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16th National Certification Exam Energy Managers & Auditors SEPTEMBER 2015 Paper 1

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Paper 1 Set A REGULAR 16th NATIONAL CERTIFICATION EXAMINATION FOR ENERGY MANAGERS & ENERGY AUDITORS September, 2015 PAPER 1: GENERAL ASPECTS OF ENERGY MANAGEMENT & ENERGY AUDIT Date: 19.09.2015 Timings: 0930-1230 HRS Duration: 3 HRS Max. Marks: 150 General instructions: o o o o o Please check that this question paper contains 11 printed pages Please check that this question paper contains 64 questions The question paper is divided into three sections All questions in all three sections are compulsory All parts of a question should be answered at one place Section I: OBJECTIVE TYPE (i) (ii) (iii) 1. Marks: 50 x 1 = 50 Answer all 50 questions Each question carries one mark Please hatch the appropriate oval in the OMR answer sheet with Black Pen, as per instructions Which one is not a consequence of global warming a) rise in global temperature c) food shortage and hunger 2. Which of the following will not be a major component of mass balance a) steam 3. b) water b) kCal/ton c) kJ/kg Which of the following comes under mandatory labeling programme b) induction motors d) LED lamps Transit time method is used in which of the instrument a) lux meter 7. d) kg/kCal b) Sulfur Hexafluoride (SF6) d) Per FluoroCarbon (PFC) a) diesel Generators c) tubular Fluorescent Lamps 6. d) lubricating oil Which of the following GHGs has the longest atmospheric life time a) CO2 c) CFC 5. c) raw materials Which of the following terms does not refer to specific energy consumption a) kWh/ton 4. b) rise in sea level d) fall in global temperature b) ultrasonic flow meter c) pitot tube d) fyrite To improve the boiler efficiency, which of the following needs to be done _______________________ Bureau of Energy Efficiency 1 Paper 1 Set A REGULAR a) maximize O2 in flue gas c) minimize CO2 in flue gas 8. The simplest technique for scheduling of tasks and tracking the progress of energy management projects is called a) Gantt chart 9. b) 59% c) 4 d) 5 b) Rs 45 lakhs c) Rs 138 lakhs d) None of above b) boiler c) condenser d) turbine The ISO standard for Energy Management System is b) ISO 50001 c) ISO 140001 d) None of the above The indicator of energy performance in a thermal power plant is b) % aux. power consumption d) all the above The fixed energy consumption for the company is 1,000 kWh. The slope in the energy production chart is found to be 0.3. Find out the actual energy consumption if the production is 80,000 Tons b) 24,000 c) 26,000 d) 23,000 The cost of replacement of inefficient compressor with an energy efficient compressor in a plant was Rs 50 lakhs. The net annual cash flow is Rs 12.5 lakhs. The return on investment is a) 15% 19. d) Rs. 10,000 The major share of energy loss in a thermal power plant is in the a) 25,000 18. c) Rs. 349 b) 3 a) heat rate (kCal/kWh) c) specific coal consumption 17. d) none of the above The monthly electricity bill for a plant is Rs. 100 lakhs which accounts for 45% of the total monthly energy bill. How much is the plant s monthly energy bill a) ISO 9001 16. c) one kilo calorie The number of moles of water contained in 54 kg of water is ------------ a) generator 15. e)10% b) Rs. 386 a) Rs 222.22 lakhs 14. d) 44% b) one kilojoule a) 2 13. d) WBS The present value of Rs. 1,000 in 10 years time at an interest rate of 10% is a) Rs. 2,594 12. c) PERT The quantity of heat required to raise the temperature of 1 kg of water by 1 OC is termed as a) latent heat 11. b) CPM The ratio of wind power in the wind actually converted into mechanical power and the power available in the wind is about a) 75% 10. b) maximize CO2 in flue gas d) maximize CO in flue gas b) 20% c) 25% d) 19.35% The contractor provides the financing and is paid an agreed fraction of actual savings achieved. This payment is used to pay down the debt costs of equipment and/or services. This is known as a)traditional contract c) performance contract _______________________ Bureau of Energy Efficiency b) extended technical guarantee/service d) shared savings performance contract 2 Paper 1 Set A REGULAR 20. PERT/CPM provides which of the following benefits a) predicts the time required to complete the project b) shows activities which are critical to maintaining the schedule c) graphical view of the project d) all the above 21. Input fuel of fuel cell a) petrol 22. b) 50% b) 266.6 c) 600 KVA d)1600 KVA b) 100 times c) Two times d) 25 times b) decrease d) can t say c) no Change b) 73 d) Can t say c) 114 If heat rate of power plant is 860 kcal/kWh then the cycle efficiency of power plant will be b) 55% c) 100% d) 86% If air consists of 77% by weight of nitrogen and 23% by weight of oxygen, the mean molecular weight of air is b) 28.8 c) 17.7 d) insufficient data How much power generation potential is available in a run of river mini hydropower plant for a flow of 40 liters/second with a head of 24 metres. Assume system efficiency of 60% a) 5.6 kW 32. b) 2222 KVA If the pressure of water is 0.7 kg/cm then boiling point will be approximately a) 11.9 31. d) 114.3 2 a) 41% 30. c) 130 If we heat the air without changing absolute humidity, % relative humidity will a) 100 29. d) none of the above In a 50 Hz AC cycle, the current reverses directions ________ times per second a) increase 28. c) 80000 kWh In a DG set, the generator is consuming 400 litres per hour diesel oil. If the specific fuel consumption of this DG set in 0.30 litres/kWh at that load then what is the kVA loading of the set at 0.6 power factor a) 50 times 27. d) 90% In a drying process, moisture is reduced from 60% to 30%. Initial weight of the material is 200 kg. Calculate the weight of the product a) 1200 KVA 26. c) 25% b) 30000 kWh a) 104 25. d) natural gas In an industry the average electricity consumption is 5.8 lakhs kWh for the period, the average production is 50,000 tons with a specific electricity of 11 kWh/ton for the same period. The fixed electricity consumption for the plant is a) 58000 kWh 24. c) nitrogen In India power sectors consumes about_______% of the coal produced a) 75% 23. b) hydrogen b) 9.4 kW c) 4.0 kW d) 2.8 kW Fuel cell using methanol as anode and oxygen as cathode is _______________________ Bureau of Energy Efficiency 3 Paper 1 Set A REGULAR a) proton exchange membrane fuel cell b) alkaline fuel cell 33. For expressing the primary energy content of a fuel in tonnes of oil equivalent (toe) which of the following conversion factors is appropriate a) toe=1x106 kcal 34. b) toe=116300 kwh b) reference year s production d) capacity utilization b) sold c) banked for next cycle b) capital costs c) salvage value d) none of the above At standard atmospheric pressure, specific enthalpy of saturated water, having temperature of 50 OC will be _________ kcal/kg a) 1 39. b) GDP/fuel consumption d) energy consumption / GDP Costs associated with the design, planning, installation and commissioning of a project are a) variable costs 38. d) traded directly between DCs Energy intensity is the ratio of a) fuel consumption / GDP c) GDP/ energy consumption 37. d) all the above ESCerts cannot be a) bought 36. c) toe=41.870 GJ For calculating plant energy performance which of the following data is not required a) current year s production c) reference year energy use 35. b) phosphoric acid fuel cell d) direct methanol fuel cell b) 50 c) 100 d) Can't say AT & C losses means a) administration transmission and commercial b) aggregate technical and commercial c) average technical and commercial d) none of the above 40. As per primary commercial energy consumption mix in India, the fuel dominating the energy production mix in India is a) natural gas 41. b) 1584 c) 106 d) 114 b) 20 days c) 19 days d) 18 days Among which of the following fuels, the difference between the GCV and NCV is maximum a) coal 44. d) nuclear energy An activity has an optimistic time of 15 days, a most likely time of 18 days and a pessimistic time of 27 days. What is the expected time a) 60 days 43. c) coal An oil-fired boiler operates at an excess air of 6 %. If the stoichiometric air fuel ratio is 14 then for an oil consumption of 100 kg per hour, the flue gas liberated in kg/hr would be a)1484 42. b) oil b) furnace Oil c) natural gas d) rice husk A waste heat recovery system costs Rs. 54 lakhs and Rs. 2 lakhs per year to operate and maintain. If the annual savings is Rs. 20 lakhs, the payback period will be _______________________ Bureau of Energy Efficiency 4 Paper 1 Set A REGULAR a) 8 years 45. b) 2.7 years b) 45000 kcal b) 10 m3/hr d) 6.6 m 3/hr c) 0.37 kWh d) 4.0 kWh 3 20 m of water is mixed with 30 m of another liquid with a specific gravity of 0.9. The volume of the mixture would be c) 50 m3 b) 48 m3 d) 53 m3 100 tons of coal with a GCV of 4200 kcal/kg can be expressed in tonnes of oil equivalent as a) 42 50. c) 5.5 m3/hr b) 6.37 kWh 3 a) 47 m3 49. d) 2000 kcal A 400W lamp was switched on for 10 hours per day. The supply volt is 230V (current= 2 amps & PF= 0.8). What is the energy consumption per day a) 3.68 kWh 48. c) 500 kcal A centrifugal pump draws 12 m 3/hr. Due to leakages from the body of the pump a continuous flow of 2 m3/hr is lost. The efficiency of the pump is 55%. The flow at the discharge side would be a) 12 m3/hr 47. d) 10 years A process requires 10 Kg of fuel with a calorific value of 5000 kcal/kg. The system efficiency is 80% and the losses will be a) 10000 kcal 46. c) 3 years b) 50 c) 420 d) 125 1 kg of wood contains 15% moisture and 7% hydrogen by weight. How much water is evaporated during complete combustion of 1 kg of wood a) 0.78 kg b) 220 grams c) 0.15 kg d) 0.63 kg . . End of Section I .. . Section II: SHORT DESCRIPTIVE QUESTIONS (i) (ii) S-1 Marks: 8 x 5 = 40 Answer all Eight questions Each question carries Five marks A gas fired water heater heats water flowing at a rate of 20 litres per minute from 25 0 C to 85oC. If the GCV of the gas is 9200 kcal/kg, what is the rate of combustion of gas in kg/min (assume efficiency of water heater as 82%) Solution: Volume of water heated = 20 liters/min Mass of water heated = 20 Kg/min Heat supplied by gas * efficiency = Heat required by water. 1 mark Mass of gas Kg/min * 9200 * 0.82 = 20 Kg/min * 1 kcal/Kg/oC)* (85-25)oC _______________________ Bureau of Energy Efficiency 5 Paper 1 Set A REGULAR 1 mark Mass of gas Kg/min = (20*1*60)/ (9200*0.82) = 0.159 Kg/ min. . 3 marks S-2 Calculate the net present value over a period of 3 years for a project with the following data. The discount rate is 12%. Year 0 1 2 3 4 Ans: NPV Investment (Rs) 75,000 Savings (Rs) 50,000 25,000 75,000 75,000 35,000 = - 75,000 + 25,000/(1+0.12) + 75,000/(1+0.12)2 + (75,000 50,000)/(1+0.12)3 3 marks = -75,000 + 22,321 + 59,789 + 17, 794 = 24,904 Rs. 2 marks S-3 In a process plant, an evaporator concentrates a liquor containing solids of 6% by w/w (weight by weight) to produce an output containing 30% solids w/w. calculate the evaporation of water per 500 kgs of feed to the evaporator. Solution : Inlet solid contents = 6 % Output solid contents = 30% Feed = 500 kgs Inlet solid content in kg in feed = 500 x 0.06 = 30 kg Outlet solid content in kg = 30 kg 1 mark 1 mark Quantity of water evaporated = [500 {(30 / 30) x 100}] = 400 kg. 3 marks S-4 List down at least five schemes of BEE under the Energy Conservation Act 2001 Ans: Schemes of BEE under the Energy Conservation Act - 2001 are as follows: Energy conservation building codes (ECBC) Standards and labeling (S&L) Demand side management (DSM) Bachat Lamp Yojana (BLY) Promoting energy efficiency in small and medium enterprises (SME s) Designated consumers Certification of energy auditors and energy managers _______________________ Bureau of Energy Efficiency 6 Paper 1 Set A REGULAR .. (5 marks for any of the above five schemes) S-5 What parameters are measured with the following instruments? a) b) c) d) e) Pitot tube Stroboscope Fyrite Psychrometer Anemometer Ans: a. b. c. d. e. Pitot tube Stroboscope Fyrite Psychrometer Anemometer Static, Dynamic and Total Pressure of Gas Speed, RPM CO2 % or O2 % Dry Bulb Temperature and Wet Bulb Temperature Air or wind velocity (1 mark each) S-6 What are ESCerts and explain the basis for their issue and trading under PAT scheme ? PAT scheme provides the option for industries who achieve superior savings to receive energy savings certificates for this excess savings, and to trade the additional certified energy savings certificates with other designated consumers (energy intensive industries notified as Designated Consumers under the Energy Conservation Act and included under PAT Scheme) who can utilize these certificates to comply with their specific energy consumption reduction targets. Energy Savings Certificates (ESCerts) so issued will be tradable at Power Exchanges. The scheme also allows units which gain ESCerts to bank them for the next cycle of PAT, following the cycle in which they have been issued. .. (5 marks) S 7 Pressure of a nitrogen gas supplied to an oil tank for purging is measured as 100 mm of water gauge when barometer reads 756 mm of mercury. Determine the volume of 1.5 kg of this gas if it s temperature is 25 0C. Specific gravity of mercury: 13.6. Take R = 8.3143 kJ/(kMol x K) Ans: Nitrogen pressure = 100 mm of Water Gauge = 100 / 13.6 = 7.353 mm of Hg .. (0.5 mark) Absolute Temperature, T = 25 + 273 = 298 K, Mass = 1.5 kg & Barometric pressure = 756 mm of Hg. Absolute pressure = 756 + 7.353 = 763.353 mm of Hg .. (0.5 mark) Pressure, P _______________________ Bureau of Energy Efficiency = Density, (kg/m3) x Gravity, g (m/s2) x Mtr of Liquid, h (Mtr) / 1000 = (13,600 x 9.81 x 0.763)/1000 = 101.79 kPa 7 Paper 1 Set A REGULAR .. (1.5 marks) Molar mass of Nitrogen = 28 kg/kMol. Number of kMol, n = Mass / Molar Mass = 1.5/ 28 = 0.0536 kMol (1 mark) Using the ideal gas equation and putting the above values; PV = nRT 101.79 x V = 0.0536 x 8.3143 x 298 V = 1.395 m3 .. (1.5 marks) S 8 Distinguish between designated agency and designated consumer as per energy conservation act 2001 Ans: Designated Agency: Designated agency means an agency which coordinates, regulates and enforces of Energy Conservation Act 2001within a state. .. (2.5 marks) Designated Consumer: Designated consumer means any users or class of users of energy in the energy intensive industries and other establishments specified in Schedule as designated consumer. .. (2.5 marks) . . End of Section II .. . Section III: LONG DESCRIPTIVE QUESTIONS (i) (ii) L-1 Marks: 6 x 10 = 60 Answer all Six questions Each question carries Ten marks a) A furnace heating steel ingots is fired with oil having a calorific value of 10,500 kCal/kg and efficiency of 75%. Calculate the oil consumption per hour when the throughput of the furnace is 50 TPH and the temperature of the finished product is 600 oC. Take ambient temperature as 30 oC and Specific Heat of Steel as 0.12 kCal/kg oC b) In Steel industry, different types of gases are generated during steel making process. Volumetric Flow rate and Calorific Values of each gases are: Type of Gas Coke Oven Gas COREX Gas BOF Gas Blast Furnace Gas _______________________ Bureau of Energy Efficiency Flow (SM3/hr) 75,000 50,000 55,000 80,000 CV (kCal/SM3) 4,000 2,000 1,500 700 8 Paper 1 Set A REGULAR All these gases are mixed in the gas mixer before combustion. Find out the Calorific Value (in kCal/SM3) of mix gas. Ans: a) Oil Consumption / hr = 50 (TPH) x 0.12 (kCal/kg oC) x (600 30) (oC) -----------------------------------------------------------------0.75 (%) x 10,500 (kCal/kg) = 0.43 TPH (5 marks) b) Total flow of Mix Gas = 75,000 + 50,000 + 55,000 + 80,000 = 2,60,000 SM3/hr (1 mark) CV of Mix Gas = [(75,000 x 4,000) + (50,000 x 2,000) + (55,000 x 1,500) + (80,000 x 700)] / 2,60,000 = 2,071 kCal/SM3 (4 marks) L 2 A) Briefly explain the following terms with respect to energy management? I. Normalizing II. Benchmarking B) Explain the meaning of Fuel and Energy substitution with examples. Ans: A) I) Normalizing: The energy use of facilities varies greatly, partly due to factors energy efficiency of the equipment and operations. These factors weather or certain operating characteristics. Normalizing is the removing the impact of various factors on energy use so performance of facilities and operations can be compared. beyond the may include process of that energy (3 marks) II) Benchmarking: Comparison of energy performance to peers and competitors to establish a relative understanding of where our performance ranks. (2 marks) B) Fuel and Energy substitution with examples: _______________________ Bureau of Energy Efficiency 9 Paper 1 Set A REGULAR Substituting existing fossil fuels/energy with more efficient and / or less cost/less polluting fuel. .. (1 mark) Few examples of fuel substitution Natural gas is increasingly the fuel of choice as fuel and feedstock in the fertilizer, petrochemicals, power and sponge iron industries. Replacement of coal by coconut shells, rice husk etc. Replacement of LDO by LSHS (2 marks) Few examples of energy substitution Replacement of electric heaters by steam heaters. Replacement of steam based hot water by solar systems. (2 marks) L-3 The details of activities for a pump replacement project is given below: a) Draw a PERT chart b) Find out the duration of the project c) Identify the critical path. Activity A B C D E F G H Immediate Predecessors A B C C C D, E, F G Time (days) 1 2 4 6 3 5 8 7 Ans: _______________________ Bureau of Energy Efficiency 10 Paper 1 Set A REGULAR . .(6 marks) Duration = 28 days .. (2 marks) Critical Path: A-B-C-D-G-H .. (2 marks) L 4 The production capacity of a paper drying machine is 500 TPD and is currently operating at an output of 480 TPD. To find out the steam requirement for drying, the Energy Manager measures the dryness of the paper both at inlet and outlet of the paper drying machine which found to be 60% and 95% respectively. The steam is supplied at 4 kg/cm2, having a latent heat of 510 kCal/kg. The evaporated moisture temperature is around 100 0C having enthalpy of 640 kCal/kg. Plant operates 24 hours per day. Assume only latent heat of steam is being used for drying the paper and neglect the enthalpy of the moisture in the wet paper. i) ii) Estimate the quantity of moisture to be evaporated per hr. Input steam quantity required for evaporation per hr. Ans: Output of the drying machine = 480 TPD with 95% dryness. Bone dry mass of paper at the output = 480 x 0.95 = 456 TPD . (2 marks) Since the dryness at the inlet is 60%, Total mass of wet paper at the inlet = (456 x 100) / 60 = 760 TPD ..(2 marks) Moisture evaporated per hour = (760 480)/ 24 = 11.67TPH .(3 marks) Mass of Steam, m = (11.67 x 640)/ 510 = 14.6 TPH ..(3 marks) L-5 Use CUSUM technique to develop a table and to calculate energy savings for 8 months period. For calculating total energy saving, average production can be taken as 6,000 MT per month. Refer to field data given in the table below. _______________________ Bureau of Energy Efficiency 11 Paper 1 Set A REGULAR Month Actual SEC, kWh/MT Predicted SEC, kWh/MT May 1311 1335 June 1308 1335 July 1368 1335 Aug 1334 1335 Sept 1338 1335 Oct 1351 1335 Nov 1322 1335 Dec 1320 1335 Ans Month Actual SEC, kWh/MT Predicted SEC, kWh/MT Diff = ( Act - Pred ) ( - = Saving ) CUSUM ( - = Saving ) 1311 1308 1368 1334 1338 1351 1322 1320 1335 1335 1335 1335 1335 1335 1335 1335 -24 -27 33 -1 3 16 -13 -15 -24 -51 -18 -19 -16 0 -13 -28 May June July Aug Sept Oct Nov Dec ..(7 marks) Savings in energy consumption over a period of eight months are 28 x 6000 =1,68,000 kWh ..(3 marks) L-6 Write short notes on? 1. 2. 3. 4. Time of the day tariff Comparative label Endorsement label Benefits of ISO 50001 Solution: 1) In Time of the Day Tariff (TOD) structure incentives for power drawl during off-peak _______________________ Bureau of Energy Efficiency 12 Paper 1 Set A REGULAR hours and disincentives for power drawl during peak hours are built in. Many electrical utilities like to have flat demand curve to achieve high plant efficiency. ToD tariff encourage user to draw more power during off-peak hours (say during 11pm to 5 am, night time) and less power during peak hours. Energy meter will record peak and off-peak consumption and normal period separately. ToD tariff gives opportunity for the user to reduce their billing, as off peak hour tariff is quite low in comparison to peak hour tariff. This also helps the power system to minimize in line congestion, in turn higher line losses and peak load incident and utilities power procurement charges by reduced demand .. (2.5 marks) 2) Comparative label: allow consumers to compare efficiency of all the models of a product in order to make an informed choice. It shows the relative energy use of a product compared to other models available in the market. .. (2.5 marks) 3) Endorsement label: define a group of products as efficient when they meet minimum energy performance criteria specified in the respective product schedule/regulation/statutory order. .. (2.5 marks) 4) ISO 50001 will provide the following benefits A framework for integrating energy efficiency into management practices Making better use of existing energy-consuming assets Benchmarking, measuring, documenting, and reporting energy intensity improvements and their projected impact on reductions in greenhouse gas (GHG) emissions Transparency and communication on the management of energy resources Energy management best practices and good energy management behaviours Evaluating and prioritizing the implementation of new energy-efficient technologies A framework for promoting energy efficiency throughout the supply chain Energy management improvements in the context of GHG emission reduction projects. .. (2.5 marks) . . End of Section III .. . _______________________ Bureau of Energy Efficiency 13

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