2ndNATIONALCERTIFICATIONEXAMINATION2005

FOR
ENERGYAUDITORS

MODELTESTSERIES1

Paper4:EnergyPerformanceAssessmentforEquipmentandUtilitySystems

Duration:2HRSMax.Marks:100

Generalinstructions:
oPleasecheckthatthisquestionpapercontains16questions
oThequestionpaperisdividedintothreesections
oAllquestionsinallthreesectionsarecompulsory
oAllpartsofaquestionshouldbeansweredatoneplace
oOpenBookExamination

SectionI:ShortQuestionsMarks:10x1=10
(i)AnswerallTenquestions
(ii)EachquestioncarriesOnemark

1 Howboilerratedcapacityisspecified?

Conventionally,boilersarespecifiedbytheircapacitytoholdwaterandthesteam
generationrate.Often,thecapacitytogeneratesteamisspecifiedintermsof
equivalentevaporation(kgofsteam/hourat100oC).Equivalentevaporationfrom
andat100oC.Theequivalentoftheevaporationof1kgofwaterat100oCtosteamat
100oC.

2 Whatarethecomponentsofsurfaceheatlossinthefurnacesanditsdependentfactors
affectingloss?

Radiationloss:ThelowcomponentsofSurfaceheatlossareSurface
temperatureandemissivityand
Convectionloss:RadiationlossisdefinedasSurfacetemperatureandwind
Velocity
3 HowEfficiencyandPowerFactorvariesinmotorswithVSDDrives.

Thevariablefrequencydriveshouldhaveanefficiencyratingof95%orbetteratfull
load.

Variablefrequencydrivesshouldalsooffera truesystempowerfactorof0.95orbetter
across the operational speed range, to save on demand charges, and to protect the
equipment(especiallymotors).
Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page1
of10
4 Whatarethethreereasonsforpoorfanperformanceinthefield?

a) Leakage,recirculationorotherdefectsinthesystem
b) Excessivelossinsystemcomponentclosetothefan
c) Disturbancetofanperformanceduetobendorothersystemcomponents

5 Howdoyoudeterminesystemresistanceforapump?

Systemresistance=frictionalhead+totalstatichead

Frictionalheadinasystemofpipesroughlyvariesasthesquareofthecapacity
flow.Ifsystemresistanceforfullflowisknown,resistanceforotherflowcanbe
calculatedas%offullflow.

6 Whatarethemeasuringinstrumentsrequiredforacompressedairdeliverytestby
nozzlemethod?

ThermometersorThermocouple
PressuregaugesorManometers
DifferentialpressuregaugesorManometers
StandardNozzle

7 Arefrigerationplantoperatingat600Tisconsuming564kWofcompressorpower.
FindoutthekW/ton,COPandEER

KW/ton=0.94

COP=3.72

EER=12.8

8 WhatisLampCircuitEfficacy?

LampCircuitEfficacyistheamountoflight(lumens)emittedbyalampforeachwattof
powerconsumedbythelampcircuit,i.e.includingcontrolgearlosses.Thisisamore
meaningfulmeasureforthoselampsthatrequirecontrolgear.Unit:lumenspercircuit
watt(lm/W

9 Whatisthecapacityfactorofwindturbine

TheCapacityFactor(CF)issimplythewindturbine'sactualenergyoutputfortheyeardividedbythe
energyoutputifthemachineoperatedatitsratedpoweroutputfortheentireyear.Areasonable
capacityfactorwouldbe0.25to0.30andaverygoodcapacityfactorwouldbearound0.40.Itis
importanttoselectasitewithgoodcapacityfactor,aseconomicviabilityofwindpowerprojectsis
extremelysensitivetothecapacityfactor

Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page2
of10

10 Namefourtypeofwastageduetopoorhousekeeping?

Wastageofwateroilsteamduetothefollowing
Leakingtaps/valves/flanges
Spillages
 Overflowingtanks
Wornoutmaterialtransferbelts

SectionII:LongQuestionsMarks:2x5=10
(i)AnswerallTwoquestions
(ii)EachquestioncarriesFivemarks

1 Comparetheadvantageofbiogasgeneration
overthedirectburningof25kgbiomass?
Biogasgenerationhashigherefficiency
andadditionalmanuregenerationcompared
toburningprocessasshownbelow

2 WhataretheFactorsAffectingFurnacePerformance?

Theimportantfactors,whichaffecttheefficiency,arelistedbelowforcriticalanalysis.
Underloadingduetopoorhearthloadingandimproperproductionscheduling
ImproperDesign
Useofinefficientburner
Insufficientdraft/chimney
AbsenceofWasteheatrecovery
AbsenceofInstruments/Controls
Improperoperation/Maintenance
Highstackloss
Improperinsulation/Refractories

Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page3
of10

SectionIII:NumericalQuestionsMarks:4x20=80
(i)AnswerallFourquestions
(ii)EachquestioncarriesTwentymarks

1 ABoilerEfficiencytrialwasconductedinanFurnaceOilfiredprocessboilerduring
EnergyAuditStudyandthefollowingdatawerecollected.

BoilerData:

BoilerRatedCapacity=10TPH(F&A100oC)
RatedBoilerEfficiency=84%
 Actualsteamgenerationpressure=7kg/cm2(g)Saturated
FeedwaterTemperature=45oC

FuelOilData:

FurnaceOilConsumption=600litreperhour
GCVofOil=10200Kcal/kg
Specificgravityofoil=0.92
%Carbon=84%
%Hydrogen=12%
%Sulphur=3%
%Oxygen=Nil
%Nitrogen=1%

FlueGasData:

%O2inFlueGas=5.5%byvolume
CO=Nil
FlueGasTemperature=240oC
SpecificHeatofFlueGas=0.24
MoistureatAmbientair=0.03kg/kgofair
Ambientairtemperature=40oC

Determinetheboilerefficiencybyindirectmethodbyassuming2%boilersurfaceheat
loss.Alsofindoutthefueloilsavinginlitreperhour,ifefficiencyofboilerwas
improvedtoRatedefficiency.

Solution:

TheoriticalairRequirementforFurnaceOil

Theoriticalairrequiredbasedonultimateanalysis.

11.6x84+((34.8x(120))+4.35x3
100

Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page4
of10

=11.6x84+34.8x12+4.35x3=14.05
100

ExcessairSupplied(EA)=5.5x100
215.5

Excessairfor5.5%O2influegas

=35.48%

Actualairsupplied(ASS)=1+EAxTheoreticalair
100

1+35.48x14.05=19.03kgofair/kgofoil
100
 MassofDryFluegas=.84x44+19.03x77+.01+(19.0314.05)x23
12100100

+0.03x64/32

=3.08+14.65+0.01+1.14+0.06
=19.94kgofair/kgofoil

CalculationofAllLosses:

1.Dryfluegasloss=19.94x0.24(24040)x100
10200

=9.38%

2.LossduetoHydrogenintheFuel=9x0.12(584+0.45(24040)x100
10200

=7.14%

3.LossduetoMoisturevapour
presentincombustionair=19.03x.03x.45(24040)x100
10200

=0.50%
4.boilersurfaceheatloss(given)=2%

(i)BoilerEfficiency=100(9.38+7.14+0.5+2%)
Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page5
of10

=10019.02=81%

EfficiencyImprovementfromExistingtoRated=3%

FuelInputafterimprovement
inboilerefficiency=600x.81=578.57lit./hr
0.84

(ii)OilSavingperhour=600578.57=21.42litre/hr.

2 Aprocessplantrequires28tonnesofsteamperhour.Thepowerrequirementis2250
kW.Theplantoperatesfor8000hoursperannum.

Steamisgeneratedat2barinacoalfiredboilerwithanefficiencyof75%Thefeed
watertemperatureis80OC.Thecalorificvalueofcoalis4000kcal/kg.Thecostofcoal
isRs.2000/tonne.

PowerisdrawnfromthegridatRs.4/kWh.Thecontractdemandis3000kVAandthe
companyischargedfor100%ofthecontractdemandatRs.300/kVA.
 Thecompanyisplanningforabackpressurecogenerationplantusingthesamecoal
withthefollowingparameters.Thepowerandsteamdemandwerefullymetbythe
cogenerationplant.

Boilergenerationpressure18bar,310OC
Boilerefficiency81%
Acontractdemandof1000kVAwiththegridwaskeptforemergencypurpose.
InvestmentrequiredRs.20crores
Generatedpower=2250kW
FindouttheIRRoveraprojectlifecycleof6years

Coalconsumption 28,000x[(2706.23/4.18)80]
0.75x4000

5296kg/hr

Fuelcostperannum 5.296x2000x8000

Rs.8.5crores

Annualelectricalenergycharges 2250x8000xRs.4

Rs.7.2crores

Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page6
of10

Maximumdemandcharges 3000x12x300

Rs.1.1crores

Totalelectricitybillperannum Rs.8.3crores

Totalenergybillperannum Rs.16.8crores

Withcogenerationplant

Enthalpyofsteamatturbineinlet 3052.56kJ/kg

Coalconsumption 28,000x[(3052.56/4.18)80]
0.81x4000

5780kg/hr

Incrementalcoalconsumption 484kg/hr

Incrementalfuelcostperannum 0.484x8000xRs.4000

Rs.1.5crores

Maximumdemandchargesperannum 1000x12xRs.300
 Rs.0.36crores

Totalcostperyear 8.5+1.5+0.36=10.36crores
Savings= 16.810.36=Rs.6.44crores

Investment Rs.20crores

IRR 27%

3 A centrifugal pump at base of cooling tower pumps 120 m3/hr at pressure 2.1
kg/cm2.Thecoolingtowerrangewasmeasuredtobe4oC.Whatisthepowerinput
atthemotor?(Efficiencyofpumpis65%andmotorefficiencyis82%).

Pump is throttled such that cooling tower range was 6oC. What is the new flow
rate under throttled conditions? (Pressure drop across the throttle valve is 0.5
kg/cm2).

Ifinsteadofthrottling,theexistingimpellerisreplacedwithanewimpellerata
costofRs.25000/findtheoperatingpointanddifferentialsavingsvisvis
Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page7
of10

throttling case considering 8760 operating hours and unit cost of Rs.4/ (assume
pumpefficiencyof63%andmotorefficiencyof82%)

Headloadincoolingtowerwithrangeof40C=120x1000x4
=480x103kCal/hour

Totalpumphead=2.1
=2.1kg/cm2

Motorinputpower=120x21x1000x9.81
3600x0.65x0.82x1000

=12.88kW

Underthrottledconditions

Flowrateincoolingtowerwithrangeof60C=480x103/(6x1000)
=80m3/hour

Flowrate=80m3/hr
Head=21+5
=26m

Motorinputpower=80x26x1000x9.81
3600x0.65x0.82x1000

=10.62kW

Afterreplacingtheexistingimpellerwithanewimpellertogivetherequiredflow
rateof80m3/hr,thenewheadwillbe
 Consideringthefanlaw

Underimpellerreplacedconditions

Q1=120m3/hour,H1=21m,Q2=80m3/hr,H2=?

(Q1/Q2)2=(H1/H2)

H2=H1x(Q2/Q1)2

=21x(80/120)2
=9.33m

Motorinputpower=80x9.33x1000x9.81
Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page8
of10

3600x0.63x0.82x1000

=3.94kW

Annualsaving=(10.623.94)x8760x4
=Rs.96360/

Investment=Rs.234067/

Simplepaybackperiod=25000/96360
=0.26year
~3.2months

4 Inanairconditioningsystem,theairflowrateis80,000m3/hratadensityof1.2
kg/m3..TheinletandoutletenthalpiesofairatAirHandlingUnitis105kJ/kgand79
kJ/kg.TheCOPofthesystemis3.82.Itisproposedtoreplaceitwithavapour
absorptionsystematacostofRs.50lacswithanannualmaintenancecostofRs.4lacs..
Thesteamconsumptionwillbe4.5kg/hr/TR.Thesteamistobegeneratedbyacoal
firedboilerwithanevaporationratioof4.5.TheenergyelectricalenergycostisRs.4
perkWhandthesystemoperatesfor8000hrsperannum.Thecostofcoalis
Rs.2000/tonne.Findoutthepaybackperiodfortheinvestment.

Refrigerationload =mx(hin hout)

4.18x3024

M=massofairflow =80000x1.2=96000kg/hr
Refrigerationload(TR) =[96000x(10579)]/(4.18x3024)
=198tons

KW/TR =3.516/COP
COP =3.82
KW/TR =3.516/3.82
=0.92
 Powerdrawn(kW) =198x0.92
=182kW

Annualenergycost =182xRs.4x8000
=Rs.58.24lacs

SteamrequiredforVAR =198x4.5
=891kg/hr

Costofsteam =2000/4.5
Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page9
of10

=Rs.444/ton
=Rs0.44/kg

SteamcostforVAR =0.44x891
=Rs.392/hr

Annualcost =Rs.392x8000
=Rs.31.36lacs

Annualmaintenancecost =4lakhs

Paybackperiod =50/31.364)
=22months
Paper4/ModelTestSeries1Dr.AmbedkarInstituteofProductivity,NPCChennai.Page10
of10