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 ---------