Paper 4 – Energy Auditor – Set B 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 B 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. Calculate the blow down rate for a boiler with an evaporation rate of 4 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 % Makeup
Blow down (%) =
Permissible TDS in Boiler  Feed water TDS

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 Paper 4 – Energy Auditor – Set B Key

250 X 10
Percentage blow down =  0.91%
3000  250
If boiler evaporation rate is 4000 kg/hr then required blow down rate is:
= 4000 x 0.91/ 100

= 36.4 kg/hr

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 4000 kg/hr then required blow down rate is:
= 4000 x .83/100 = 33.2 kg/hr

L-2 The suction head of a pump is 5 m below the pump centre line. The discharge
pressure is 3 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 = 3 kg/cm2

= 30 metre head.
Suction Head = - 5 metre.
Total Head = 30 – (-5) = 35 metre

Hydraulic Power = (100/3600) x 1000 x 9.81 x 35/1000

= 9.53 kW
Pump Efficiency = 100 x 9.53 / 15 = 63.5 %

-------- 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 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.

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 Paper 4 – Energy Auditor – Set B Key

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
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 = 70%

Boiler efficiency with Imported coal = 75%
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

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 Paper 4 – Energy Auditor – Set B Key

Indian coal
Imported coal
Q= 100,000 x (668 – 80)
100,000 x (668 – 80)
0.70 x 4000 Q=
0.75 x 5900
21.0 T/hr
13.28 T/hr

Find theoretical air requirement

= [(11.6 x C) + {34.8 x(H2 - O2/8)} + (4.35 x S)] kg / kg of coal

100

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
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+ 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

Imported Coal: = 10.01 x 0.23 x (200 – 30) x 100 = 6.63%

5900

N-2 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. 1,20,000 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.

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 Paper 4 – Energy Auditor – Set B Key

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 Retrofit Cost of Maintenan Cash Discount Present

cost Energy & ce cost flow Factor Value
demand savings for 12%
savings
0 120000 0 0 -120000 1.000 -120000
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

Total 20,000 1,38,000 14,493.8

The NPV for the upgrade option against 12% interest rate = Rs 14,494/-

N-3 A pharma unit had installed a centralized refrigeration system of 120 TR Capacity
several years ago. The refrigeration system operators 24 hours a day, 300 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:

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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:

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 / 1.03 = 3.41

EER : 12 / 1.03 = 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

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 Paper 4 – Energy Auditor – Set B Key

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 (7200 hrs) 72000 61920 28800
Annual monetary savings (Rs) @ Rs. 4.5/ 324000 278640 129600
kWh

N-4 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
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 = 70%
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
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 Paper 4 – Energy Auditor – Set B Key

6 7
MTOE due to electrical savings = ( 3287 x 10 x 860 ) / 10
= 282682 MTOE

MTOE due to coal savings= ( 3.5 x 10 5 x 1000 x 4000 ) / 10 7

= 140000 MTOE

MTOE due to natural gas savings= ( 15728 x 10 5 x 8500 ) / 10 7

= 1336880 MTOE
MTOE due to Fuel oil savings = ( 1.85 x 105 x 0.94 x 1000 x 10000 ) / 10 7

= 173900 MTOE

MTOE due to captive diesel generation = 1000 x 106 x 0.85 x 10000 / 3.5 x 107
= 242857 MTOE

Total MTOE = 282682 + 140000 + 1336880 + 173900 + 80702 + 242857 = 2257021 MTOE

ii) Grid Electricity Saved = (62 +1216 + 1374 + 635 ) million k Wh =

6
= 3287 x 10 kWh

Therefore Avoided Capacity = 3287 x 10 6 / ( 0.70 x .80 x 365 x 24 x 1000 )

= 670 MW

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

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