o
 Specific heat of ice = 0.5 kcal/kg C
 Energy consumption in the
ice plant chiller compressor = 85% of the total energy consumption
 Efficiency of compressor motor = 88%

Estimate the,
a) Energy consumption per tonne of ice ‘output’,
b) Total daily cooling load in kcals for freezing water into ice blocks,
c) Refrigeration load on the chiller in TR (Tonne refrigeration) and
d) E.E.R. of ice plant chiller compressor.
The Management intends to pre-cool the inlet water from 30oCto 12oC using a
separate water chiller, drawing0.8 kW/TR.

e) Find out the reduction in energy consumption per tonne of ice block output
f) % reduction in the condenser heat load of the plant chiller due to the use of pre-
cooled water.
 Paper 4 – Set A with Solutions

Assume overall auxiliary energy consumption of the plant remains same and only
consider water chiller compressor energy consumption for estimating the savings.

Ans a) Monthly energy consumption = 37950 Kwh

Daily energy consumption = 37950 / 30 = 1265 kWh
 Energy consumption per tonne of ice delivered = 1265/15
= 84.33 kWh/tone
………………..3 marks
b)
3
Quantity of water input for the production 16.5 m = 16500 kg.
(sp.wt of water = 1000 Kg./m3)

Total cooling load per day

Q = Q1 + Q 2 + Q 3
o o
Q1 = Heat removed from lowering temperature from inlet 30 C to 0 C in kcals
o
Q2 = Latent heat removed in freezing water to ice at 0 C in kcals
o o
Q3= Heat removed for sub-cooling of ice from 0 C to -8 C in kcals

Q = (16,500 X 1 X (30-0)) + (16,500 X 80) + {16,500 X 0.5 X [0 – (-8)]}

= 4,95,000 + 13,20,000 + 66,000

Total Daily Cooling Load = 18,81,000 kCals

………………..3 marks
c)
18,81,000
Refrigeration load on the Chiller = ------------ =25.92 TR
24 X 3024
………………..3 marks

d)E.E.R. ice plant chiller

Ice plant chiller consumption per day = 0.85 X 1265

1075.25 kWh
Ice plant auxiliary consumption per day = 1265 – 1075.25
189.75 kWh
Power consumption of the chiller = 1075.25 / 24
44.80 KW
Input KW/TR Ice Plant chiller = 44.80 / 25.92
1.728
Motor Efficiency = 88%
Input power to the ice plant compressor = 0.88 X 1.728
 Paper 4 – Set A with Solutions

1.52 KW / TR
E.E.R. ice plant chiller (3024)kcal/hr/(1.52X860)
kcal/hr
2.313
………………..4 marks

e) Reduction in energy consumption per tonne of ice block output

Condenser heat rejection load in the existing = QE + Q C

case Q1
(25.92 X 3024) + (25.92 X
1.52 X 860)
1,12,264 kcals/hr
o 16500 X 1 X (30 – 12)/ (24 X
Refrigeration load for pre-cooling from 30 C
o 3024)
to 12 C in a separate water chiller
4.09 TR
Energy consumption in water chiller = 0.8 X 4.09 X 24 = 78.53 kWh
Reduced ice plant chiller load = 25.92 – 4.09 = 21.83 TR
Energy consumption for the plant chiller = 21.83 X 1.728 X 24 =
905.33 kWh
Total energy consumption per day by = Energy consumption in ice
resorting to pre-cooling of inlet water in a plant chiller+ Auxiliaries in ice
separate water chiller is plant
(no change) + Energy
consumption in water chiller
for pre-cooling
= 905.33 + 189.75 + 78.53
1173.61 kWh/day
Reduction in energy consumption = (1265 – 1173.61) /15
kWh/tone for ice delivered
6.092
………………..4 marks

f)
Heat rejection load in the ice plant = (21.83 X 3024) + (21.83 X
condenser 1.52 X 860)
94550 kcal/hr
% reduction in ice plant condenser heat = (1,12,264–94,550)x100
load /(1,12,264)
15.8 %

………………..3 marks
 Paper 4 – Set A with Solutions

N3 In a Petrochemical Industry a gas turbine cogeneration system comprising of 20

MW gas turbine generator along with a waste heat boiler (WHB) of 70 Tonne
per hour capacity at 10 kg/cm2 (g) are operated to meet the power and steam
requirements. The existing operating data is given below:

Power supplied by the Cogenerator = 16000 kW

Power drawn from the grid = 1500 kW
Grid power cost = Rs 5 /kWh
2
Steam at 10 kgf/cm g supplied by WHB = 48 Tonne/hr
(without supplementary fuel firing)
Efficiency of gas turbine on G.C.V. = 28%
Efficiency of generaror= 95%
G.C.V. of fuel (Natural Gas) = 13000 Kcal/Kg
3
Density of natural gas = 0.7 Kg./m
3
Cost of natural gas = Rs.25/m
o
Temperature of gas turbine exhaust gas entering WHB = 515 C
o
Specific heat of exhaust gas =0.3 kcal/kg C
o
Ambient temperature = 30 C
Air to natural gas ratio for gas turbine combustion = 60:1
Enthalpy of steam at 10 kgf/sq.cm.g = 665 Kcal/Kg
Enthalpy of feed water = 105 Kcal/Kg

a) Find out the heat rate of the gas turbine generator and

b) Estimate the efficiency of the waste heat boiler.

The plant personnel claim and believe that by resorting to supplementary fuel
firing to increase steam generation in the WHB. is likely to improve its efficiency
by 1.5% points.

c) Determine if it is economical to generate additional steam requirement of 10

Tonne per hour by supplementary fuel firing in WHB. as against in a separate
natural gas fired smoke tube boiler of 82% efficiency on G.C.V.

The plant operations are steady and continuous with 8760 yearly hours of operation.

Ans a)

Efficiency of gas turbine generator= 28%

Heat Rate = 860 / 0.28
= 3071.43 kcal/kWh
………………..4 marks
b)
 Paper 4 – Set A with Solutions

Gas Rate = 3071.43 / 13000

= 0.236 kg.Natural gas/kWh
………………..2 marks
Power generated by Gas turbine = 16000 KW
Steam supplied by WHB = 48000 Kg./hr
 power to Steam ratio = 3 KW / Kg. steam
Air to fuel ratio of gas turbine combustion = 60 : 1
Exhaust gas per Kg. of natural gas fired = 60 + 1 = 61 Kg. per Kg
of natural gas

48000 x (665 – 105)

Efficiency of waste heat boiler = ---------------------------------------
(without supplementary fuel firing) 6000 X 0.236 X 61 X 0.3 X 515

= 75.5%
………………..4 marks
c)

Efficiency of WHB with supplementary firing (as per claim)= 75.5+1.5

= 77%

Additional gas consumption for meeting 10 Tonne/hr steam through

supplementary firing in WHB =

10000 (665 – 105)

= ---------------------- = 559.44 Kg./hr.
0.77 X 13000

10000 (665 – 105)

Gas consumption in separate gas fired boiler with 82% on GCV = -----------------------
0.82 X 13000

= 525.33 Kg/hr
………………..5 marks

Operating separate gas fired boiler is economical.

Saving in gas consumption by meeting additional steam through
gas fired boiler =
= 559.44 – 525.33
= 34.1 Kg/hr
= 34.1 / 0.7
3
= 48.714 m /hr
 Paper 4 – Set A with Solutions

Yearly monetary savings = 48.714 X 25 X 8760

= Rs.1,06,68,366
= Say Rs.10.67 million
………………..5 marks
N-4 Answer any one of the following
A) The heat balance of a stenter in a textile industry is given below:

Heat used for Drying = 48%

Heat loss in exhaust air = 42%
Heat loss through insulation = 6%
Heat loss due to air infiltration = 4%

The above stenter is drying 75 meters per min. of cloth to final moisture of 7%
o
with inlet moisture of 50%. Temperature of cloth at inlet and outlet is 25 C and
o
75 C respectively.

The hot air for drying in the stenter is heated by thermic fluid. The thermic fluid
heater is fired by furnace oil, having an efficiency of 84%. The following data
has been given:

Density of furnace oil = 0.95 Kg/litre

GCV = 10000 kcal/kg
Cost of furnace oil = Rs.24 per litre

Weight of 10 mts of outgoing dried cloth= 1 Kg

a) Find out the existing furnace oil consumption for stenter drying.

b) What will be the annual furnace oil savings and annual monetary saving if
the overall thermal efficiency of the stenter is improved by reducing the
combined thermal insulation loss and the loss due to air infiltration, by half,
for operations at 22 hours per day and 330 days per year.

Ans Stenter speed = 75 meters / min

Dried cloth output = 75 x 60 /10
= 450 kg/hr
Weight of bone dry cloth per hr. = 450 x 0.93
i.e. W = 418.5 kg./hr
………………..2.5 marks
Weight of outlet moisture per kg. of bone dry cloth
mo = (450 – 418.5) / 450
= 0.0753 kg/kg
 Paper 4 – Set A with Solutions

………………..2.5 marks
Inlet moisture = 50%
Inlet wet cloth flow rate = 418.5/ 0.5 = 837kg/hr
mi inlet moisture per Kg. of bone dry cloth= (837 – 418.5) / 418.5
mi = 1 kg/kg bone dry cloth
Heat load on the dryer = Wx(mi – mo)x[(Tout – Tin)
+ 540] Kcal/hr
Tout= Outlet cloth temperature
o
= 75 C
Tin= Inlet cloth temperature
o
= 25 C

Heat load on the dryer=418.5 kg/hrx

(1 – 0.0753)kg/kg dry.clthx
[(75 – 25) + 540]
= 2,28,322.3 kcal/hr
………………..2.5 marks

Based on heat balance, dryer efficiency is 48%.

Heat input to the dryer = 228322.3 / 0.48
= 4,75,671.46 kcal/hr

Furnace oil consumption in =

Thermic fluid heater = 4,75,671.46/(0.84x10000)
= 56.63 kg./hr.
………………..2.5 marks

After reducing insulation and air infiltration loss by half, the heat energy
input will reduce by 100% – 0.5 (6 + 4)% = 95%

Dryer efficiency will increase to = (48/0.95) x 100

= 50.52%

Furnace oil consumption with = 2,28,322.3/(0.5052x0.84x

10000)
improved dryer efficiency
= 53.80 kg/hr
………………..4 marks
Saving in Furnave oil
consumption due to
improved stenter efficiency = 56.63 – 53.80
= 2.83 kg/hr
AnnualFurnace oil savings = 2.83x22x330
 Paper 4 – Set A with Solutions

= 20545.8 kgs/year
………………..3 marks

Annual monitory savings = 20545.8x(1/0.95)x24

= Rs.5,19,051.8
………………..3 marks
Note:
If candidates had done the calculation with temperature of cloth at inlet at 75 oC and outlet
at 25oC. the marks can be awarded according the steps.
B) In a secondary steel manufacturing unit, steel scrap is melted in an arc furnace.
The molten metal is then taken for ladle refining followed by vacuum degassing,
before being cast into ingots.

After the ingots are cooled down to ambient temperature, the entire lot is loaded
in a batch forging furnace and heated to 1150 oC. The heated ingots are forged
into desired shapes. The monthly number of batches are 160.

The management has decided to improve energy efficiency of the system by

incorporating a holding furnace ( electric resistance furnace) in between the
electric arc furnace and the fuel fired forging furnace, in order that the hot ingots (
after casting) could directly fed into the intermediate holding furnace to maintain
temperature and be fed at high temperature to the forging furnace, instead of at
atmospheric temperature.

Following are the data obtained in the energy audit study of the unit.

1. Scrap material fed into the arc furnace = 10 tons per heat
2. Yield of ingot casting from scrap = 95%
3. Temperature of casting after removal of mould = 600 oC
4. Ambient temperature = 30 oC
5. Specific heat of steel = 0.682 kJ/ kg oC
6. Efficiency of forging furnace = 25 %
7. Calorific value of Furnace oil fuel = 10500 kcal/ kg
8. Specific gravity of F.O = 0.9
9. Yield of forged steel in forging furnace = 97 %
10. Melting point of steel = 1650 0C
11. Latent heat of melting of steel = 272 kJ/kg
12. Electrical energy consumption measured per ton of steel melted = 800 kWh
13. Electrical energy consumption for holding ingots at 600oC in electric furnace
= 75kWh per batch
14. Cost of electricity = Rs.6 /kWh
15. Cost of Furnace oil = Rs. 30,000 / ton
 Paper 4 – Set A with Solutions

Calculate
a. Efficiency of electric arc furnace ignoring heat loss due to slag
b. Specific oil consumption in litres per ton of finished forged product.
c. Annual net savings in energy cost by holding the hot forged casting in an
intermediate electric furnace at 600 oC before feeding into forging furnace.

Ans a) Efficiency of the arc furnace.

Theoretical heat required for melting one ton of steel

*
1,000 x 0.682 x 1650 − 30 + 272
=
3600
{kJ per ton of molten metal/(4.18kj / kcal x 860kcals/kwh)}

= 382.45 kWh per ton of molten steel

………………..3 marks

Efficiency = 382.45 x 100 /800 = 47.8 %

………………..2 marks

b) Specific oil consumption in liters per ton of finished forged product

from the forging furnace

Amount of material heated in forging furnace

= 10,000 kg x (0.95) = 9500 kg steel / batch
Oil consumption = 9500 x (0.682 /4.18) x (1150-30) / (10500 x 0.25)
= 661.3 kg FO
………………..3 marks
Amount of material forged = 9500 kg x (0.97) = 9215 kg steel / batch
Specific oil consumption = 661.3 kg FO / 9.215 tons steel = 71.76 kg FO/ton
= 71.76 / 0.9 = 79.73 Lts FO / ton of forged steel
………………..3 marks
 Paper 4 – Set A with Solutions

c) Net Savings in energy cost by holding the hot forged casting in an

intermediate electric furnace at 600oC before feeding into forging
furnace
Oil consumption = 9500 x (0.682 /4.18) x (1150-600) / (10500 x 0.25)
= 324.76 kg FO per batch
………………..2.5 marks
Additional electrical energy consumption for holding ingots at 600 oC
= 75kWh per batch
Reduction in FO consumption by hot charging the forge furnace
= 661.3 - 324.76 = 336.54 kg FO per batch
………………..2.5 marks
Net savings in energy cost = (336.54 x 30) – (75 x 6) = Rs. 9646.2 per batch
Annual Net savings in energy cost = 9646.2 x 12 x 160 = Rs. 185,20,704 /yr
………………..4 marks

C) A steam power plant consisting of high pressure Turbine(HP Turbine) and low pressure
Turbine(LP Turbine) is operating on Reheat cycle(schematic of power plant is
represented below).

Steam from Boiler at a pressure of 150 bar(a) and a temperature of 550 0C expands
through the HP Turbine. The exhaust steam from HP Turbine is reheated in a reheater at
a constant pressure of 40 bar(a) to 550 0C and then expanded through LP Turbine. The
exhaust steam from LP Turbine is condensed in a condenser at a pressure of 0.1 bar (a).

The isentropic efficiencies of HP Turbine and LP Turbine are same and is 90%. The
generator efficiency is 96%

The other data of the power plant is given below:

Main steam flow rate : 228 TPH

Enthalpy of main steam: 3450 kJ/kg
Enthalpy of feed water : 990.3kJ/kg
Isentropic Enthalpy of cold reheat steam : 3050 kJ/kg
Enthalpy of hot reheat steam : 3560 kJ/kg
Condenser pressure and temperature: 0.1 bar(a)
and 45.80C
Isentropic enthalpy of LP Turbine exhaust steam : 2300 kJ/kg
Enthalpy of dry saturated steam at 0.1 bar(a) and 45.8 0C : 2584.9kJ/kg
Enthalpy of water at 0.1 bar(a) and 45.8 0C:191.9 kJ/kg

Based on the above data calculate the following parameters

(a) Power developed by the Generator
(b) Turbine heat rate
(c) Turbine cycle efficiency
(d) Specific steam consumption of turbine cycle.
 Paper 4 – Set A with Solutions

Ans (a) Power developed by the Generator: Turbine output x Generator efficiency------------ (1)
Turbine output = Q1 (H1 – h2) + Q2(H3 – h4)/860 MW ---------------------------------------(2)
Where, Q1=main steam flow rate =228 TPH
H1=main steam enthalpy=3450 KJ/Kg
h2=actual enthalpy at HP Turbine outlet= ?(cold reheat enthalpy)
Q2=steam flow through reheater=228TPH
H3=enthalpy of hot reheat steam=3560 KJ/kg
h4= actual enthalpy of LP turbine exhaust steam=?

HP Turbine isentropic efficiency= Actual enthalpy drop/isentropic enthalpy drop

0.9= (H1- h2)/(H1-h2is) , h2is=isentropic enthalpy of cold
reheat
Steam=3050KJ/kg
0.9= (3450 –h2)/(3450—3050)
h2= 3090KJ/kg

LP Turbine isentropic efficiency= (H3—h4)/(H3—h4is), h4is=isentropic enthalpy of LP

Turbine
Exhaust steam=2300KJ/kg
0.9=( 3560-h4)/(3560—2300)
h4= 2426 KJ/kg

Substituting the values in equation-2,we get

Turbine output = 228(3450—3090) + 228(3560—2426)/3600 = 94.62MW

Generator output= 94.62 x 0.96= 90.83 MW--------------------ANSWER (9 MARKS)

(b) Turbine heat rate=Q1 (H1—hfw) +Q2(H3—h2)/Generator output =KJ/kwhr-------------(3)

 Paper 4 – Set A with Solutions

hfw=enthalpy of feed water=990.3KJ/kg

Substituting the values in the above equation-3, we get

Turbine heat rate=228 (3450—990.3) + 228(3560—3090)/90.83

=7354.08 KJ/kWhr------------------------------ANSWER (5 MARKS)

(C) Turbine cycle efficiency= 860/Turbine heat rate

=860/(7354.08/4.18) =48.95%------------------ANSWER (3MARKS)

(d) Specific steam consumption of cycle=Steam flow/generator output

=228/90.83
=2.51 tons/MWhr----ANSWER(3MARKS)

D) In a cement kiln producing 4500 TPD of clinker output, the grate cooler hot exhaust air
temperature is vented to atmosphere at 275 oC.

It is proposed to generate hot water from this waste exhaust for operating a Vapour
Absorption Machine(VAM)chiller. This will replace the existing Vapour Compression
Chiller (VCR) of 50 TR capacity used for air-conditioning of control rooms and office
buildings.

The following are the data:

 Diameter of the cooler vent : 2 m
 Velocity of cooler exhaust air : 18.6 m/s
 Density of cooler exhaust air at 275 oC : 0.64 kg / m3
 Existing VCR Chiller Specific power consumption : 0.9 kW/TR
 Existing VCR condenser water pump power
consumption : 2.8 kW
 Investment towards 50TR VAM & its associated system :Rs 30 lakhs
 CoP of VAM system : 0.75
 Power consumption of VAM auxillaries: 2.83 kW
 Temperature of circulating hot water of VAM generator: Inlet - 90oC;
outlet - 80 oC
 Specific heat of exhaust cooler air : 0.24 kcal/ kgoC
 The efficiency of all pumps and their drive motors are 75% & 90%
respectively.
 The cost of electricity :Rs.6/kWh
 No of hours of operation : 8000 hrs/ yr

Calculate
a) Cooler Exhaust air temperature after heat recovery
b) Payback period by replacement of VCR by VAM

Ans a) Cooler Exhaust air temperature after heat recovery

 Paper 4 – Set A with Solutions

 Area of the duct= 𝜋r 2 = 3.14 x (2/2)^2 = 3.14 m2

 Volume of cooler exhaust air2750C= 3.14 x 18.6 = 58.4 m3/s = 2,10,240 m3/h
 Mass flow rate of cooler exhaust air275oCmcxa= 210240 x 0.64 = 134553 kg/ hr
Capacity of existing chiller= 50 TR
 Cooling load = 50 x 3024
 = 151200 kcal/ hr
CoP of VAM= 0.75
= (Cooling Load / Heat Input)
 Heat Input to VAM generator = 151200 / 0.75
 = 201600 kcal/hr
201600 kcal/hr= mhwxCp-hw x (90oC -80oC)
 Hot water flow rate mhw= 201600 / (1 x 10) = 20160 kg/hr
 Heat input to VAM generator = Heat recovered from Cooler Exhaust Air (m cxaxCp-cxax
(275-To)
 Cooler Exhaust air temperature after heat recovery
To = 275- [201600 / (134553 x 0.24)]
= 268.76oC
………………..5 marks
b) Payback period by replacement of VCR by VAM

Hot water circulation pump capacity

 motor input power Pm= mhw x head developed x 9.81 / (1000 x Pump η x motor η m)
Pm= [(20160 /3600) x 20 x 9.81/ (1000 x 0.75x 0.9)] = 1.63 kW
Heat load in the cooling tower= heat load from chilled water + heat load from
generator hot water
= 151200 + 201600 = 352800 kcal/ hr
 Condenser water circulation rate = 352800 / 5 = 70560 kg / hr

………………..3 marks

Condenser water circulation pump capacity

 motor input power Pm = mhw x head developed x 9.81 / (1000 x Pump η x motor η m)
Pm= [(70560 /3600) x 20 x 9.81/ (1000 x 0.75x 0.9)] = 5.69 kW
………………..4 marks
Savings
 Existing VCR Chiller Specific power consumption = 0.9 kW/TR
 Existing VCR Chiller total power consumption = 50 x 0.9
= 45 kW
 Existing VCR condenser water pump power consumption = 2.8 kW
 Total Energy Saving = Existing VCR Chiller total power consumption – (Proposed
VAM chiller power consumption)
=(45+2.8) – (1.63+2.83+5.69)
= 37.65 kW

………………..5 marks
 Paper 4 – Set A with Solutions

 Annual Energy savings = 37.65 x 8000 = 301200 kWh/yr

 Annual Monetary savings = 301200 x 6 = Rs. 18.07 Lakhs /y
 Investment towards 50TR VAM & its associated system = Rs 30 lakhs
 Simple payback period = 30 / 18.07 = 1.7 yrs or 19.9 months

………………..3 marks

-------- End of Section - III ---------

 Paper 4 Set A

19th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS - September, 2018

PAPER – 4: ENERGY PERFORMANCE ASSESSMENT FOR EQUIPMENT AND UTILITY SYSTEMS

Section - I: BRIEF QUESTIONS Marks: 10 x 1 = 10

(i) Section I contains Ten questions

(ii) Each question carries One mark

S-1 The capacity of a screw compressor cannot be controlled by discharge throttling.

True or False

Ans True

S-2 A package air conditioner of 5 TR capacity delivers a cooling effect of 4 TR. If Energy Efficiency
Ratio (W/W) is 2.90, the power in kW drawn by compressor would be ___________

Ans =(4*3024)/860 = 14.065/2.90 = 4.85

S-3 If the steam generation in a boiler is reduced to 45%, the radiation loss from the surface of the
boiler will reduce by the same ratio. True or False

Ans False

S-4 If the coal Gross Calorific Value is 4200 kcal/kg and specific coal consumption is 0.6 kg/kWh, what
is the power station gross efficiency ?

Ans (860 /(4200 x 0.6)) x100 = 34.12%

S-5 If the measured input power of a 90 kW motor is 45 kW, then the calculated loading of the motor
is 50 %. True or False

Ans False

S-6 The speed of an energy efficient motor will be more than the standard motor of same capacity
because ________________ decreases.

Ans Slip

S-7 O2 % in flue gas is required in the direct method efficiency evaluation of a boiler.
True or False

Ans False

S-8 To minimize scale losses in a reheating furnace, the furnace should be operated at a negative
pressure. True or False

Ans False
 S-9 The heat rate of a power plant will reduce when there is an increase in the inlet cooling water
temperature to the condenser. True or False

Ans False

S-10 A typical co-generation system in a cement plant will come under the category of topping cycle.
True or False

Ans False

…………. End of Section - I ………….

Section - II: SHORT NUMERICAL QUESTIONS Marks: 2 x 5 = 10

(i) Section II containsTwo questions
(ii) Each question carries Five marks

L-1 A coal based power plant A is having a Gross Unit Heat Rate of 2400 kCal/kWh with Auxiliary
powerconsumption of 8 % whereas Plant B of same size and make, has an operating Net Heat
Rate of 2500 kCal/kWh. In your opinion, which plant is more efficient and why?
Gross Heat Rate of Plant A – 2400 kcal/kwh
Auxiliary Power Consumption – 8%
Net Heat Rate of Plant A = Gross Heat Rate/(100- APC)
= 2400/(1-0.08)
Ans = 2608.70 kcal/kwh
Therefore, Plant B is more efficient with a lower Net Heat Rate of 2500 kcal/kwh than that of Plant A
(2608.70 kcal/kwh).

L-2 Milk is flowing in a pipe cooler at a rate of 0.85 kg/sec. Initial temperature of the milk is
55 °C and it is cooled to 18 °C using a stirred water bath with a constant temperature of
10 °C around the pipe. Specific heat of milk is 3.86 kJ/kg °C. Calculate the heat transfer rate
(kCal/hr) and also LogrithmicMeanTemprature Difference (LMTD) of the exchanger.

Heat transfer in cooling milk = 0.85 * 3.86 * (55 – 18)

= 121.4 kJ/sec

= (121.4* 3600)

= (437040 kJ/hr) / (4.18)

Ans = 104555 kcal/hr

LMTD:
DT1 = 55 – 10 = 45 °C
DT2 = 18 – 10 = 8 °C
LMTD of the heat exchanger = (45 – 8)/ ln (45 / 8)
= 21.4 °C

…………. End of Section - II …………

 Section - III: LONG NUMERICAL QUESTIONS Marks: 4 x 20 = 80
(i) Section III containsFour questions

(ii) Each question carries Twenty marks

N-1 The schematic and operating data of a steam turbine cogeneration plant with a back pressure
turbine is given below.

Enthalpy of steam at 180 bar, 550 0C – 3420 kJ/kg

Exhaust steam enthalpy at isentropic expansion from 180 bar to 2 bar – 2430 kJ/kg
Enthalpy of boiler feed water – 504.7 kJ/kg
Efficiency of boiler - 80 %
Calorific value of coal – 4500 kcal/kg
Steam flow rate into the Turbine - 91 TPH
Turbine isentropic efficiency - 90 %
Generator efficiency - 98 %
Gear box efficiency - 97 %

Calculate: (each carries 5 Marks)

a) Electrical output from the generator in MW
b) Fuel consumption in Boiler in TPH
c) Energy Utilization factor of the cogeneration plant
d) Heat to power ratio of the cogeneration plant, kCal/kW

Ans a) Electrical output from the generator in MW

Actual exhaust steam enthalpy = [3420 - (0.9 x (3420 - 2430))]

= 2529 kJ/kg

Turbine power output = 1 x (1000/3600)) x (3420 - 2529)]/1000

= 22.52 MW

Electrical output = (22.52 x 0.97 x 0.98)

= 21.4 MW

b) Fuel consumption in Boiler in TPH

 Fuel consumption in Boiler = (91,000 x (3420 – 504.7)) / (4.18 x 4500 x 0.80)

= 17.6 TPH

c) Energy Utilization factor of the cogeneration plant

= [(21,400 x 860) + (91000 x ((2529 – 504.7)/ 4.18))] / (17,600 x 4500)

= [(1,84,04,000 + 44069689) / (7,92,00,000)]

= 0.79

d) Heat to power ratio of the cogeneration plant, kCal/kW

Heat to power ratio, kcal/kW = (91000 x (2529 - 504.7)/4.18) / 21400

= 2059 kCal/kWh (or)
= 2.39 kWthermal/kWelectrical

N-2 In a process plant, the hot effluent having a flow rate of 63450 kg/hr at 80 0C from the process is
sent to a finned tube air cooled heat exchanger for cooling. The outlet temperature of theeffluent
from the heat exchanger is 38 0C.

Air at a temperature of 30 0C enters the heat exchanger and leaves at 60 0C. The fan develops a
static pressure of 30 mmWC. The operating efficiency of the fan is 65 % and fan motor efficiency
is 90 %. The plant operates for 5000 hours per year.

The management decided to replace the existing air-cooled heat exchanger with water-cooled
Plate Heat Exchanger (PHE).

Following are the relevant data:

Existing:

• Specific heat of air : 0.24 kcal/kg 0C

• Specific heat of hot effluent : same as water

• Density of air : 1.29 kg/m3

Proposed:

• Cooling water pump efficiency : 75 %

• Pump motor efficiency : 90 %

• Effectiveness of water cooled heat exchanger : 0.4

• Cooling water inlet temperature : 25 0C

• Total head developed by the cooling water pump : 30 m

• Over all heat transfer coefficient of PHE : 22300 kcal/hrm2 0C

Calculate the following:

 •Annual energy savings due to replacement of existing air cooled plate heat exchanger by
water cooled counter flow plate heat exchanger. (15 Marks)

•Area of the proposed water cooled plate heat exchanger. (5 Marks)

Ans Heat duty in hot fluid = M x Cp hot x (Ti - To)

= 63450 x 1 x (80 - 38)

= 2664900 kcal / hr

In a heat exchanger,

Heat duty in hot fluid = Heat duty in cold Air

Mass of the cold air = 2664900 / (0.24 X (60-30))

= 370125 kg/hr

Existing System:

Fan Shaft Power = Volume,m3/s X Static Press mmWc

102 X Fan Efficiency factor

= (370125/( 3600x 1.29)) x 30

102 X 0.65

= 36.06 kW

Motor Input Power = 36.06/ 0.9 = 40.07 kW

Proposed System:

Effectiveness of water cooled heat exchanger= 0.4

Cold Water outlet temperature = TWO

Cold water inlet temperature = T Wi

Hot effluent inlet temperature = TEff.in

Hot effluent outlet temperature = TEff.out

TWO – TWi
Effectiveness =
TEff.in – TWi

Cold Water Outlet = (0.4 x (80 – 25)) + 25

= 47 OC

Heat duty in hot fluid

Mass flow rate of cooling water (M)=
Cp x (TWO – TWi)

= 2664900

1 x (47 – 25) x 1000

= 121.13 m3 /hr
Hydraulic Power Requirement for one Cooling Water Pump:

= (Flow in m3/hr x Head in m x Density in kg/m3 x g in m/s2)

(1000 x 3600)

= (121.13 x 30 x 1000 x 9.81)

(1000X3600)

= 9.9 kW

Pump input Power Requirement = 9.9 kW / 0.75

2 kW

Pump Motor Input Power = 13.2 / 0.9

= 14.67 kW

Thus savings = Power consumption by fans – Water Pumping Power

= 40.07 – 14.67

= 25.4 kW

Annual energy savings in kWh = 25.4 kW x 5000 hrs

= 127000 kWh/annum

Calculations for LMTD for Proposed counter flow PHE:

LMTD for counter flow in PHE= {(80-47) – (38-25)} / ln {(80-47) / (38-25)}

= 21.5 OC

Considering overall heat transfer coefficient (U) = 22300 kCal/hrm20C

Heat transfer Area = Q / (U x ∆Tlmtd)

= 2664900 /(22300 x 21.5) = 5.56 m2

N3 In a process industry, the wet products are to be dried in a drier. The plant has a pressurizedhot
water boiler which supplies hot water at 145 0C to the heating coils in the drier. The return water to
the boiler is at a temperature of 110 0C. The boiler is fired by saw dustbriquettes.
The other relevant data are given below.

• Fuel firing rate = 375 kg/hr

• O2 in flue gas = 12.2 %

• CO in flue gas = 189 ppm

• CO2 in flue gas = 8.5 %

• Avg. exit flue gas temperature = 235 0C

• Ambient temperature = 31 0C

• Humidity in ambient air = 0.0204 kg / kg dry air

• Gross Calorific Value of ash = 800 kCal/kg

• Radiation & other unaccounted losses = 0.5 %

• Specific heat of flue gas = 0.23 kCal/kg0C

Fuel (briquettes) Ultimate Analysis (in %)
• Ash = 8.0

• Moisture = 7.5

• Carbon = 45.3

• Hydrogen = 4.4

• Nitrogen = 1.4

• Oxygen = 33.3

• Sulphur = 0.1

• Gross Calorific Value of saw dust briquette = 3300 kCal/kg

Calculate the hot water circulation rate (m3/hr) in the boiler.

An 1. Theoretical air required for complete combustion

s
= [(11.6 x C ) + {34.8 x ( H 2 − O2 / 8)}+ (4.35 x S )] / 100 kg/kg of coal

= [(11.6 x 45.3) + {34.8 x (4.4 – 33.3/8)} + (4.35 x 0.1)] / 100

= 5.34 kg / kg of briquette.

2. Excess air supplied

Actual O2 measured in flue gas = 12.2 %

O2 %
% Excess air supplied (EA) =  100
21 − O2 %

12.2%
=  100
21 − 12.2%

= 138.6 %
3. Actual mass of air supplied
= {1 + EA/100} x theoretical air

= {1 + 138.6/100} x 5.34

= 12.74 kg/kg of briquette

4. To find actual mass of dry flue gas

Mass of dry flue gas = Mass of CO2 +Mass of N2 content in the fuel+ Mass of N2 in the combustion air
supplied + Mass of oxygen in flue gas + Mass of SO2in flue gas

0.453 x 44 12.74 x 77 (12.74 − 5.34) x 23 0.001x64

= + 0.014 + + +
12 100 100 32

= 13.19 kg / kg of briquette

5. To find all losses

m x C p x (T f − Ta )
a) % Heat loss in dry flue gas (L1) = x 100
GCV of fuel

13.19 x 0.23 x (235 − 31)

= x 100
3300

= 18.75 %

b) % Heat loss due to formation of water from H2 in fuel (L2)

9 x H 2 x {584 + C p (Tf - Ta )}
= x 100
GCV of fuel

9 x 0.044 x {584 + 0.45 (235 - 31 )}

= x 100
3300

= 8.1 %

c) % Heat loss due to moisture in fuel (L3)

M x {584 + C p (Tf - Ta )}
= x 100
GCV of fuel

0.075 x {584 + 0.45 (235 - 31 )}

= x 100
3300
= 1.54 %
 AAS x humidity x C p x (T f − Ta )
d) % Heat loss due to moisture in air (L4) = x 100
GCV of fuel

12.74 x 0.0204 x 0.45 x (235 − 31)

= x 100
3300

= 0.723 %

e) % Heat loss due to partial conversion of C to CO (L5)

%CO x C 5654
= x x 100
%CO + %CO2 GCV of fuel

0.0189 x 0.453 5654

= x x 100
0.0189 + 8.5 3300

= 0.172 %

f) % Heat loss due to Ash (L6)

Gross Calorific Value of Ash =800 kCal/kg

Amount of Ash in 1 kg of coal = 0.08 kg/kg coal

Heat loss in bottom ash = 0.08 x 800

=64 kcal/kg of coal

% Heat loss in bottom ash = (64x 100) / (3300)

= 1.94 %

g) % Heat loss due to radiation & other unaccounted losses (L7) = 0.5% (given)

HWG efficiency by indirect method = 100- (L1+ L2+ L3+ L4+ L5+ L6+ L7)

=100-(18.75 + 8.1+ 1.54+ 0.723+ 0.172 +1.94+0.5)

= 68.28 %

Hot water circulation rate in m3/hr:

(Mass of hot water x Cp x T)

HWG efficiency % = x 100
Mass of fuel x GCV of fuel

375 x 3300 x 0.6828

Mass of hot water =
(145 - 110) x 1
=24,141.86kg/hr

=24.142 m3/hr
N-4 Answer any ONE of the following

A) A 60 MW captive power plant (CPP) of a chemical plant has a coal fired Boiler, condensing steam
Turbine and Generator. The CPP after meeting its auxiliary power consumption is exporting
power to the chemical plant. The operating data of CPP is as follows:
Generator output : 60 MW
Auxiliary power consumption : 6 MW
Steam flow to the turbine : 231 Tons/hr
Steam inlet pressure and temperature : 105 kg/cm2 (a) and 480 0C
Enthalpy of inlet steam at operating pressure and temperature : 793 kCal/kg
Enthalpy of feed water to boiler : 130 kCal/kg
Condenser exhaust steam pressure and temperature : 0.1 kg/cm2(a) and 45.5 0C
Enthalpy of water at operating pressure
and temperature of condenser : 45.5 kCal/kg
Latent heat of vaporisation of steam at operating
pressure and temperature of condenser : 571.6 kCal/kg
Enthalpy of exhaust steam : 554 kCal/kg
GCV of coal used : 4240 kCal/kg
Efficiency of the boiler : 86.5 %
Based on the above data, calculate the following parameters of the power plant:
a) Gross Heat Rate (8 Marks)
b) Net Heat Rate (3 Marks)
c) Dryness fraction of exhaust steam (2 Marks)
d) Condenser heat load (3 Marks)
e) Specific coal consumption (2 Marks)
f) Overall efficiency (2 Marks)

Ans (a) Gross heat rate

Gross heat rate= Coal consumption (kg/hr) x GCV of coal (kcal/kg)

------------------------------------------------------------ --------------(1)
Generator output (kw)

Given : Coal consumption=?

GCV of coal=4240 Kcal/kg
Generator output= 60 MW

Boiler efficiency= Q (H-h)/ (q x GCV) --------------(2)

Where, Q= Quantity of steam generation (kg/hr)=231x1000

H= Enthalpy of steam (Kcal/kg) =793
h=Enthalpy of boiler feed water (kcal/kg) =130
q=Coal consumption (kg/hr) =?
Boiler efficiency=0.865
Substituting the given values in equation (2) we get,
0.865=( 231 x 1000 x (793—130) )/q x 4240
q= 41758 kg/hr
 Substituting the calculated value of q in equation (1) we get,

Gross heat rate= (41758 x 4240) / (60x1000) =2950.9 kcal /kWh

(b) Net heat rate

Net heat rate = Gross heat rate
------------------------------------------------------ ----------------------(3)
1—( % Auxiliary Power consumption/100)
Auxiliary consumption =6 MW
Generation= 60 MW
% Auxiliary consumption=( 6/60) x 100 = 10%
Substituting the values in the equation (3) we get,
Net heat rate= 2950.9/( 1—10/100)= 3278.8 kCal/kWh

(C) Dryness fraction of exhaust steam

Enthalpy of exhaust steam = Enthalpy of feed water + Dryness fraction of steam x L.H. of vaporisation of
steam
Substituting the given values in the above, we get
554= 45.5+ dryness fraction of steam x 571.6
Dryness fraction of steam= (554—45.5)/571.6 = 0.889

(d) Condenser heat load

Heat load on condenser= Steam flow rate x L.H of vaporisation of steam x dryness fraction of steam
= 231x 1000 x 571.6 x 0.889
=117383.2 MCal/hr

(e) Calculation of specific coalconsumption

Specific coal consumption = Total coal consumption/Gross generation

= 41758 kg/hr / (60 x 1000) kW
= 0.696 kg/kWh

(f) Calculation of overall efficiency of plant

Overall efficiency= 860/Gross heat rate, kCal/kWh -----------------------(4)

Substituting the values we get, 860/2950.9 =29.14%

(OR)

Overall efficiency
= (Generator Output, kW x 860 kCal/kWh) /(Mass flow rate of coal kg/hr x GCV of coal,kCal/kg)
= (60 x 1000 x 860)/(41758 x 4240 )
=29.14%

OR

B) In the energy audit of a 6-stage Preheater (PH) section of a 4000 TPD (clinker) Cement kiln
operating at full load, the following were the field measurements taken.
 S.No. Description Value

1. Reference temperature (0C) 0

2. Reference pressure and the Barometric pressure (mmWG) 10323

3. Average Dynamic Pressure (mmWC) 17.1

4. Static Pressure at Fan Inlet (mmWC) -860

5. Static Pressure at Fan outlet (mmWC) -16

6. Temperature (0C) 328

7. Density of the PH Gas (NM3/kg), at reference condition 1.422

8. Pitot Tube constant 0.854

9. Diameter of PH Duct (m) 3.2

10. Cp of PH Gas (kcal/kg0C) 0.245

11. Power Input to the PH fan motor (kW) 1812

12. PH fan Motor Efficiency (%) 95

13. GCV of coal (kCal/kg) 5600

14. Annual Operating Hours 7300

15. Cost of Coal (Rs./Ton) 4836

a) Estimate the specific heat losses (kCal/kg clinker) carried away by PH gases. (5 Marks)

b) Estimate the PH fan Efficiency. (5 Marks)

c) Estimate the envisaged specific fuel savings (kCal/kg clinker), annual fuel savings and annual
monetary savings by reduction in PH gas temperature to 290 0C by appropriate modification
in the PH cyclones. (5 Marks)

d) Estimate energy savings in fan power consumption in the proposed case where PH exit
temperature is reduced to 290 0C. Also consider the static pressure at the fan inlet will reduce
by 8 % from the present level due to PH modification (Fan and motor efficiency in both the
cases are same). (5 Marks)

Ans: a) Specific heat losses by PH gases(kCal/kg clinker)

10323 * − PS 273
Density of gas at Present t , p =  stp   kg/m3 0.59
10323 273 + t e
operating Conditions (kg/m3)
= 1.422*(273/(273+328))*((10323 -860)/10323) kg/m3
Velocity =Pt × √(2g(ΔPrms)avg / t , p ) m/sec
20.36
Velocity of PH Gas (m/s) 0.5
=0.854 * ((2 * 9.81 * 17.1/0.59))

= Pi/ 4 * D2 8.04
Area of the PH Duct (m2)
= 3.14 * (3.22)/4
Flow rate of the PH Gas = Area * Velocity 589299.8
(m3/hr) = 8.04 * 20.36 *3600 m3/hr
Flow rate of the PH Gas = Flow rate of the PH Gas (m3/hr) x (0.59/1.422) 244505.5
(Nm3/hr) = 589299.8 X (0.59/1.422)
= Flow rate of Ph gas (Nm3/hr) / Clinker Production
Specific PH Gas generation 1.467
(kg/hr)
(Nm3PH gas /kg Clinker)
= 244505.5/ ((4000x1000)/24)
= Specific PH Gas generation (Nm3PH gas /kg Clinker) x 1.422
Specific PH Gas generation 2.086
kg/Nm3
(kgPH gas /kg Clinker)
=1.467 x 1.422
Specific Heat Loss in existing = m Cp (Tph-Tref.) 167.6
case (kcal/kg Clinker) =2.086*0.245*(328-0)

b) PH fan efficiency
= ((Q (m3/hr)/3600)x (Pst(mmWC)))/102 1354.5
Air Power (kW)
= (589299.8/3600)* (-16+860)/102
= Air power*100/(motor power *motor effi) 78.7
Fan Efficiency (%)
= (1354.5*100)/(1812*0.95)

c) Envisaged fuel and monetary savings

Specific Heat Loss in the = M Cp (Tph-new-Tref.) 148.21
proposed case (Kcal/Kg Clinker) =2.086 * 0.245 * (290-0)
=old heat loss/kg cli- new heat loss/kg cli 19.39
Fuel Savings (Kcal/Kg Cli
=167.6-148.21
=Clinker prod. * run hrs/yr* heat saving/kg cli /coal gcv
Annual Fuel Savings 4212.79
=166.67*7300*19.39/5600
Annual Monetary savings (Rs. =fuel savings in tons * fuel cost in (Rs. Ton)
203.73
Lakhs/yr) = (4212.79 *4836)/100000

d) Fan energy savings

Envisaged static pressure at = 92% of Original Static pressure at Fan inlet (reduction in
-791.2
Fan Inlet after PH modification Friction loss due to temperature reduction- given)
(mmWC) = 92% * 860
= Flow (Nm3/hr) * ((273+Tph-new)/273) * (10323/(10323+Pst-new)) 546091.5
Envisaged Fan Flow after PH
= 244505.5* ((273+290)/273)*(10323/(10323-791.2))
modification
78.7
Fan efficiency (%) Already estimated above (considering the same)
Fan motor Input power in the = ((Q (m3/hr)/3600)x (Pst(mmWC)))/102 1541
proposed case (kW) = ((546091.5/3600)* (-16+791.2))/(102*.787*.95)
=Fan power (old-new) 271
Fan Power saving (kW)
=1812 - 1541
Annual Energy saving (Lakh =(power saved * Annual operating hrs)/105 19.783
kWh/yr) = ( 271 * 7300) / 10^5

OR
C) A building is currently using Vapour Compression Refrigeration (VCR) chillers for meeting its
cooling requirements. The following are the existing data pertaining to the building.

Existing System:

• Total Power drawn from grid for the whole

building including chiller loads : 1300 kW

• Grid Power required for VCR : 300 kW

• Building cooling load : 7,56,000 kCal/hr

• Cost of Grid Power : Rs.8 /kWh

The management proposes to install a natural gas engine with a Waste Heat Recovery
Boiler (WHRB), which will generate power as well as steam for an operating Vapour
Absorption Machine (VAM). A part of the total chilling load and power requirement of the
building is proposed to be met by this cogeneration system. The following are the data for
the proposed system.

Proposed System:

• Total power generated from gas

engine co-gen plant : 1000 kW

• Gas engine efficiency : 40 %

• Heat absorbed for steam generation

in WHRB (as a % of heat input to gas engine) : 21 %

• Specific steam consumption for VAM : 5 kg/TR

• Calorific value of Natural Gas : 8500 kcal/sm3

• Cost of Natural Gas : Rs.40/sm3

• Annual operating hours : 4000

• Total enthalpy of steam : 660 kCal/kg

• Feed water temperature to WHRB : 60 0C

Calculate the following:

• Cost of generating one unit of electricity from the gas engine ? (5 marks)

• TR generated from Vapour Absorption Chiller driven by WHRB generated steam?

(5 Marks)

• Total energy cost of existing & proposed system and state whether the proposed
scheme is viable ? (10 marks)

Ans 1. Cost of generating one unit of electricity from gas engine?

• Fuel Consumption = 1000 kW X 860 / ( 0.4 X 8500)

= 252.94 sm3/hr
• Cost per unit of electricity from gas engine = (252.94 sm3/hr X 40 Rs./ sm3) / 1000 kW
 = Rs.10.12/ kWh

2. TR generated from VAM driven by WHRB generated steam?

▪ Heat absorbed by WHRB for Steam generation = 21% x (252.94 x 8500)

= 451497.9 kcal /hr

▪ Amount of steam generated = 451497.9/(660-60)

= 752.49 kg/hr

▪ TR generated by VAM = 752.49/5 = 150.49 TR

3. Techno-economic viability of the proposed scheme?

▪ Present cost of Electricity (Grid) = 1300 x 8 = 10,400 Rs./hr

Proposed Scheme

• Cost of NG for Electricity = 252.94 sm3/hr X 40 Rs./ sm3

= 10,118 Rs. /hr

• TR required by the building = 756000/3024

= 250 TR

• Energy performance of chiller (VCR) = 300/250

= 1.2 kW/TR

• Cost of Electricity from Grid to meet the balance chiller load

= (250-150.49) x 1.2 x 8
= 955.30 Rs./ hr

• Total energy cost with proposed system = 10118 +955.30

= 11,073 Rs./hr

Proposed project is not viable, because total cost is more in proposed scheme than in present
scheme.

OR

D) In a textile process unit, a five chamber stenter is installed for drying the cloth. The inlet and
outlet conditions of the cloth are shown in the figure below. The production output of the stenter
is 10,000 kgs/day.

The heat input to the stenter is provided by a thermic fluid heater fired by fire wood as
fuel. Gross Calorific Value (GCV) of Fire Wood is 3500 kcal/kg. The efficiency of the thermic fluid
heater is 70% and distribution loss in the thermic fluid system is 20,000 kcal/hr. The average
 fire wood consumption rate is 427 kg/hr.

Calculate the following: (each carries 10 Marks)

a) Drier efficiency
b) Fuel savings in thermic fluid heater if the inlet moisture is reduced from 60 % to 50 %
by mechanical squeezing. (Assume that drier efficiency does not change)
Ans Calculation of Stenter Efficiency

Stenter Efficiency, % = W x ( min – mout) x {( Tout - Tin ) + 540}

x 100
Qin
OR
Stenter Efficiency, % = (moisture removed from fabric) x {( Tout - Tin ) + 540}
x 100
Qin
Where,
W =Bone dry weight of the fabric, kg/hr
min = kg moisture / kg bone dry fabric at inlet
mout = kg moisture / kg bone dry fabric at outlet

Qin = Thermal energy input to the stenter (kCal/hr)

(a) Drier Efficiency

Amount of moisture removed:

Bone dry weight of fabric = (10,000 x (95%)) = 9500 kg/day

Hence, Total weight of inlet fabric = (9500)/(0.4/1.0)
= 23,750 kg/day
Inlet Moisture weight = (23,750 – 9500)
= 14,250 kg/day

OR

min = (14,250 kg/day) / (9500 kg/day)

= 1.50 kg/kg dry fabric

Outlet Moisture weight = 10000 - 9500

= 500 kg/day

OR

mout = (500 kg/day) / (9500 kg/day)

= 0.053 kg/kg dry fabric

Moisture removed from fabric in Stenter

min -mout = 1.5 – 0.053

= 1.447 kg/kg dry fabric
W x (min -mout) = 9500 x 1.447
=13747 kg/day
= 573 kg/hr
 OR

Moisture at I/L– moisture at O/L = (14,250-500)

= 13,750 kg/day
= 573 kg/hr

Heat required for removing the moisture = 573 x {(80-28) + 540}

= 3,39,216 kcal/hr

Heat input to the Thermic Fluid = (Firewood consumption rate x Calorific value x thermic
fluid heater efficiency)
= (427 kg/hr x 3500 kcal/kg x 70%)
= 10,46,150 kcal/hr

Heat input to the Drier = 10,46,150 – 20,000 = 10,26,150 kcal/hr

Stenter Efficiency (%) = (Heat reqd. for removing moisture / Heat input to the
stenter)
= (3,39,216 / 10,26,150) x 100
= 33%

(b) Fuel savings if the inlet moisture reduced from 60 to 50%

Moisture removed in Drier with 50% input moisture

(At 50 % moisture : Bone dry weight = moisture weight = 9500 kg)

Moisture removed from the fabric in the Stenter = Inlet moisture – Outlet moisture
= (9500-500)
= 9000 kg/day
= 375 kg/hr
Drier efficiency, 33 %
= [375 kg/hr x {(80-28) 0C + 540 kCal/kg} ] / [(Fuel consumption kg/hr x 0.70 x 3500 kCal/kg) –
20000kCal/hr]

Therefore, Fuel consumption, kg/hr (for reduction of inlet moisture)

= [{(375 kg/hr x {(80-28) 0C + 540 kCal/kg}) /0.33} + 20000] / (0.70 x 3500)
= (672727 + 20000)/ (0.70 x 3500)
= 283 kg/hr
Fuel Savings = 427 – 283 = 144 kg/hr = 3456 kg/day

…………. End of Section - III …………

 Paper 4 Code: Green

20th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS - September, 2019
PAPER – 4: ENERGY PERFORMANCE ASSESSMENT FOR EQUIPMENT AND UTILITY SYSTEMS

Section - I: BRIEF QUESTIONS Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries ONE mark

1. Two pumps can be operated in parallel provided their closed valve heads are not the same. False

Installing a VFD and operating a screw compressor at 50 Hz will increase the power
2. consumption. True

Building energy performance index (kWh/yr/m2) will not include captive power used in the
3. building. False

4. The COP and EER (w/w) in a refrigeration system will be numerically different. False

5. The gross heat rate of the power plant does not include auxiliary consumption. False

6. The unit of Specific humidity is kg moisture / kg dry air. True

In a water Lithium bromide refrigeration system, the concentration of the lithium bromide is
7. increased, in the evaporator. False

For the same no of poles and kW rating, the rpm of an energy efficient motor is higher that of
8. a standard motor. True

9. The atmospheric pressure of 1 kg/cm2 (a) is 76 mm of mercury column. False

10. The capacity of diesel generator designed for sea level condition decreases at high altitude. True

…………. End of Section – I ………….

Section – II: SHORT NUMERICAL QUESTIONS Marks: 2 x 5 = 10

(120) Answer all the Two questions
(ii) Each question carries FIVE marks

L1 A highly viscous oil which requires rapid initial heating, with a flow rate of 22 tonnes/hr, has to be heated
in a shell and tube heat exchanger, from 55 OC to 155 OC, using saturated steam at 175 OC. The specific
heat of oil is 0.5 kcal/kg OC. Only latent heat of steam at 485 kcal/kg is used for heating.

1. What type of heat exchanger is recommended? (1 Mark)

2. Draw a schematic of fluid flows with directions and temperatures. (2 Marks)
3. Find the LMTD for this application and also the steam requirement. (2 Marks)
 Ans :

1. Parallel flow Heat Exchanger

The appropriate choice is parallel flow heat exchanger, mainly to cater for providing rapid initial
heating of the viscous fluid.

2. Schematic Diagram

Schematic of Parallel flow Heat Exchanger

3. LMTD and Steam Requirement:

Δ T1 at feed end = 175 – 55

= 120 OC
Δ T2 at discharge end = 175 – 155
= 20 OC

Δ T1 – Δ T 2
LMTD (parallel) = ----------------
Ln Δ T1 / Δ T2

120 – 20
LMTD (parallel) = --------------- = 55.81 OC
Ln 120 / 20

Steam requirement = (22000 x 0.5 x (155 – 55)) / 485

= 2268.04 kg/hr

L2 A food processing industry has been importing 3 tonnes/hr of steam, at 8 kg/cm2(g), with an enthalpy of
661 kcal/kg, at a price of Rs 3,300 per tonne, from a neighboring industry. The steam metering is done at
the point of delivery. However, the seller is demanding for higher price, as the steam has to be
transported over a distance of 1 km, through a 100 mm (internal diameter) pipe line, from the boiler
house.

• The thickness of the pipe is 4 mm and it is insulated with 50 mm of insulation.

• The measured outside surface temperature of insulation is 45 OC, whereas the ambient temperature
is 30 OC.
Estimate the following:

1. Heat loss in piping distribution in ‘kg equivalent of steam /tonne of steam’. (2.5 Marks)
2. Final price of steam per tonne after accounting for distribution losses. (2.5 Marks)

Ans :

Outer dia. Of insulated pipe = (100+4+4+50+50)

= 208 mm
= 0.208 m

Surface area of the 1 km pipe = πDL

= 3.14 x 0.208 x 1000
= 653.12 m2
Surface heat loss per unit area = [10+ (Ts – Ta)/20] x (Ts–Ta) kcal/m2.hr
Total heat loss = [10+ (45–30)/20] x (45–30) x 653.12
= 1,05,315.6 kcal/hr
 Equivalent steam loss (for surface heat loss in the piping distribution), occurring while
transporting 3 tonnes/hr of steam = (1,05,315.6) / (661)
= 159.327 kg steam/hr
Equivalent steam loss in
kg of steam per tonne of steam = (159.327 / 3)
= 53.109 kg/tonne steam
Additional price to compensate
for heat losses per tonne of steam = (53.109 x (3300/1000))
= Rs 175.26/ tonne steam
Final price of steam = (Rs.3300+ Rs.175.26)/ tonne
= Rs. 3475.26/ tonne steam

………. End of Section - II ………….

Section - III: LONG NUMERICAL QUESTIONS Marks: 4 x 20 = 80

(i) Answer all the Four questions
(ii) Each question carries TWENTY marks

Pressurized hot water circulation system is employed for heating in a process industry. Hot water at
N1
140 oC is supplied to a process, through a steel piping of 100 mm internal diameter and equivalent length
of 2000 meters by an oil-fired hot water boiler of 6,00,000 kcal/hr output capacity.

After each weekend holiday, at the beginning of the first shift during startup, while raising the water
temperature from 50 oC to 140 oC, the entire piping system carrying water also gets heated from 50 oC to
140 oC.

1. Find out the start-up heating time if the boiler operates at 90% capacity, during this period.
(12 Marks)
2. Also, find out the % reduction in start-up heating load and fuel savings, with each start up, if the initial
temperature at the start up is increased to 65 oC due to improved housekeeping and insulation.
(8 Marks)
Make use of the following data and information:

Efficiency of the hot water boiler = 80%

GCV of fuel oil = 10,000 kcal/kg
Specific heat of water = 1 kcal/kg oC
Density of water = 1000 kg/m3
Specific heat of steel = 0.12 kcal/kg oC
Density of steel = 8000 kg./m3
Outer diameter of the pipe = 108 mm

Ignore the heat loss from the surface of the insulated pipe during start up, in the calculations.

Ans :
1. To Find Start-up Heating Time:
Outer diameter of pipe = 108 mm
= 0.108 m
Inner diameter = 100 mm
= 0.1 m
Equivalent length of pipe network = 2 km
= 2000 m
Hold up volume of water = /4 x (0.1)2 x 2000
= 15.7 m3
Mass of water = (15.7 X 1000)
= 15,700 Kg
Volume of steel pipe = /4 x [(0.108)2 – (0.1)2] X 2000
= 2.612 m3
Mass of steel pipe = 2.612 X 8000
= 20,896 Kg

Startup heating load = Heat required to heat water and steel from 50 oC to 140 oC
 = (Mass x Specific heat x Temperature difference)
= [15700 x 1 x (140 – 50)] + [20896 x 0.12 x (140 – 50)]
= [14,13,000 + 2,25,677]
= 16,38,677 kcals

Time taken for start-up heating = 16,38,677 / (600000 x 0.90)

= 3.035 hrs
2.
Temperature differential for heating
in the existing case = 140 – 50
= 90oC
Temp. differential when
Initial temp is increased to 65oC = 140 – 65
= 75oC

% reduction in start-up heating load = ((90 – 75) x 100)/ (90)

= 16.67%

Savings in fuel due for each start up = (0.1111 X 1638677) / (10000 X 0.8)
= 34.14 kg per start up

(or)

Startup heating Load = Heat required to heat water and steel from 65oC to 140oC
= ( mass x Specific heat x temp. difference)
= [15700 x 1 x (140 – 65)] + [20896 x 0.12 x (140 – 65)]
= [11,77,500 + 1,88,064]
= 13,65,564 kcal

% reduction in start-up heating load = ((16,38,677 – 13,65,564) x 100)/ (16,38,677 )

= 16.67%

Savings in fuel due for each start up = (16,38,677 – 14,56,602) / (10000 X 0.8)
= 34.14 kg per start up

The management of a process industry is planning to switch over from the existing 300 TR directly-gas-
N2
fired double effect absorption water chiller to a 300 TR centrifugal water chiller, as a cost saving measure.

The double effect absorption chiller is rejecting its heat in to a cooling tower. The proposed centrifugal
chiller will be rejecting its heat to the same cooling tower.

The management is also planning to connect the heat load of a water-cooled process heat exchanger to
the same cooling tower. The cooling water entering the heat exchanger will cool the hot oil from 110 OC
to 50 OC. The hot oil flow rate in the heat exchanger is 18,000 kg/hr.

Make use of the following data:

C.O.P. of double effect absorption chiller = 1.2

Electrical energy input to centrifugal chiller motor = 0.8 kW/TR
GCV of Natural Gas = 9450 kcal/m3
Cost of Gas = Rs.27/m3
Efficiency of gas firing = 80%
Electrical energy cost = Rs.8.5 / kWh
Specific heat of oil to be cooled by water = 0.5 kcal/kg OC
Motor efficiency = 87.5 %
Annual operating hours = 7200 hrs.

Find out the following -:

a) The yearly monetary savings in operating centrifugal chiller in place of the double effect absorption
chiller. (8 Marks)
b) C.O.P. of the centrifugal chiller. (2 Marks)
c) Whether the capacity of the cooling tower is sufficient to take the additional heat load of the process
heat exchanger, in addition to that of centrifugal chiller. (10 Marks)
Ans :
C.O.P. of double effect chiller = 1.2
 1TR (Ton refrigeration) = 3024 kcal/hr
Heat input to double effect chiller (Generator) = (3024/1.2) kcal/hr
= 2520 kcal/hr
Overall heat input considering gas firing efficiency = (2520 kcal/hr / 0.80 Effy of gas firing)
= 3150 kcal/hr
Operating cost of double effect chiller = ((3150 x 27) / 9450)
= Rs.9 /TR
Electrical input power in centrifugal chiller = 0.8 KW/TR
Operating cost of centrifugal chiller = (0.8 X 8.5)
= Rs.6.8 / TR
Saving in cost = Rs.9.0 – Rs.6.8
= Rs.2.2 / TR
Yearly monitory saving = (2.2 x 300 x 7200)
= Rs.47,52,000/-
= Rs.47.52 Lakhs
Heat rejection load from double effect chiller for 1 TR = (Chilling load at evaporator + Heat input to generator)
= (3024 kcal/hr + 2520 kcal/hr)
= 5544 kcal/hr
C.O.P. of centrifugal chiller (1 TR) = (3024) / (0.8 x 0.875 x 860)
= 5.02
Heat rejection load for 300 TR double effect chiller = (5544 X 300)
= 16,63,200 kcal/hr
Capacity of the cooling tower should be = 16,63,200 kcal/hr.
Heat rejection load to cooling tower in the case of of 300 TR Elec’l Centrifugal chiller power for 1 TR = (Electrical Input x Motor eff.)
= (0.8 kW/TR X 0.875)
= 0.7 kW / TR
In case of centrifugal chiller, heat rejection / TR = ((3024) + (0.7 x 860))
= 3626 kcal/TR
Heat rejection load of 300 TR centrifugal chiller = (3626 x 300)
= 10,87,800 kcal/hr
Heat load on the cooling tower due to
process heat exchanger oil cooling = 18,000 X 0.5 X (110 – 50)
= 5,40,000 kcal/hr
Total heat rejection load on the cooling tower = 10,87,800 + 5,40,000
= 16,27,800 kcal/hr
Cooling tower capacity is adequate to take the heat load of process heat exchanger in addition to heat
rejection load of the centrifugal chiller
The operating details and particulars of a natural gas-fired, smoke tube boiler, are given below :
N3
Steam flow = 8 tonnes/hr steam
Steam Pressure = 10 kg/cm2g.
Feed water temperature = 80 oC.
% O2 in dry flue gas = 4%
Exit flue gas temperature = 215 oC.
G.C.V. of natural gas = 13,500 kcal/kg
Density of natural gas = 0.7 kg/m3
Cost of natural gas = Rs 27/m3
Enthalpy of steam at 10.0 Kg./.cm2.(g) = 666 kcal/kg.
Inlet feed water temperature = 80 oC
Loss due to Hydrogen = 9.92%
Radiation losses in the N.G. boiler = 1.52%
Specific heat of flue gases = 0.29 kcal/kg oC
Ambient temperature = 30 oC
Density of air = 1.125 kg/m3
Daily hours of operation = 24 hours
Yearly operation = 320 days

Composition of natural gas (per kg)

Carbon = 0.74 kg /kg Hydrogen = 0.22 kg /kg
Nitrogen = 0.03 kg /kg Oxygen = 0.01 kg /kg
Ignore Sulphur & Moisture

Find out the following

a. Steam to fuel ratio, in the existing case, in kg/kg ( 8 Marks)

b. Total combustion air required in m3/min ( 4 Marks)
c. % improvement in the steam to fuel ratio, when the feed water temperature is raised to 95 OC due to
improved condensate recovery ( 2 Marks)
d. Savings in gas consumption in m3/hr ( 4 Marks)
e. Yearly monetary savings ( 2 Marks)
Ans :

Theoretical air required = 11.6 C + [34.8 (H2 – O2/8)] + 4.35 S] kg air / kg gas
= 11.6 x 0.74 + [34.8 (0.22 – 0.01/8)]
= 16.2 kg air / kg gas
Excess Air, % = (% O2) / (21 – % O2) x 100
= (4 ) / (21 – 4) x 100
= 23.5%
Actual Air Supplied (AAS) = (1+0.235) x 16.2
= 20.0 kg air / kg gas
Mass of dry flue gas (mdfg) = (Mass of combustion gases due to presence
C,N,S) + (Mass of N2 in the fuel) + (Mass of N2
in air supplied) + (Mass of excess O2 in flue gas)

= (0.74*44/12) + 0.03 + (20*0.77) + (20–16.2) x 0.23

= 19.02 kg (dfg )/ kg gas

L1 = % heat loss due to dry flue gases

Mdfg x Cp x (Tq – Ta)

= -------------------------- X 100
G.C.V. of fuel

19.02 X 0.29 X (215 – 30)

= ----------------------------------- x 100
13500

= 7.56%

L2 = 9.92% (Given)

Radiation losses L3 = 1.52% (Given)

Efficiency of natural gas

boiler on G.C.V. = 100 – [7.56 + 9.92 + 1.52]

= 81%

Steam to fuel ratio = (0.81 x 13500) / (666 – 80)

= 18.7

Amount of gas required for steam load of 8000 kg/hr = (8000 / 18.7)
= 427.81 kg/hr
Total Combustion air required = 427.81 x 20
= 8556.2 kg/hr
= 8556.2 /(1.125x60) m3/min
= 126.76 m3/min
Steam to fuel ratio with feed water temp of 95OC = (0.81 x 13500) / (666 – 95)
 = 19.15 kg/kg
% Improvement in steam to fuel ratio = ((19.15 -18.7) x 100) / (18.7)
= 2.41 %

Gas consumption with feed water temp at 95OC = 8000 / 19.15

= 417.75 kg/hr
Gas savings due to increase in feed water temp = 427.81 – 417.75
= 10.06 kg/hr
= 10.06/ 0.7
= 14.4 m3/hr
Yearly monetary savings = 14.4 x 24 x 320 x 27
= Rs.29,85,984
= Rs. 29.86 lakhs
N4 Answer any ONE of the following
In a particular biomass power plant, 33.6 TPH of steam at 63 kg/cm2g, 450 OC is expanding to
A
0.1 kg/cm2(a), and temperature of 45 OC. The boiler and the turbine are designed for
superheat temperature of 475 0C.

The following data has been given.

Enthalpy of steam at turbine inlet with 450 OC = 787.9 kcal/kg

Actual enthalpy at turbine outlet at 0.1kg/cm2(a) = 564.78 kcal/kg
Combined efficiency of gearbox and generator = 92%
Enthalpy of steam at turbine inlet with temp of 475 OC = 802.4 kcal/kg
Enthalpy at turbine outlet under isentropic condition
(with 475 OC at inlet, exhaust pressure, 0.1 kg/cm2(a) = 511.77 kcal/kg
Isentropic efficiency of the turbine with turbine inlet at 475 0C = 79%
Biomass Boiler Efficiency = 72%
Calorific value of biomass fuel = 3450 kcal/kg
Cost of biomass fuel = Rs 3.5 /kg
Electricity price for power sold = Rs 7/ kWh
Yearly hours of operation = 8000 hrs.
Auxiliary consumption = Remains Same

Calculate the following: ( Each 4 Marks)

a) Power generated in kW with turbine inlet temperature of 450 OC.

b) Steam rate in kg/kWh with improved turbine inlet temperature of 475 OC.
c) Additional power generated in kW with improved turbine inlet temperature of 475 OC, assuming
steam flow rate remains the same.
d) Increase in fuel consumption kg/hr with improved turbine inlet temperature of 475 OC, assuming
steam flow rate remains the same.
e) Yearly benefit by operating the turbine at inlet temperature of 475 OC.

Ans:
A–
O
a) Power generated in kW with turbine inlet temperature of 450
Ans
Turbine power output with inlet temp 450OC = m (h1 – h2)/ (860) x Comb eff (gg).

Where;
m = 33,600 kg/hr;
h1 = 787.9 kcal/kg;
h2 = 564.78 kcal/kg

Power output = (33600 (787.9 - 564.78) x (0.92))/ (860)

= 8019.86
= say 8020 kW

b) Steam rate in kg/kWh with improved turbine inlet temperature of 475 oC

Steam rate with improved turbine inlet temperature of 475OC = 860 / [(h1 – h2s) x s x gg ]
where
s = isentropic turbine efficiency = 79% = 0.79
gg = combined gear box and generator efficiency = 92% = 0.92

Steam rate at inlet of 475 OC = 860 / [(802.4- 511.77) x 0.79 x 0.92)]

 = 4.071 kg/kWh

(Or)

Steam rate with improved turbine inlet temperature of 475OC:

Turbine isentropic efficiency, 79% = (Actual enthalpy drop / Isentropic enthalpy drop) x 100
0.79 = (802.4 – H2) / (802.4 – 511.77)
Actual enthalpy at the turbine exhaust, H2 = 572.8 kcal/kg

Power generated in kW with turbine inlet temperature of 475 OC

= (33600 x (802.4 – 572.8) x (0.92))/ (860)
= 8252.8
= say 8253 kW

Steam rate with improved turbine inlet temperature of 475OC = 33600/8253

= 4.071 kg/kWh

O
c) Additional power generated in kW with improved turbine inlet temperature of 475 C,
assuming steam flow rate remains the same

Power output with inlet temp of 475OC = 33600 /4.071

= 8253.5 kW
= Say 8254 kW

Additional power generated = 8254 – 8020

= 234 kW

Additional revenue through power sold = 234 x 7

= Rs.1638/hr
O
d) Increase in fuel consumption kg/hr with improved turbine inlet temperature of 475 C,
assuming steam flow rate remains the same

Increase in fuel consumption = 33600 (802.4 – 787.9)/(0.72 x 3450)

= 196.135 kg/hr

e) Yearly benefit by operating the turbine at inlet temperature of 475 OC

Increase in fuel cost = 196.135 x 3.5

= Rs 686.47/hr
Yearly benefit, net increase in revenue = (1638 – 686.47) x 8000
= Rs. 76,12,240 /- (or)
= Rs 76.12 lakhs

OR
A Multispecialty hospital has conducted energy audit of all their utilities. In the existing system, an
B
electrical chiller is operated and the operating cost is Rs. 11.25 / TR. Steam from the boiler, is used for
hot water generation by indirect heating. Latent heat of steam is 500 kcal/kg and steam cost is Rs 2.85 /
kg.

Other data’s for existing system:

Electrical Load of the Hospital : 625 kW

Cost of Grid Electricity : Rs 9.25 / kWh

The audit has proposed to install trigeneration system with a gas engine of 700 kW. The gas engine is
operating at 28 % efficiency. Chilled water will be produced through a single effect Vapour Absorption
Chiller Machine (VAM) in the trigeneration system, using the entire heat rejected to the jacket cooling
water. Hot water requirement will be met using heat recovered from the engine exhaust.

The data pertaining to tri-generation system is given below:

Cost of Gas = Rs 45/ sm3
GCV of Gas = 9000 kcal/sm3
Heat Rejected by the engine to the Jacket cooling water = 29% of the engine heat input
COP of VAM = 1.65
Heat utilized from engine exhaust for hot water generation
for hospital purpose = 20% of total engine exhaust heat
Temperature of inlet water for hot water system = 30o C
Temperature of outlet water from hot water system = 60o C

Calculate the following:

1. Hourly Gas Consumption in sm3/hr (2 Marks)

2. TR delivered by VAM (6 Marks)
3. Quantity of hot water generated from exhaust heat for hospital purpose in kg/hr (4 Marks)
4. Annual cost savings in Rs. lakhs/yr on account of Trigeneration system, for 8000 hours of
operation. (8 Marks)

Ans:

1. Hourly Gas Consumption

Power Generation = 625 kW

Gas Engine Efficiency = 28 %
Heat rate = 860 / 0.28
= 3071.43 kcal/ kWh
Hourly Gas Consumption = (625 x 3071.43) / 9000
= 213.29 sm3/hr
2. TR delivered by VAM

Input heat = 213.29 sm3/hr x 9000 kcal/sm3

= 1919610 kcal/hr
Heat used for power generation = 1919610 x 0.28
= 537491 kcal/hour
Balance heat available after power generation = 1919610 - 537491
= 1382119 kcal/hr
Heat Utilized for VAM through jacket cooling water = 1919610 kcal/hr x 0.29
= 556687 kcal/hr
COP of VAM = 1.65
COP,1.65 = (TR X 3024 kcal/hr) / (Input Heat, 556695 kcal/hr)
TR delivered by VAM = (1.65 x 556687) / 3024
= 303.8 TR

3. Quantity of hot water generated from exhaust heat for hospital purpose in kg/hr

Heat available for hot water generation = 1919610 x ((100 – 29 – 28 ) /100)

= 825432 kcal/hr
(Or) Engine Exhaust Heat
= Heat Input – Heat output for power – Heat for VAM thro’ jacket cooling water
= 1919610 – 537491 – 556687 = 825432 kcal/hr
 20 % of the heat in the exhaust is used for
hot water generation from 30oC to 60 oC
for hospital purpose = 825432 x 0.20 kcal/hr
= 165086.4 kcal/hr
Equivalent Qty of hot water generated
from 30oC to 60 oC for hospital purpose = 165086.4 kcal/hr / (60 -30)
= 5503 kg/hr

4. Annual cost savings due to Tri-generation for 7500 hours of operation.

Cost of Existing System:

Cost of grid power per hour = (625 kW x 9.25 Rs./kWh)
= Rs. 5781.25 / hr
Cost of chiller operation per hour = (303.8 TR x 11.25 Rs/TR)
= Rs. 3417.75 / hr
Cost of hot water generation from boiler = [(5503 kg/hr x 1 x (60-30)) / (500 kcal/kg stm)]
= 330.18 kg steam/hr x 2.85 Rs./kg steam
= Rs 941 / hr
Total Operating cost of existing system = Rs (5781.25 + 3417.75 + 941) /hr
= Rs 10140 /hr

Cost of operation with tri-generation = Gas consumption x Cost of gas

= 213.29 sm3/hr x Rs.45 / sm3
= Rs. 9598.1 /hr

Hourly savings = (Existing Cost / hr – Trigeneration Cost / hr )

= Rs.10140 / hr - Rs. 9598.1 /hr
= Rs 541.9 / hr
Annual savings for 8000 hrs operation = Rs 541.9 / hr x 8000 hrs / yr
= Rs.43,35,200/yr
= Rs 43.35 lakhs /yr
An integrated cement plant is having vertical roller mill (VRM) of 200 TPH capacity for cement grinding,
C
drawing hot air (Temperature: 380 oC and Sp.heat Cp : 0.246 kcal/kg oC) from clinker cooler exhaust.
The operational data while grinding PPC, is as under :
Particulars Unit Value Particulars Unit Value
VRM output (dry basis) TPH 200 Mill exit temperature oC 90

oC Total gas mass flow rate of

Average feed temperature 52 kg/hr 487490
circuit at process fan inlet
Stack exhaust gas mass
Avg. feed moisture % 3 kg/hr 128124
flow rate
oC False air into the circuit
Ambient temperature 30 % 15
(% of total fan flow)
VRM motor efficiency % 95 Sp. heat (Cp) of material kcal/kg oC 0.21
Mill water spray TPH 3.5 Sp. heat of mill false air kcal/kg oC 0.238
Coal NCV kcal/kg 7000 Sp. heat of mill exit air kcal/kg oC 0.239
Rs./M VRM motor operating
Coal cost 9000 kW 4000
T power
Latent heat of evaporation of water kcal/kg 540
 A recent energy audit of the plant recommended to install Waste Heat Recovery System (WHRS) for
power generation, that may be sold out at Rs. 5.0 per kWh and cement mill heat requirement can be
fulfilled by installing a separate Hot Air Generator (HAG) with 90% thermal efficiency.

Feed VRM Bag House

Cement
Moisture
Mill
False Air Recirculation air

Cooler hot air HAG

Proposed Heating
System Exhaust Stack

Schematic Diagram of Cement Mill (VRM) Circuit

Estimate the following:

a) Calculate the heat and mass balance of input and output components of the VRM (cement mill),
considering radiation and convection heat loss to be negligible and also estimate the heat
requirement (kcal/hr) of VRM. (6 Marks)
b) Determine the amount of hot air being drawn from the clinker cooler. (4 Marks)
c) The power generation potential in the cooler hot air, which is presently used for VRM (cement mill)
heating, at 28% overall efficiency of WHRS. (6 Marks)
d) Hourly coal requirement in HAG. (2 Marks)
e) Hourly monetary saving of WHRS power generation using HAG, for cement mill heating. (2 Marks)

C- Water Balance:
Dry Feed = 200 TPH
Ans
Feed moisture = 3%
Wet Feed = 200 / (1 - 0.03) = 206.186 TPH
Moisture = (206.186 – 200) = 6.186 TPH
Total moisture (including water spray) = 6.186 + 3.5 = 9.686 TPH
Air Balance:
False air = Total process fan mass flow rate x 15/100 = 487490 x 0.15 = 73123 kg/hr

Recirculation air = Total mass flow rate at Process fan Inlet – Mass flow rate of exhaust from stack
Recirculation air = 487490 – 128124 = 359366 kg/hr

S.No. Description Calculation Value (kcal/hr)

Sensible heat in dry feed Hfi = mfi x Cp x ΔT
1. 924000
(Hfi) = 200x1000x0.21x(52-30)
Sensible heat input in feed Hwi = mwi x Cpx ΔTa
2.
moisture (Hwi) = 6186 x 1 x (52-30) 136092
Sensible heat input in mill
= 3500x 1 x (30-30) 0 kcal/hr
water spray
Sensible heat in false air Hfa = mfa x Cp x ΔT
3. 0 kcal/hr
(Hfa) =73123.5 x 0.238 x (30-30)
4. Sensible heat in hot air (Hha) Hha= mha x Cp x ΔT Hha is unknown
Sensible heat in Hrec= mrec x Cp x ΔT
5. 5153308.4
recirculation air (Hrec) = 359366 x 0.239 x (90-30)
Heat input equivalent of HElect= P x 860 x motor eff.
6. 3268000
electrical energy (HElect) = 4000 x 860 x 0.95
Total Heat Input Hfi + Hwi +Hfa+Hha+ Hrec+ HElect Hha+9481400.4
Output Heat Components:
Sensible heat in product Hprod= mp x Cp x ΔT
1. 1596000
(cement) (HProd) = 200000 x 0.21 x (90-52)
 Sensible heat in mill exit gas HEG = mg x Cp x ΔT
2. 6990606.6
(HEG) = 487490x 0.239x (90-30)
Heat of evaporation of HEvp= mw x [540+ΔTexit]
3. 3575508
moisture in feed (HEvep) = 6186 x [540+(90-52)]
Heat of evaporation of
= 3500x1x[540+(90-30)] 2100000
Water (mill spray)
Total Heat Output = Hprod + HEG + HEvp 14262114.6
(Hha)
Heat supplied from clinker cooler air 4780714.2
= 14262114.6 – 9481400.4
= Hha+ 9481400.4
VRM heat requirement 14262114.6
= 4780714.2 + 9481400.4
mha
Amount of hot air drawn from cooler 55525 kg/hr
= 4780714.2 /(0.246x (380-30))
Power generation potential in cooler P
1556.5 kW
hot air = 4780714.2 x (0.28/860)
mcoal
Hourly coal requirement in HAG 758.8 kg/hr
= 4780714.2 /(7000 x 0.9)
Revenue from WHR power Rs. 7782.5 per
R = 1556.5 x 5
(Rs. per hour) hour
Cost of coal consumption in HAG Rs. 6829.2 per
= 758.8 x 9
(Rs./hr) hour
Rs. 953.3 per
Monetary Saving S = 7782.5 – 6829.2
hour
OR

In a textile process house, a stenter is running at a speed of 75 meters/min where, the dried finished cloth
D
is leaving at 6% moisture and 75 oC, whereas the wet cloth is entering at a temperature of 25 oC.
The hot air for drying in the stenter is heated by circulating thermic fluid, which in turn is heated in a
dedicated furnace oil-fired thermic fluid heater, having an efficiency of 84%. The furnace oil consumption
in the thermic fluid heater is 90 kg/hr.
The unit takes measures to reduce the inlet moisture. The inlet moisture is now found to be 55%, at the
same temperature of 25 oC. The outlet conditions remain the same. The stenter operates 24 hours a day
and 30 days a month. The other data is given below -:
Stenter dryer efficiency = 50%
G.C.V. of furnace oil = 10000 kcal/kg
Weight of 10 meters of dried cloth at the outlet = 1 kg
Find out :

a) Feed rate in kgs/hr (12 Marks)

b) Percentage reduction in stenter drying load with the change in inlet moisture. (6 Marks)
c) Furnace oil savings in Tonnes/month. (2 Marks)

D- Ans:
Ans Feed rate in kgs/hr and percentage reduction in stenter drying load with the change in inlet
moisture.
Moisture % at stenter inlet = % moisture (unknown)
Temperature at stenter inlet, Tin = 25 oC
Moisture % at stenter outlet = 6% moisture,
Temperature at stenter outlet, Tout = 75 oC
Stenter speed = 75 meters / min
Dried cloth output = (75 x 60 x (1/10))
= 450 kg/hr
Wt. of bone-dry cloth at outlet per hr (W) = 450 x (1 - 0.06)
= 423 kg/hr
Hence, Wt. of outlet moisture per kg.
of bone dry cloth (mo) = (450 x 0.06) / 423
= 0.0638 kg/kg bone dry cloth
Heat supplied by stenter for drying = (Fuel consumption x GCV x Heater eff x Dryer eff)
= (90 x 10,000) x 0.84 x 0.50
 = 3,78,000 kcal/hr
Heat load on the dryer (Heat Consumed) = W x (mi – mo) x [(Tout – Tin) + 540] kcal/hr
= 423 x (mi – 0.0638) x [(75 – 25) + 540]

Heat supplied by stenter for drying = Heat load on the dryer (Heat Consumed)
3,78,000 kcal/hr = 423 x (mi – 0.0638) x [(75 – 25) + 540]
Inlet moisture per kg of bone dry cloth, mi = 1.578 kg moisture / 1 kg bone dry cloth
Total weight of inlet cloth = (1 + 1.578)]
Inlet moisture %, wet cloth = (Inlet moisture per kg of bone dry cloth)________
(bone dry cloth + Inlet moisture per kg of bone dry cloth)
= (1.578 x 100)/(1+ 1.578)
= 61.21 %

Reduction in moisture inlet, the moisture will be 55%

Hence, feed rate = 423 x (100/(100-55))
= 940 kg/hr
mi = (940 x 0.55)/( 423)
= 1.222 kg/ kg bone dry cloth
Stenter dryer load with 55% inlet moisture = 423 x (1.222 – 0.0638) x [(75–25)+540]
= 2,89051.974 kcal/hr
= say 2,89,052 kcal/ hr
Reduction in stenter drying load = 3,78,000 - 2,89,052
= 88,948 kcal/hr
% Reduction in stenter drying load = (88,948 x100) / (3,78,000)
= 23.53%

Furnace oil savings in Tonnes/month.

Monthly furnace oil savings = 0.2353 x 90 x 24 x 30

= 15247.44 kgs / month
= 15.25 tonnes/month

………. End of Section - III …………

 Paper 4 – Set A, Energy Auditor Key

Regn No: _________________

Name: ___________________
(To be written by the candidates)

7th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY AUDITORS – Nov., 2008

PAPER – 4: Energy Performance Assessment for Equipment and Utility

Systems
Date: 23.11.2008 Timings: 1400-1600 HRS Duration: 2 HRS Max. Marks: 100

Section - I: SHORT DESCRIPTIVE QUESTIONS Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark
(iii) Answer should not exceed 50 words

S-1 What will be the synchronous speed of a VFD driven 4-pole induction motor operating at
38 Hz ?

Ans. Ns = 120 x f/P

= 120 x 38/4
= 1140 RPM

S-2 If the power consumed by a refrigeration compressor is 2 kW per ton of refrigeration, what
is the energy efficiency ratio?

Ans.
12000 Btu
EER = 2000 W = 6

S-3 Explain why heat rate of back pressure turbine is greater than that of a condensing
turbine.

Ans. As it does not take into account of the heat content of the exhaust steam used in the
process.

S-4 Why line current method used for estimating loading of a motor is not applicable for motor
loading less than 75%.

Ans. At lower loadings, power factor of a motor degrades significantly and ampere-load curve
becomes nonlinear

S-5 Explain why actual air delivered is always converted to (FAD) while measuring delivered
air volume flow rates in an air compressor.

Ans. As air is compressible, its volume flow rate will vary with pressure on delivery side and
hence for comparison purposes the volume flow rates are always converted to their value
at standard atmospheric pressure.

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 Paper 4 – Set A, Energy Auditor Key

S-6 What is the minimum wind speed which is acceptable for viable power generation from a
wind turbine?

Ans. 15 kmph

S-7 If the dry bulb temperature of air is 35oC and the wet bulb temperature is 35oC what will be
the relative humidity %.
Ans. 100 %

S-8 For which fuel the difference between GCV and NCV will be smaller, Coal or Natural Gas?
Ans. Coal

S-9 What is the conversion efficiency range of a biomass gasifier ?

Ans. 60 – 70 %

S-10 How many units of energy will be generated by a wind turbine of 250 kW operating at a
capacity factor 0.25 in 8760 hours ?

Ans. 250 x 0.25 x 8760 =

5,47,500 kWh

-------- End of Section - I ---------

Section - II: LONG DESCRIPTIVE QUESTIONS Marks: 2 x 5 = 10

(i) Answer all Two questions

(ii) Each question carries Five marks

L-1 A trial for finding out the actual capacity of a reciprocating instrument air
compressor of nominal capacity of 900 Nm^3/Hr was done.

The following observations were made :

Atmospheric pressure : 1.033 kg/sq.cm
Ambient temperature : 30 deg. C
Receiver capacity : 12 m^3
Additional hold-up volume : 10% of receiver volume
Initial pressure (after bleeding) : 0.2 kg/sq.cm g
Final pressure (after pump-up) : 7.0 kg/sq.cm g
Pump-up time : 5 min:30sec
Motor power(avg) : 105 kW (as per power analyzer)
Discharge temperature : 45 deg. C
Calculate:
i) The actual compressor capacity
ii) The specific power consumption in kW/nm3/hr

Ans.
i) Actual capacity,FAD Q= ( P2 – P1) *V * (273+t1) Nm^3/mte
P0 T (273+t2)

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 Paper 4 – Set A, Energy Auditor Key

where ,
P2 = final pressure at receiver after pump-up ,kg/sq.cm a
P1 = initial pressure at receiver after bleeding, kg/sq.cm a
P0 = atmospheric pressure, kg./sq.cm a
V = total storage volume , m^3
T = pump-up time ,mte

Q = (8.033-1.233) * 12*1.1/5.5 *303/318

1.033

= 15.05 Nm3/min, say 15 Nm3/min

ii) specific power consumption:= 105 kW/Nm3

15*60
= 0.117 kW/Nm3

L-2 The following parameters were observed during the performance testing of
pump.
Flow rate of fluid :900m3/hr.
Density of fluid :950kg/m3
Discharge pressure : 5.0kg/cm2(a)
Suction head :5 metre above the pump centerline.
Measured power :180kW
Motor efficiency :90%
Calculate the pump efficiency.

Ans. Hydraulic power = (900/3600) x 45 x 950 x 9.81/ 1000

= 104.7 kW

Pump shaft power= 180 x 0.9

= 162 kW

Pump efficiency = 104.7/162

= 64.6 %

-------- End of Section - II ---------

Section - III: Numerical Questions Marks: 4 x 20 = 80

(i) Answer all Four questions

(ii) Each question carries Twenty marks

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 Paper 4 – Set A, Energy Auditor Key

N-1 A furnace oil fired boiler is generating steam 20 t/hr @10 kg/cm2 ( enthalpy – 650
kcal/kg & feed water temp-80 0C) The evaporation ratio of the oil fired boiler is
14. The GCV of the fuel is 10,200 kCal/kg. Due to high furnace oil cost the
management wants to covert from oil firing to Agro residue briquettes firing with a
GCV of 3200 kcal/kg. The expected efficiency of the new Briquette fired boiler is
75%. The cost of furnace oil is Rs.28000/t and briquette cost is Rs.4000/t. The
annual operating hrs of the boiler is 7000 hrs. The emission factor for furnace oil
is 3 t CO2/ton.

a. Find out the annual savings for the company by shifting to Briquettes.
b. In addition the management wants to claim carbon credits for fuel switch.
Calculate the estimated carbon credits for this measure.

Ans.

Parameter Unit F.Oil Briquettes

Steam Generation T/hr 20 20
Steam Enthalpy kcal/kg 650 650
o
Feed water temp C 80 80
Evap. Ratio t/t 14
Efficiency % 0.75
GCV kcal/kg 10200 3,200
20(650-80)
Fuel Consumption t/hr (20/14) /(3200*0.75)
1.43 4.75
fuel cost Rs/T 28000.00 4000
Cost of operation (1.43 x 28000) (4.75x 4000)
Rs./hr 40000 19000
Energy Cost
Savings (40000-19000)
21000
annual operating
hrs hrs 7000 7000
annual cost (21000 x 7000)
Savings Rs. Lakh/hr /100000=
1470
Carbon Credits
t
Emission Factor CO2/Ton 3
annual F.Oil
savings Ton/year (1.43x 7000)
10000
Expected Carbon
Credits CERs 10000 x 3
30000

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 Paper 4 – Set A, Energy Auditor Key

N-2 The following are the operating parameters of rerolling mill furnace

Weight of input material - 10 T/hr

Furnace oil consumption - 600 litres/hr
Specific gravity of oil - 0.92
Final material temperature - 1200oC
Initial material temperature - 40oC
Outlet flue gas temperature - 650oC
Specific heat of the material – 0.12 kCal/kg/oC
GCV of oil - 10,000 kCal/kg
Percentage yield - 92 %

a. Calculate furnace efficiency by direct method

b. Calculate Specific fuel consumption on finished product basis

The management installed a recuperator to preheat combustion air from 40oC to

300oC resulted in following benefits:

Increase in material input by 10 %

Reduction in fuel consumption by 13 %
Yield improvement from 92% to 96%

c. Calculate the furnace efficiency after the modifications

d. Reduction in specific fuel consumption after installing the waste heat
recovery

Ans.
a) Furnace efficiency by direct method

Heat input 600 lit/hr x 0.92 x 10000

55,20,000 kCal/hr
Heat output 10,000 x 0.12 x (1200 – 40)
1,39,2000 kcal/hr
Efficiency 1,39,2000 /55,20,000
25.21 %

b) Specific fuel consumption on finished product basis

Weight of finished products 10 x 0.92

9.2 T/hr
Furnace oil consumption 600 litres/hr
Specific fuel consumption 600/9.2
65.2 litres/ton

c) Furnace efficiency with 10 % increase in input material

Fuel consumption after 600 x 0.87
modification
522 litres/hr
Production after modification 10 + 10 x 0.1

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 Paper 4 – Set A, Energy Auditor Key

11 T/hr
Heat input 522 lit/hr x 0.92 x 10000
48,02,400 kCal/hr
Heat output 11,000 x 0.12 x (1200 – 40)
15,31,200 kcal/hr
Efficiency 15,31,200/48,02,400
31.9 %

d) Reduction in Specific fuel

consumption
Yield of finished product 11 x 0.96
10.56 T/hr
Fuel consumption 522 litres
Specific fuel consumption 522/10.56
49.43 litres/T
Original specific fuel consumption 65.2 litres/T
65.2 – 49.43
15.77 litres/T

N-3 For a double extraction cum condensing turbine with data as given in the following
diagram, evaluate

a. Power generated if the efficiency of the turbine is 90 %

b. Cooling water flow rate circulation in the condenser if the range is 7oC

Ans.
a. Power generated if the efficiency of the turbine is 90 %

Input heat to turbine = 72000 x 3439.6

= 2.477 x 108 kJ/hr
= 2.477 x 108 / 3600
= 68792 kW

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 Paper 4 – Set A, Energy Auditor Key

Output heat of different streams

1st extraction = 5000 x 2957.2

= 0.148 x 108 kJ/hr
= 4107 kW

2nd t extraction = 50,000 x 2768.8

= 1.38 x 108 kJ/hr
= 38456 kW

Condenser input heat load

= 17,000 x 2633.4
= 0.448 x 108 kJ/hr
= 12436 kW

Total heat leaving the turbine = 4107 + 38456 + 12436

= 54999 kW

Heat available for power generation = 68792 – 54999

= 13793 kW

Power generation at 0.9 turbine efficiency = 13793 x 0.9

= 12414 kW

b. Cooling water flow rate circulation in the condenser if the range is

7oC

Condenser heat load = 17,000 x (2633.4 – 191.8)

= 2442 kJ/hr
= 2442 x 4.18
= 10208000 kCal/hr

At a range of 7oC cooling water flow rate = 10208000 / 7

= 1458 m3/hr

N-4 A steam radiator is used for heating air with steam. Saturated steam enters the
radiator at a temperature of 133oC. Air enters the radiator at 30oC and leaves at
85oC. The heat transfer area is 794 m2. The heat duty of the radiator is 14,50,000
kCal/hr. If the correction factor is 0.95 calculate the overall heat transfer
coefficient in kW/m2 K.

Ans.

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Bureau of Energy Efficiency
 Paper 4 – Set A, Energy Auditor Key

LMTD, counter flow [(133-30) – (133-85)]/ln [(133-30)/133-85)]

72oC

Corrected LMTD 72 x 0.95

68.4oC

Heat duty, Q 14,50,000 kCal/hr

1683 kW

Area 794 m2
Overall heat transfer Q/ A x corrected LMTD
coefficient
1683 / (794 x 68.4)
0.031 kW/m2 K

-------- End of Section - III ---------

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Bureau of Energy Efficiency
 Paper 4 – Energy Auditor – Set A Key

Regn No: _________________

Name: ___________________
(To be written by the candidates)

8th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY AUDITORS – May, 2009

PAPER – 4: ENERGY PERFORMANCE ASSESSMENT FOR EQUIPMENT AND

UTILITY SYSTEMS

Date: 24.05.2009 Timings: 1400-1600 HRS Duration: 2 HRS Max. Marks: 100

General instructions:
o Please check that this question paper contains 6 printed pages
o Please check that this question paper contains 16 questions
o The question paper is divided into three sections
o All questions in all three sections are compulsory
o All parts of a question should be answered at one place

Section - I: SHORT DESCRIPTIVE QUESTIONS Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark
(iii) Answer should not exceed 50 words

S-1 Between a thermal power plant and a cogeneration plant with a back pressure
turbine, which will have a higher heat rate?

Ans: A cogeneration plant will have a higher heat rate

S-2 Which loss is considered the most unreliable or complicated to measure in electric
motor efficiency testing?

Ans. The stray load loss, because this loss is only estimated and not measured

S-3 How is the Overall Heat transfer Coefficient related to surface area?

Ans Inversely proportional.

S-4 The inclined manometer connected to a pitot tube is sensing which pressure in a gas
stream?

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 Paper 4 – Energy Auditor – Set A Key

Ans: The difference between total and static pressure (also called velocity pressure)

S-5 The more fouling fluid should be on which side of a shell & tube heat exchanger and
why?

Ans. Tube side, because it is easier to clean

S-6 For which fuel the sulphur dew point of the flue gases is lower: Furnace oil or Natural
gas.

Ans : Natural gas , because the sulphur content is less

S-7 What is the range of conversion efficiency of the gasification process using biomass?

Ans. 60 - 70 %

S-8 Calculate the annual power generated from a 100 kW wind turbine generator with a
capacity factor of 20% ?

Ans : 100 x .20 x 8760 = 175200 kWhr

S-9 Define Profitability Index?

Ans. Profitability Index is defined as the Sum of the discounted net savings to the
Capital Cost

S-10 In a power plant boiler if there is air ingress in the flue duct, which auxiliary system
would be most affected?

Ans: Induced Draft Fan

-------- End of Section - III ---------

Section - II: Long Questions Marks: 2 x 5 = 10

(i) Answer all Two questions

(ii) Each question carries Five marks

L-1 The suction head of a pump is 5 m below the pump centerline. The discharge
pressure is 4 kg/cm2. The flow rate of water is 100 m3 /hr. Find out the pump
efficiency if the actual power input at the shaft is 15 kW.

Ans: Discharge Head = 4 kg/cm2

= 40 metre head.
Suction Head = - 5 metre.
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 Paper 4 – Energy Auditor – Set A Key

Total Head = 40 – (-5) = 45 metre

Hydraulic Power = (100/3600) x 1000 x 9.81 x 45/1000

= 12.26 kW
Pump Efficiency = 100 x 12.26/15 = 81.7 %

L-2. Calculate the blow down rate for a boiler with an evaporation rate of 3 tons/hr, if the
maximum permissible TDS in boiler water is 3000 ppm. The make up water addition
rate is 10 % and the feed water TDS is around 250 ppm.
Ans.
Feed water TDS x % Make up
Blow down (%) =
Permissibl e TDS in Boiler  Feed water TDS

250 X 10
Percentage blow down =  0.91%
3000  250
If boiler evaporation rate is 3000 kg/hr then required blow down rate is:
3000 X 0.91
=  27.3 kg / hr
100

OR

Blow down (%) =Feed water TDS x % Makeup/ Permissible TDS in Boiler
Percentage blow down = 250 x 10/ 3000 = 0.83%
If boiler evaporation rate is 3000 kg/hr then required blow down rate is:
= 3000 x .83/100 = 24.9 kg/hr

-------- End of Section - II ---------

Section - III: Numerical Questions Marks: 4 x 20 = 80

(i) Answer all Four questions

(ii) Each question carries Twenty marks

N-1 Government of India has undertaken various schemes to promote energy efficiency
in the country. In the last one year implementation of these schemes have resulted in
savings as given below:

S. Name of the scheme Energy Source Units Quantity Saved

No.
1 Energy Efficiency in Electricity from Million kWh 62
Buildings grid
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 Paper 4 – Energy Auditor – Set A Key

2 Energy Efficiency in Electricity from Million kWh 1216

Industries Grid
Electricity from Million kWh 1000
Captive Diesel
Generation
Fuel Oil Lakh kilo 1.85
liter
Coal Lakh tons 3.5
Natural Gas Lakh Sm3 15728
3 Domestic Appliance Electricity from Million kWh 1374
Labelling Scheme grid
4 Various other schemes Electricity from Million kWh 635
as reported by different grid
States exclusive of GOI
schemes
Thermal Energy MTOE 80702
Saved

Given that:

1 kWhr = 860 kCal

GCV of Coal = 4000 kCal/ kg
GCV of Natural Gas = 8500 k Cal/Sm3
Assuming GCV of fuel Oil & Diesel = 10000 kCal/kg
Specific gravity of fuel Oil = 0.94, & for diesel 0.85
Assume average Transmission and Distribution Losses in India = 20%
Average Plant Load Factor = 78%
Specific diesel consumption = 3.5 kWh/ltr

Calculate : i) Total Energy Saved in MTOE (metric ton oil equivalent)

ii) Total Generation Capacity Avoided (in MW) in the country because of energy
savings due to grid connected power.

Ans: Total Electricity Saved from grid = 62 + 1216 + 1374 + 635 = 3287 million kWh

MTOE due to electrical savings = ( 3287 x 10 6 x 860 ) / 10 7

= 282682 MTOE

MTOE due to coal savings= ( 3.5 x 10 5 x 1000 x 4000 ) / 10 7

= 140000 MTOE
5 7
MTOE due to natural gas savings= ( 15728 x 10 x 8500 ) / 10

= 1336880 MTOE
MTOE due to Fuel oil savings = ( 1.85 x 10 x 0.94 x 1000 x 10000 ) / 10 7
5

= 173900 MTOE

MTOE due to captive diesel generation = 1000 x 106 x 0.85 x 10000 / 3.5 x 107
= 242857 MTOE

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 Paper 4 – Energy Auditor – Set A Key

Total MTOE = 282682 + 140000 + 1336880 + 173900 + 80702 + 242857 = 2257021 MTOE

ii) Grid Electricity Saved = (62 +1216 + 1374 + 635 ) million k Wh =

= 3287 x 10 6 kWh

Therefore Avoided Capacity = 3287 x 10 6 /( 0.78 x .80 x 365 x 24 x 1000 )

= 601.3 MW

N-2 A pharma unit had installed a centralized refrigeration system of 120 TR Capacity
several years ago. The refrigeration system operators 24 hours a day, 200 days per
annum and the average electricity cost is Rs. 4.5/ kWh. The following are the key
operational parameters.

 Compressor operating current and power factor : 153 amps. 0.9 pf

 Condenser pump operating current and power factor: 43 amps, 0.88 pf
 Chiller pump operating current and power factor : 25 amps, 0.9 pf
 CT fan operating current and power factor : 20 amps. 0.65 pf
 ΔT across the chiller (evaporator) : 3.5OC
 Chilled water flow : 23 Lit / Sec
 Total head developed by chiller pump : 35 mtrs.
 Condenser water flow : 41 Lit / Sec
 Total head developed by condenser pump : 30 mtrs.

PS: all the motors operate at 415 Volts:

Calculate:
 The power consumed by the compressor, condenser pump, chiller pump and CT fan.
 TR developed by the system
 Specific power consumption i.e. overall kW/TR and COP and Energy Efficiency ratio
(EER)
 Combined efficiency (motor and pump) of condenser and chiller pumps

The unit proposes to replace the existing condenser and chilled water pumps with efficient
pumps having a combined efficiency of 65%. Also the unit goes in for condenser cleaning by
which the power consumption of compressor has reduced by 10%.

Calculate:
 The envisaged power consumption of the compressor, condenser and chiller pump
 Hourly energy savings (compressor, condenser and chilled water pump)
 Annual energy and equivalent monetary savings (compressor, condenser and chilled
water pump)
 Specific power consumption i.e. overall kW/ TR and COP and Energy Efficiency ratio
(EER)

Answer

Present Condition:

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Bureau of Energy Efficiency
 Paper 4 – Energy Auditor – Set A Key

Compressor Power : 99 kW
Condenser Pump Power : 27.2 kW
Chiller Pump Power : 16.2 kW
CT Fan : 9.4 kW
Total Power : 151.8 kW
TR Devp : (23 * 3600 * 3.5 / 3024) = 95.83
Sp. Power : 1.58 kW/ TR
Compressor kW/TR : 99/95.83
: 1.03 kW/tR

COP : 3.516/kW/TR = 3.41

EER : 12/kW/TR
: 11.65
Condenser pump efficiency : 44.4%
Chiller pump efficiency : 48.8%

Proposed condition:

Compressor Power : 89 kW
Condenser Pump Power : 18.6 KW
Chiller Pump Power : 12.2 kW
CT Fan : 9.4 kW
Total Power : 129.2 kW
TR Devp : 95.83 TR i.e. (23 LPS * 3600 Sec * 3.5 / 3024)
Sp. Power : 1.35 kW/ TR
Compressor kW/TR : 89/95.83 = 0.93 kW/TR
COP : 3.516 / 0.93 = 3.78
EER : 12 / 0.93 = 12.90

Compressor Condenser Chiller

Pump Pump
Hourly energy savings – kWh (99-89) = 10 (27.2-18.6) = (16.2–12.2)
8.6 = 4.0
Annual energy savings – kWh (4800 hrs) 48000 41280 19200
Annual monetary savings (Rs) @ Rs. 4.5/ 216000 185760 86400
kWh

N-3 A fertilizer plant consuming 100TPH of saturated steam at 45 kg/sq.cm pressure has
been using Indian coal as fuel to the boiler and is now switching over to Imported
coal.
Typical ultimate analysis of the two types of coals:

------------------------------------------------------------------------------------------------
Parameters Indian coal Imported coal
% %
-------------------------------------------------------------------------------------------------
Carbon 41.11 58.96
Hydrogen 2.76 4.16
Nitrogen 1.22 1.02
Oxygen 9.89 11.88

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Sulphur 0.41 0.56

Moisture 5.98 9.43
Ash 38.63 13.99
---------------------------------------------------------------------------------------------------
GCV (kCal/kg) 4,000 5,900

Determine:

(i) Coal requirement in each case

(ii) Calculate % dry flue gas losses in both cases

Assume: in both cases

Flue gas temperature = 200oC
Ambient temperature = 30oC
Enthalpy of steam = 668 kCal/kg
Feed water temperature = 80oC
Specific heat of flue gases = 0.23

Boiler efficiency with Indian coal = 75%

Boiler efficiency with Imported coal = 82%
Oxygen content in flue gases with Indian coal = 10%
Oxygen content in flue gases with Imported coal = 4%

Answer
Coal requirement

Steam (q) x (hg – hf)

Q=
Efficiency x GCV

Indian coal
Imported coal
100,000 x (668 – 80)
Q= 100,000 x (668 – 80)
0.75 x 4000 Q=
0.82 x 5900
19.6 T/hr
12.1 T/hr
Find theoretical air requirement

Indian coal
= [(11.6 x C) + {34.8 x(H2 - O2/8)} + (4.35 x S)] kg / kg of coal
100
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For Indian coal

= [(11.6 x 41.11) + {34.8 x(2.76 – 9.89/8)} + (4.35 x 0.41)] = 5.3 kg / kg of coal
100

For Imported Coal

= [(11.6 x 58.96) + {34.8 x(4.16 – 11.88/8)} + (4.35 x .56)] = 7.79 kg / kg of coal

100

Excess air percentage in Indian coal = 10 x 100/ 21 - 10 = 90.9%

Excess air percentage in Imported coal = 4 x 100/ 21 – 4 = 23.5%

Actual mass of air (AAS)

Kg/ kg of coal = 5.3 x 1.9 = 10.07 kg (Indian coal)

= 7.79 x 1.235= 9.62 kg (Imported coal)

Heat loss in dry flue gas = M x CP (Tf – Ta) x 100

GCV
- Indian coal = (10.07+1) x 0.23 x (200 – 30) x 100
4000

= 10.8%

- Imported coal = (9.62+1) x 0.23 x (200 – 30) x 100

5900
= 7.04%
Alternatively:

Indian Coal : Mass of dry flue gas = Mass of (CO2 + SO2 + N2 + O2) in flue gas
+ N2 in air we supply
= 0.4111x44 + 0.0041x64 + 0.0122 + 10.07x77 + {(10.07-5.3)x23/100}
12 32 100
= 10.38 kg/kg of fuel.

Imported Coal:
= 0.5896x44 + 0.0056x64 + 0.0102 + 9.62x77 + {(9.62- 7.79)x23/100}
12 32 100
= 10.01 kg/kg of fuel.

Heat loss dry flue gas:

Indian Coal: = 10.38 x 0.23 x (200 – 30) x 100 = 10.1%
4000
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Imported Coal: = 10.01 x 0.23 x (200 – 30) x 100 = 6.63%

5900

N-4 The cost and estimated savings data for an energy saving retrofit project is given in
table below.

Retrofit cost Energy & demand Maintenance cost savings

savings
Rs. 1,00,000 6000 kWh/year & Annual maintenance cost savings
Rs.3800/year as will be Rs. 2000/-.
demand charges

 The key data is given below:

 Energy savings are based on Rs 3.00/kWh
 No changes in energy rates for 10 years
 The project has a 10 year life period
Calculate NPV for the upgrade option against 12% discount rate.

Cost of Energy & demand savings per year = 6000 x 3 + 3800 = Rs 21,800
Ans
The cash flow detail for ten year duration is given below:

Year Retrofi Cost of Maintenan Cash Discou Present

t cost Energy & ce cost flow nt Value
demand savings Factor
savings for 12%
0 100000 0 0 -100000 1.000 -100000
1 0 21800 +2000 23800 0.893 21253.4
2 0 21800 +2000 23800 0.797 18968.6

3 0 21800 +2000 23800 0.712 16945.6

4 0 21800 +2000 23800 0.636 15136.8

5 0 21800 +2000 23800 0.567 13494.6

6 0 21800 +2000 23800 0.507 12066.6

7 0 21800 +2000 23800 0.452 10757.6

8 0 21800 +2000 23800 0.404 9615.2

9 0 21800 +2000 23800 0.361 8591.8

10 0 21800 +2000 23800 0.322 7663.6

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Total 20,000 1,38,000 34,493.

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The NPV for the upgrade option against 12% interest rate = Rs 34,494/-

-------- End of Section - III ---------

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Bureau of Energy Efficiency
 Paper 4 – Energy Auditor – Set A Solutions
Regn No: _________________
Name: ___________________
(To be written by the candidate)

9TH NATIONAL CERTIFICATION EXAMINATION– December, 2009

FOR
ENERGY AUDITORS

PAPER – 4: Energy Performance Assessment For Equipment and Utility

Systems

Date: 20.12.2009 Timings: 1400-1600 HRS Duration: 2 HRS Max. Marks: 100

General instructions:
o Please check that this question paper contains 8 printed pages
o Please check that this question paper contains 16 questions
o The question paper is divided into three sections
o All questions in all three sections are compulsory
o All parts of a question should be answered at one place

Section - I: SHORT DESCRIPTIVE QUESTIONS Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark

S-1 A cogeneration plant with a back pressure turbine has a constant steam demand and
fluctuating power demand. What is the common option to meet the fluctuating power
demand?

Ans
Parallel operation with grid
S-2 What are the two major sources of waste heat available from a water-cooled Diesel
Generator set?

Ans
Exhaust flue gases and jacket cooling water
S-3 For determining heat loss in flue gases due to incomplete combustion which flue gas
constituent needs to be measured?

Ans
Carbon monoxide

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 Paper 4 – Energy Auditor – Set A Solutions

S-4 Which parameter needs to be measured to assess the percentage loading of a motor
by slip method neglecting voltage correction?

Ans
Motor speed
S-5 How many volt-amperes (VA) does a 100 Watt incandescent light require?

Ans
100 VA
S-6
In the indirect method of boiler efficiency evaluation, list any two additional losses
computed for solid fuel fired boilers as compared to liquid and gas fired boilers?
Ans.
Unburnt losses in fly ash (Carbon)
Unburnt losses in bottom ash (Carbon)

S-7 Why do biomass combustion projects qualify for CDM benefits even though they emit
carbon dioxide?

Ans:
Because it absorbs the same amount of carbon in growing as it releases when
consumed as fuel
Or
Biomass is carbon neutral

S-8 Name two most common bio fuels used for transportation

Ans
1. Biodiesel
2. Ethanol
S-9 Which loss is assumed in the determination of electric motor efficiency?

Ans
The stray load loss is estimated and not measured for testing electric motor
efficiency.

S-10 In a shell and tube heat exchanger, engaged in heat transfer between fouling fluid and
clear fluid, the fouling fluid should be put on shell side or tube side?

Ans
Tube side

…………. End of Section - I ………….

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 Paper 4 – Energy Auditor – Set A Solutions

Section - II: LONG DESCRIPTIVE QUESTIONS Marks: 2 x 5 = 10

(i) Answer all Two questions

(ii) Each question carries Five marks

L-1 The steam flow to a process plant is 5000 kg/hr. 2000 kg/hr of condensate at 173oC is
returned to boiler feed water tank due to its own pressure. However there is 10% heat
loss in transit to boiler feed tank. The balance is made up as feed water at 30oC. The
final feed water temperature observed was 95oC. Comment on the feed water
temperature. The plant personnel are sure that the temperature gauge is in order.

Ans Heat in condensate (less 10%) + Heat in make up water = Heat in feed water

2000 X 173 X 0.9 + 3000 X 30 = 5000 X Tf

311400 + 90000 = 5000 X Tf

Tf = 80.28oC
(3 Marks)

The feed water temperature cannot be more than 80.28oC. The high temperature of
95oC is mostly due to live steam leakage, as the temperature gauge is OK.
(2 Marks)

L-2 The maximum demand registered by an automobile plant is 5000 KVA and the power
factor is 0.95. The plant management converts the existing electrical resistance heated
furnace with an average load of 750 kW to gas heating as a cost reduction measure.
What will be effect on maximum demand and power factor with this conversion?

Ans. Registered maximum demand = 5000 KVA

Electrical load (real power) = 5000 X 0.95
= 4750 KW
KVAR2 = KVA2 – KW2
KVAR2 = (5000)2 – (4750)2

KVAR = 100 (502) – (47.5)2

= 1561
(3 Marks)
KVAR in the system will remain same.
Reduction in real power by conversion is 750 KW.
Real Power = 4750 – 750 = 4000 KW

KVA2 = KW2 + KVAR2

= (4000)2 + (1561)2
KVA = 4294

Power factor = 4000 / 4294 = 0.932

Reduction in Electrical Demand = 5000 – 4294

= 706 KVA

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 Paper 4 – Energy Auditor – Set A Solutions
Reduction in Power Factor = 0.95 – 0.932
= 0.018
(2 Marks)

…………. End of Section - II ………….

Section - III: NUMERICAL QUESTIONS Marks: 4 x 20 = 80

(i) Answer all Four questions

(ii) Each question carries Twenty marks

N -1 Given below is a set of curves for a centrifugal fan. At its Best Efficiency Point (BEP)
determine to the nearest approximation the following:

a) Static pressure in mmwc

b) Flow in m3/hr
c) Shaft power in kW
d) Work out the static efficiency of the fan by calculation
e) Power drawn by the motor if the motor operating efficiency is 90%

Shaft power (HP)

Ans
Static pressure in inches H2O 36
(2 Marks)

Static pressure in mmwc 914.4 mmwc

(2 Marks)
Flow in CFM 2750

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(2 Marks)
Flow in m3/hr 4672.28 m3/hr ie 1.3 m3/sec
(2 Marks)
Shaft power in hp 29
(2 Marks)
Shaft power in kW 21.6 kW
(2 Marks)
Fan Efficiency Q x dP/(102 x kW)
1.3 x 914.4 /(102 x 21.6)
54 %
(5 Marks)
Motor input power at 90% 21.6 / 0.9
= 24 kW
(3 Marks)
The data is read from the graph and hence a deviation of +/- 10% in values may be
given full marks.

N-2 In a Continuous Process Industry 5 Tonne per hour hot oil on process stream has to be
cooled from 230oC to 110oC by DM water at 25oC heated to 80oC on its route to boiler
de-arator.
(i) Depict the heat exchange process on a schematic for both parallel and counter flow heat
exchanger clearly indicating inlet and outlet temperature and terminal temperature
difference.
(ii) Find out LMTD for parallel and counter flow heat exchangers and comment on the
preference of the heat exchanger.

(iii) Find out the DM water flow rate through the heat exchanger. Assume specific heat of hot
oil to be 0.5 kCal / kgoC.

Ans.

Hot Oil Hot Oil

230oC 110oC 230oC 110oC
Parallel Flow
TTD TTD TTD Counter Flow TTD
t1 = 205 t2 = 30 t1 = 150oC t2 = 85

25oC 80oC 80oC 25oC

Cold DM Water Cold DM Water

t1 - t2
LMTD parallel flow = ------------------------
Ln t1 / t2

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 Paper 4 – Energy Auditor – Set A Solutions
205 - 30
= ------------------ = 91.15oC
Ln 205 / 30
(8 Marks)

t1 - t2
LMTD counter-flow = ------------------------
Ln t1 / t2

150 - 85
= ------------------ = 114.44oC
Ln 150 / 85

(8 Marks)

Counter flow heat exchanger is preferred as the LMTD is larger and hence heat
exchanger area will be less and compact.

Mc X 1 X (80 – 25) = mh X Cph X (230 – 110)

Mc = 5000 X 0.5 X (230 – 110) / 55
= 5454.54 Kg / hr

DM water flow rate = 5454.54 Kg / hr

(4 Marks)

N-3 The following are the data collected for a boiler using furnace oil as the fuel. Determine
the boiler efficiency based on GCV by indirect method ignoring radiation and convection
losses.
Ultimate chemical analysis (% weight) : Carbon : 84, Hydrogen : 12, Nitrogen : 0.5,
Oxygen : 1.5, Sulphur : 1.5, Moisture : 0.5, GCV of fuel 10,397 kCal/kg and humidity
0.015 kg moisture/kg of dry air.
Flue gas analysis: CO2 : 12% volume, flue gas temperature : 180oC and ambient
temperature : 20oC

Ans:
a) Theoretical Air = 11.43 x 0.84 + 34.5 x (0.12 – 0.015/8) + 4.32 x 0.015 = 13.74

(or)

Theoretical Air = 11.6 x 0.84 + 34.8x (0.12 – 0.015/8) + 4.35 x 0.015 = 13.92
(2 Marks)

b) Theoretical % CO2 = Moles of C/(Moles of N2 + Moles of C + Moles of Sulphur)

= 100 x (0.84/12)/(13.74 x 0.77/28 + 0.005/28 +0.84/12 + 0.015/32) = 15.62%
(or)

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Theoretical % CO2 = Moles of C/(Moles of N2 + Moles of C + Moles of Sulphur)

= 100 x (0.84/12)/(13.92 x 0.77/28 + 0.005/28 +0.84/12 + 0.015/32) = 15.44%

(2 Marks)
Depending on the variation in the above values (a and b) the subsequent calculations will
also have a minor variation in the end result, which can be ignored.

c) Excess air supplied = 7900 x(15.62 -12)/(12(100-15.62)) = 28.24%

(2 Marks)

d) Actual mass of air supplied = (1+0.2824) x 13.74 = 17.62 kg/kg of oil.

(2 Marks)
e) Actual mass of dry flue gas =
0.84 x 44/12 + 0.005 + 17.62 x 0.77 + 0.015 x 64/32 + 3(17.62-13.74) x 0.23
= 19.3596 kg/kg oil
(2 Marks)
f) % loss by dry flue gas = 19.3596 x 0.23 x (180-20)/10,397 = 0.0685 or 6.85%
(2 Marks)

g) % loss by formation of water from Hydrogen in the fuel

9 x 0.12 x (584 + 0.45 (180-20))/10,397 = 0.681 or 6.81%
(2 Marks)

h) % loss due to moisture in fuel = 0.005 x (584 +0.45 (180-20))/10,397 = 0.03%

(2 Marks)

i) % loss due to moisture in air = 17.62 x 0.015 x 0.45 (180-20)/10,397 = 0.183%

(2 Marks)

j) Boiler efficiency = 100- 6.85 – 6.81 – 0.03 – 0.183 = 86.127%.

(2 Marks)

N-4 A process plant is installing a 5 MW gas turbine cogeneration system with 12 TPH waste
heat boiler to meet the power and steam demand of the plant. The plant will operate at
90% of capacity, meeting the entire power requirement of the plant, which is presently
drawn from grid supply. The co-gen plant will also meet the steam requirement of 10
TPH, which is presently generated in a gas fired boiler with 86% efficiency on N.C.V.
basis. Calculate the differential cost between cogenerated power and grid power per unit
and also the additional natural gas requirement per day based on the following data.

Capacity of gas turbine = 5000 kW

Plant load factor = 90%
Auxiliary power consumption = 1%
Operating hrs. per annum = 8000
Net calorific value of natural gas = 9500 kCal / Sm3
Cost of natural gas = Rs.8 / Sm3
Steam produced by co-gen waste heat = 10 TPH boiler
Annual expenditure towards depreciation
and interest = Rs 500 lacs
Annual expenditure for operation &

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maintenance of co-gen plant = Rs 200 lacs
Heat Rate of gas turbine on NCV = 3050 kCal / kWh
Cost of electric power from grid supply = Rs. 4.5/ kWh
Enthalpy of steam = 665 kCal/ kg
Feed water temperature = 85oC

Ans Power generation from cogen plant = 5000X 0.9 X 8000 = 360 lac Kwh
Auxiliary power = 1%
Net power generation = 0.99 X 360 = 356.4 lac Kwh
Natural gas requirement for = 360 X 3050 / 9500 = 115.57 lac Sm3
power generation
(4 Marks)
Cost of fuel per annum = 115.57 X 8 = Rs.924.56 lacs
Annual expenditure for interest, = 500 + 200 = 700 lacs
depreciation and O&M
Total cost of generation = Rs.1624.56 lacs.

Cost of cogeneration power =1624.56 X 105 / 356.4 X 105

=Rs.4.56 / Kwh.
(4 Marks)
Gas consumption in existing gas = [10000 (665 – 85) / (0.86 X 9500)]
fired boiler = 710 Sm3/hr
= 17040 Sm3/day

Cost of steam = 710*Rs. 8/10

= Rs. 568/Ton
Annual savings by avoiding steam= 10 X 568 X 8000
In the existing gas fired Boiler = Rs. 454.4 Lacs.

Cost of generation after giving = 1624.56 – 454.4 = Rs.1170.16 lacs

credit for steam generation
Cost of generation after accounting = 1170.16 X 105 / 356.4 X 105
for steam cost
= Rs. 3.28 / Kwh
(5 Marks)
Grid power cost = Rs. 4.5 / Kwh
Cost advantage for cogen plant = 4.5 – 3.28 = Rs.1.22 / Kwh
generation

Daily gas requirement for operating = 5000 X 0.9 X 3050 X 24

GT cogen plant 9500
= 34673.68 Sm3 / day
(3 Marks)
Additional gas requirement for = 34673.68 – 17040 = 17633.68 Sm3/day
co-gen plant
(4 Marks)
-------- End of Section - III ---------

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