NATIONAL CERTIFICATION EXAMINATION 2008

FOR
ENERGY AUDITORS
PAPER 4: ENERGY PERFORMANCE ASSESSMENT FOR EQUIPMENT
AND UTILITY SYSTEMS (Set A)

Section - I:

SHORT DESCRIPTIVE QUESTIONS

Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One marks
S-1

In the field testing for efficiency of induction motors which loss is assumed?
Stray loss

S-2

For calculating which of the boiler losses, atmospheric humidity is required to be

measured ?
Heat loss due to moisture in air.

S-3.

A cogeneration plant with a back pressure turbine has a constant steam demand
and fluctuating power demand. What is the best option to meet the fluctuating
power demand?
Parallel operation with grid

S-4

Why are boiler feed water tanks and deaerators, feeding to boiler feed pumps
always kept at an elevated position?
To take care of NPSH requirements.
Otherwise vapour lock and cavitation will occur.

S-5

What is meant by the term Solar Window ?

The period four to five hours in late morning and early afternoon (between 9 AM to
3 PM is called the solar window.

S-6

Why does a wind generator produce lesser power in summer than in winter at the
same wind speed?
Because the air density is lower in summer

S-7

Why do biomass combustion qualify for CDM benefits even though they emit
carbon dioxide?
Because it absorbs the same amount of carbon in growing as it releases when
consumed as fuel.

S-8

What are the main constituents of producer gas?

Carbon monoxide, Hydrogen, Nitrogen and Methane

S-9

What are the two major sources of waste heat available from a water-cooled
Diesel Generator set?
Exhaust flue gases and Cooling water

S-10

For determining heat loss in flue gases due to incomplete combustion which flue
gas constituent needs to be measured?
Carbon monoxide

-------- 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 water cooled condenser of a refrigeration plant is rejecting 2160 MCals of heat

per hour. A single cooling tower pump is operated to meet the desired flow to the
condenser. The total head developed by the pump is 25 m. The range of the
cooling tower is 4oC. Find out the efficiency of the pump if the power drawn by
the motor is 77 kW with an efficiency of 0.9
Heat load
Range
Flow rate of cooling water

2160000 kCal/hr
4oC
2160000 / 4
540 m3/hr

Hydraulic power

(540 / 3600) x 25 x 9.81

36.8 kW

Shaft power to the pump

77 kW x 0.9
69.3 kW
36.8 / 69.3
53 %

Pump efficiency

L-2

The dimension of an office hall is 12 m X 7 m. The lamp is located at a height of

3 m from ground level(The working plane is assumed as 0.75 m above the floor).
The total electric circuit watt for the office hall is 1600 watts. The average lux
level measured in the room is 650 lux. The office works for 8 hours a day for 300
days a year. Calculate the energy saving potential per annum. Other relevant
data required for calculation can be taken from the book.
Floor area of the interior

12 X 7
84 m2

Hm (The mounting height, which is the

height of the lighting fittings above the
horizontal working plane. The working
plane is assumed as 0.75 m above
the floor in offices)

3 0.75

2.25 m
Room Index (RI)

LxW
Hm (L + W)

RI

12 x 7
2.25 (12 + 7)
1.96

Room Index (RI)

Total circuit watts of the installation
Watts per m2
Average lux level measured
Actual lux per watt/m2
Target Lux/W/m2 lux for type of the
type of office application and RI of
1.96 (Refer Table 10.2)
Installed Load Efficacy Ration (ILER)
Annual Energy wastage
Energy Saving Potential

1600 W
1600/84
19.04 W/m2
650 lux
650/19.04
34.13 lux/W/m2
46 lux/W/m2
34.13/46
0.74
(1 ILER) x watts x No of Hours
(1 0.74) x 1600 x 8 hrs/day x 300 days
998400 Wh/year
998 KWh/Year

-------- 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

Based on the following data, you as an Energy Auditor have the task to quickly
assess the possibility of installing a Coconut Shell fired boiler in order to have
steam for Vapor Absorption System for air conditioning of a abrasive
manufacturing facility. Daily availability of Coconut Shell can be taken as 4.5
Tonnes/day.
Other data

Boiler Rated Capacity

: 1 TPH
Boiler Efficiency
: 70 %
Actual Steam Generation Pressure
: 7 kg/cm2 (g) Saturated
Boiler Feed water temperature
: 80oC
2
Enthalpy of steam at 7 kg/cm
: 661.5 kCal/kg
Calorific value of Coconut Shell (GCV) : 4565 kCal/kg
Cost of coconut shell
: Rs.2000/tonne
Steam required for Vapour absorption system: 5 kg/TR
Load factor air-conditioning system is 0.7 ( The same load factor applies for
the existing and proposed system)

1. Justify whether fuel availability is sufficient to run this boiler.

2. What is annual cost of operating the existing Vapor Compression Chilling
Plant of 200 TR capacity? (COP=4.13, load factor=70%, Tariff=5.5 Rs/KWh,
Motor efficiency = 0.93 and Annual operating Hrs=8000)
3. Calculate the annual saving and payback, if Capital cost of boiler & Vapour
absorption system = Rs. 60 lakhs. Additional cost of operation for vapour
absorption system is Rs. 10 lacks per annum.
1.
Fuel Input (Kg/hr)

1000 X (661.5 80)

0.70 X 4565
182 kg/hr
4.37 TPD

Therefore, amount of Coconut Shell

required per day
Coconut shell available per day is 4.5 tons. Hence project is feasible.
2.
KW/TR
system

of

vapour

compression

3.516 / COP
3.516 / 4.13

0.85
Annual operating cost
3
Coconut shell consumption
Cost per annum

N-2

0.85 x 200 TR x 0.7 x 5.5 x 8000 / 0.93

Rs.56.3 lakhs
182 kg/hr
182 x 8000 x 0.7 x Rs 2/kg
Rs.20.4 lakhs

4 Annual savings

56.3 20.4
Rs. 35.9 lakhs

Payback period

60 /35.9
1.67 years or 20 months

Two energy conservation projects have been proposed.

For the first project, a capital investment of Rs.1,15,000/- is required and the net
annual saving is Rs. 20,000/- for 10 years. Salvage value at the end of 10 years
is Rs. 8000/=.
For the second project, a capital investment of Rs. 1,50,000/- produces a savings
of Rs. 20,000/- for first 3 years and Rs. 25,000/- for next 7 years. Salvage value
at the end of 10 years for the second project is Rs. 10,000/-.
Determine the NPV for both the projects with a discount factor of 9%. Which
project is more financially attractive.
Solution:
i) Net present value for both the projects with a discount factor of 9% is as follows
Year

Discount
Factor 9%

0
1
2
3
4
5
6
7
8
9
10

1.000
0.917
0.842
0.772
0.708
0.650
0.596
0.547
0.502
0.460
0.422

Project 1
Net
Present
Savings
Value (Rs)
(Rs)
-115000
-115000
20000
18349
20000
16834
20000
15444
20000
14169
20000
12999
20000
11925
20000
10941
20000
10037
20000
9209
28000
11827

Project 2
Net
Present Value
Savings
(Rs)
(Rs)
-150000
-150000
20000
18349
20000
16834
20000
15444
25000
17711
25000
16248
25000
14907
25000
13676
25000
12547
25000
11511
35000
14784

Year

Discount
Factor 9%

Project 1
Net
Present
Savings
Value (Rs)
(Rs)
NPV
+9976

Project 2
Net
Present Value
Savings
(Rs)
(Rs)
NPV
+2009

It can be seen that over a 10 year life span, the NPV for project 1 is Rs.9976/=
while for project 2, it is Rs, 2,009. Hence Project 1 is the preferential proposal.

N-3

In an air cooled heat exchanger hot fluid (specific heat:1 kCal/kg o C) is entering at
a temperature of 80 0C and leaving at a temperature of 38 0C. Flow rate of the
hot fluid is 63450 kg/hr.
Air is entering at a temperature of 30 0C and leaving at a temperature of 60 0C.
Flow rate of the air is 370057 kg/hr. Power drawn by the fan is 30 kW. The plant
persons want to replace it with a water cooled counter flow plate heat exchanger.
Given data:
Annual operating hours
Pump Efficiency
Motor efficiency

: 4800 hrs
: 75%
: 90 %

Effectiveness of water cooled heat exchanger is 0.4

Water is available at 25 OC
Total head developed by the pump is 4 kg/Cm2
Over all heat transfer coefficient of PHE is 22300 kCal/m2/OC
For water cooled system the additional fan power consumption is 5 kW.
Calculate
1. saving due to replacement
2. area of the plate heat exchanger
Solution:
Heat Duty
Heat duty in hot fluid

M x Cp h x (Ti - To)
63450 x 1 x (80 - 38)
2664900 Kcal / Kg

(OR)
Heat duty in cold Air

M x Cp air x (to ti)

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

Effectiveness of water cooled 0.4

heat exchanger

Effectiveness
Cold Water Outlet
Mass flow rate of cooling water
(M)

Cold Water outlet Cold water inlet

Hot effluent inlet Cold water inlet
(0.4 x (80 25)) + 25
47 OC
Heat duty in hot fluid
Cp x (Cold Water outlet Cold water inlet)
2664900
1 x (47 25) x 1000
121.13 m3 /Hr

Total head developed by the 40 m ( 4 kg/sq.cm)

pump
Hydraulic Power of pump
(121.13 x 40 x 1000 x 9.81)/ (1000 x 3600)
13.20 KW
Pump Power Requirement at
75% pump efficiency

13.20 KW/0.75

17.6 KW
Motor Input Power Required at 17.6/0.9
90% Efficiency
20 KW
Additional power for cooling 5 kW
tower fan
Total power consumption for 25 kW
water cooled system
Savings
30 25
5 KW
Annual Saving in KWh
5 KW x 4800 Hrs
24000 KWh/Annum
Calculations for LMTD for
Proposed PHE
LMTD for counter current flow in {(80-47) (38-25)} / ln {(80-47) / (38-25)}
PHE
21.56 Deg C
Considering overall heat transfer
coefficient (U)
Heat transfer Area

22300 kCal/m2/0C
Q/ (U x Tlm)
2664900/ (22300 x 21.56)
5.54 m2
(Say 6 m2)

a) N4. A chemical plant is operating a 40 ton per hour Furnace oil fired boiler. It
has decided to indent a new energy efficient dual fuel fired boiler (furnace oil and
hydrogen with hydrogen meeting 20% of the thermal needs) to meet its steam

demand. The unit has decided to bundle carbon credits due to installation of clean
technologies by partial switching over to carbon free fuels. (The efficiency of the
existing furnace oil fired boiler and dual fuel fired boiler are same.)
The plant is seeking your services by assigning the following sub- tasks utilizing
your understanding about Combustion of fuels. You are required to compute:
a) Theoretical air, Furnace oil requirement per year and CO 2 per kg of oil for the
existing Furnace oil fired boiler.
b) Reduction in CO2 emissions by with proposed dual fuel fired boiler.
c) CO2 emissions if the boiler were to be completely on natural gas and the ratio of
emissions of gas firing to oil firing.
Furnace Oil characteristics
GCV of Oil
Specific gravity of oil
Ultimate analysis
% Carbon
% Hydrogen
% Sulphur
% Oxygen
% Nitrogen

= 10200 Kcal/kg
= 0.92
= 84%
= 12%
= 3%
= Nil
= 1%

Ultimate analysis of Natural Gas: C 74%, H; 25%, Oxygen, inert = 1.0%

GCV of furnace oil and Natural gas are nearly same, efficiency of boiler with furnace
oil firing is 86 % and natural gas firing 81%. Boiler feed water temp:80 deg.C and
enthalpy of steam:660 kcal/kg
Solution :
a).
Theoretical air required based on 11.6 x 84 + ((34.8 x (12-0)) + 4.35 x 3
ultimate analysis
100
14.05 kg/kg of oil
Kg of CO2 /kg of Oil
0.84 x (44/12)
3.08
b)
Efficiency of boiler
Heat output
Heat input

86%
40000x (660-80)
23.2 million Kcal/hr
2 3.2/0.86

26.97 million Kcal/hr

Furnace Oil Consumption

26.97*10^6/10200
2645 kg/hr
2.65 Tonnes/hr

CO2 emissions expected

2645 x 44/12 x 0.84

8146 kg/hr

Bi-fuel hydrogen firing will reduce oil requirement and emissions by 20%
Yearly furnace oil requirement
2.65 * 0.8 * 8000
16960 Tonnes/year
Emissions reductions
8146* 0.2 (burning Hydrogen does not produce
CO2)

1629.2 kg/hr
1.63*8000
13040 Tonnes

Emissions reduction/year
c)
Natural Gas consumption /year

16960 x (0.86/0.81)
18007 Tonnes

Kg of CO2 /kg of Natural Gas

0.74 x (44/12)
2.71
CO2 emission with natural gas firing 2.71* 18007
48,800 Tonnes/year
Emissions
with Gas firing
Emissions with oil firing

2.71 x 18007
3.08X16960
0.934

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