Paper 3 –Set B SOLUTION

Regn No: ____ _____________

Name: ___________________
(To be written by the candidates)

NATIONAL CERTIFICATION EXAMINATION 2007

FOR
ENERGY MANAGERS & ENERGY AUDITORS

PAPER – 3: Energy Efficiency in Electrical Utilities

Date: 22.04.2007 Timings: 0930-1230 HRS Duration: 3 HRS Max. Marks: 150

General instructions:
o Please check that this question paper contains 9 printed pages
o Please check that this question paper contains 65 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: OBJECTIVE TYPE Marks: 50 x 1 = 50

(i) Answer all 50 questions

(ii) Each question carries one mark
(iii) Please hatch the appropriate oval in the OMR answer sheet with HB Pencil, as per
instructions

1. What should be the maximum capacitor size to be installed at induction motor

terminals for power factor improvement?

a) 70% of No load kVAr of the motor b) 80% of No load kVAr of the motor
c) 90% of No load kVAr of the motor d)100% of No load kVAr of the motor

2. The transformer capacity is rated in terms of

a) HP b) kVA c) kVAr d) kW

3. Which of the following is not likely to create harmonics in an electrical system

a) induction motors b) variable frequency drives c) UPS d) soft starters

4. For a four pole induction motor operating at 50 Hz, the slip at a shaft speed of 1450
RPM will be

a) 0 % b) 3.33 % c) 0.33 % d) none of the above

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5. A three phase induction motor loaded at less than 50 %,if operated in star mode, will
result in
a) reduced operating voltage b) electrical downsizing of the motor
c) improved efficiency and power factor d) all of the above

6. Heat Rate of a thermal power plant is expressed in

a) kWh/kCal b) kCal/kWh c) kWh/kJ d) kCal/kVAh

7. A 5 kVAr, 415 V rated power factor capacitor was found to be having terminal supply
voltage of 430 V. The capacity of the power factor capacitor at the operating supply
voltage would be approximately
a) 4.65 kVAr b) 5 kVAr c) 5.5 kVAr d) none of the above

8. Identify the location of installing capacitor banks, which will result in less reduction in
the distribution losses in a factory

a) main sub-station bus bars b) distribution panel boards

c) motor control centres d) motor terminals
9. The nearest kVAr compensation required for changing the power factor of a 1000 kW
load from 0.9 lead to unity power factor is

a) 900 kVAr b) 485 kVAr c) 1000 kVAr d) none of the above

10. Improving power factor at motor terminals in a factory will

a) increase active power b) release distribution transformer capacity

c) reduce contract demand d) increase motor efficiency

11. Use of hard water for inter cooler of a two stage reciprocating air compressor will

a) reduce work done for compression b) increase pressure drop in water side
c) decrease compressor speed d) reduce air inlet temperature to second stage

12. A 500 cfm reciprocating compressor has a loading and unloading period of 5
seconds and 20 seconds respectively during a compressed air leakage test. The air
leakage in the compressed air system would be

a) 100 cfm b) 125 cfm c) 200 cfm d) none of the above

13. A 1000 cfm reciprocating compressor is operating to meet a constant demand of 500
cfm. The least cost energy efficient solution will be

a) pulley change b) multi step control

c) variable frequency drive d) load and unload

14. An air dryer in a compressed air system

a) increases dew point of air b) reduces dew point of air

c) reduces work of compression d) none of the above

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15. Which of the following can be used as refrigerant both in vapour compression and
vapour absorption system

a) R – 11 b) ammonia c) water d) lithium bromide

16. The performance of rewinding of an induction motor can be assessed by which of the
following factors

a) no load current b) stator resistance

c) both no load current and stator resistance d) none of the above

17. An induction motor rated for 75 kW and 90 % efficiency, operating at full load, will

a) deliver 83.3 kW b) draw 75 kW c) deliver 75 kW d) draw 67.5 kW

18. With increase in design speed of induction motors the required capacitive kVAr for
reactive power compensation for the same capacity range will

a) decrease b) increase c) not change d) none of the above

19. The flow rate of a reciprocating air compressor can be decreased by

a) inlet throttling b) outlet throttling c) decreasing speed d) all of the above

20. Which of the following delivers a pulsating output

a) reciprocating compressor b) centrifugal compressor

c) screw compressor d) roots blower

21. Partially closing the outlet damper in a fan system will

a) reduce flow b) increase power consumption

c) reduce fan static pressure d) all of the above

22. Which of the following flow controls in the fan system will change the system
resistance curve

a) discharge damper b) speed change with variable frequency drive

c) speed change with hydraulic coupling d) inlet guide vane

23. Parallel operation of two identical fans in a ducted system

a) will double the flow b) will double the fan static pressure
c) will not double the flow d) will increase flow by more than two times

24. Which of the following can also act as a heat pump

a) centrifugal pump b) centrifugal compressor

c) air conditioner d) none of the above

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25. A Pitot tube measures------- of the fluid in a ducting system

a) velocity b) flow
c) the difference between total and static pressures d) static pressure
26. A 2 ton air conditioner installed in a room and working continuously for two hours will
remove heat of

a) 3024 kCals b) 6048 kCals c) 12096 kCals d) 4000 kCals

27. Which of the following refrigeration systems uses vacuum for operation

a) vapour compression system using R-11

b) vapour compression system using HFC 134A
c) vapour absorption system using lithium bromide –water
d) vapour absorption system using ammonia –water

28. The refrigeration load in TR when 100 m3/hr of water is cooled from 12 OC to 7 oC is

a) 500 b) 20 c) 165 d) 50,000

29. A fan handling air in a ducted system is an example of

a) pure friction head b) pure static head

c) combination of static and friction head d) none of the above

30. Integrated Part Load Value (IPLV) in a vapour compression refrigeration refers to
average of ____with partial loads

a) TR/kW b) cooling effect c) kW/TR d) kW

31. NPSH available depends on

a) pump type b) discharge head c) inlet pipe diameter d) power drawn

32. If the wet bulb temperature is 28 oC and cooling water of 28 oC is required, then the
most appropriate cooling tower would be

a) hyperbolic tower b) cross flow tower

c) induced draft counter flow tower with fills d) none of the above
33. Higher the COC in a cooling tower, the blow down quantity will

a) decrease b) increase c) no change d) it may increase or decrease

34. The most appropriate type of fan used for induced draft cooling tower, among the
following is

a) centrifugal fan with FRP blades b) axial fan with mild steel blades
c) centrifugal fan with aluminum blades d) axial fan with aluminium blades

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35. The blowdown loss in a cooling tower depends on

a) TDS in circulating water b) TDS in make up water

c) evaporation loss d) all of the above
36. In a centrifugal pump the velocity energy is converted to pressure energy by

a) impeller b) volute c) discharge duct d) suction duct

37. The hydraulic power in a pumping system depends on

a) pump efficiency b) motor efficiency

c) both motor and pump efficiency d) none of the above

38. The friction loss in a pipe carrying a fluid is proportional to the

a) fifth power of pipe diameter b) square of the pipe diameter

c) fluid velocity d) fluid flow

39. The efficiency of a pump does not depend on

a) suction head b) discharge head c) motor efficiency d) density of fluid

40. When the flow rate increases in a pumping system

a) NPSH available increases b) NPSH required increases

c) NPSH required decreases d) both NPSH available and NPSH required increases

41. When compared to standard motors, energy efficient motors have

a) lower slip b) higher shaft speed c) lower starting torque d) all of the above
42. Use of soft starters for induction motors results in?

a) lower power factor b) lower mechanical stress

c) higher maximum demand d) all of the above

43. Which of the following is a variable torque load?

a) crusher b) centrifugal pump c) machine tool d) vibrating conveyors

44. A fluorescent tube light fitted with an electronic choke will

a) operate at 25 kHz b) do not need a starter

c) increase light output d) all of the above

45. A 1100 kVA DG set is delivering 800 kW output. If the flue gas generated is 8
kgs/kWh then the total flue gas flow rate in kg/hr is

a) 8800 b) 6400 c) 100 d) 137

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46. FRP fans consume less energy than aluminium fans because

a) they are lighter b) they deliver less air flow

c) they have less system resistance d) they have better efficiencies

47. Sodium vapour lamps are not used in indoor applications because they

a) have poor colour rendering index b) have poor energy efficiency

c) have low lumens output d) occupy a plenty of space

48. Which of the following is not a gas discharge lamp

a) fluorescent tube lamp b) incandescent lamp

c) metal halide lamp d) mercury vapour lamp

49. Maximum demand controller installed in a factory will be beneficial only if

a) the MD charges are for 100 % of the contract demand

b) maximum demand is more than 5000 kVA
c) maximum demand is less than 5000 kVA
d) it is synchronized with the utility meter

50. Luminous efficacy of a lamp is given by

a) lumens/W b) Lux/W c) W/Lux d) W/lumens

……. End of Section – I …….

Section – II: SHORT DESCRIPTIVE QUESTIONS Marks: 10 x 5 = 50

(i) Answer all Ten questions

(ii) Each question carries Five marks

S-1 A cast iron foundry has a load of 450 kVA. It has installed two transformers of 500
kVA each. The no load loss and full load copper loss are 710 W and 5300 W
respectively. From the energy efficiency point of view the foundry management wants
to take a decision on whether to operate a single transformer on full load or two
transformers equally sharing the load. What is your recommendation ? Why?
Answer
1 x 500 kVA

Transformer loss at 450 kVA No load loss + [kVA load/Rated kVA]2

x full load loss
710 + 4293
5003 W

2 x 500 kVA 2 x {710 + [225/500]2} x 5300

3567 W

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Two transformers are better because the losses are the least.

S-2 Air at 25,000 m3/hr and at 1.2 kg/m3 density is flowing into an air handling unit of an
inspection room. The enthalpy difference between the inlet and outlet air is 10 kJ/kg.
If the motor draw a power of 24 kW at an efficiency of 90%, find out the kW/TR of
the refrigeration system. (1 J = 4.18 Cal.)

Answer
Refrigeration tonnes Q x  x (h2-h1)

25000 x 1.2 x (10 / 4.2) kcal/kg

71429kcal/hr
TR 71429/3024
23.6 TR

Power input to the compressor 24 x 0.9= 21.6 kW

kW/TR 21.6/23.6 = 0.915

S-3 Air flow measurements using the pitot tube, in the primary air fan of a coal fired boiler
gave the following data

Air temperature = 33oC

Velocity pressure = 43 mmWC
Pitot tube constant, Cp = 0.9
Air density at 0oC (standard data) = 1.293 kg /m3

Find out the velocity of air in m/sec

Answer
Corrected air density 273 x 1.293 /(273+33)
1.154 kg/m3

Velocity m/s
Cp x √2 x 9.81 x ∆p x γ / γ

0.9 x √2 x 9.81 x 43 x 1.154 / 1.154

24.3 m/s

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S-4 An engineering industry which was operating with a maximum demand of 1200 kVA at
0.9 power factor brought down its demand to 1080 kVA by power factor improvement.
Find out the percentage reduction in distribution losses within the plant
Answer
kW drawn 1200 kVA x 0.9
1080 kW

New power factor 1080/1080

=1.0

Distribution loss reduction 1 – {PF1/PF2}2 x 100

1 - {0.9/1}2 x 100
19 %

S-5 A system has a static head of 47 meters and friction head of 10 meters. The pump is
operating at 1440 RPM. For reducing the flow, the pump speed is reduced to 1100
RPM. What is likely to happen as a result of this ?

Answer

Head developed at 1100 RPM - H2/57 =(1100/1440)2

New head H2 - 33.26 m

This head will be insufficient to overcome the static head and hence no flow
will occur in the system

S-6 The hot water temperature entering the cooling tower is 39 oC. If the wet bulb
temperature is 27 oC and the range is twice the approach, find out the cold water
temperature and effectiveness of the cooling tower.

Answer
Range (T1 –T2) = 2 x Approach (T2 – Twb)

(39 – T2) 2 x (T2 – 27)

Cold water temperature T2 31oC

Effectiveness = Range/(Range + 8/(8+ 4)

approach)

66.7 %

S-7 A no load test conducted on a three phase delta connected induction motor gave the
following values:

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No load power = 980 W

Stator resistance per phase at 30 oC = 0.25 Ohms
No load current = 14.6 A

Calculate the fixed losses for the motor.

Answer
No load power 980 W
Stator resistance at 30oC 0.25 Ohms
No load current 14.6 A
Stator Copper loss at no load 3 x (14.6/√3)2 x 0.25 Ohms
= 53.3 W

Fixed losses 980 – 53.3

= 926.7 W

S-8 In a cooling tower, the cooling water circulation rate is 1250 m 3/hr. The operating
range is 7oC. If the blowdown rate of the cooling tower is 1 % of the circulation rate,
calculate the evaporation loss and COC.
Answer
Evaporation Loss (m3/hr) = 0.00085 x 1.8 x circulation rate (m3/hr) x (T1 –T2)

= 0.00085 x 1.8 x 1250 x 7

= 13.39 m3/hr

Blowdown = 12.5 m3/hr

Blowdown = Evaporation loss / (COC – 1)

12.5 = 13.39 / (COC – 1)

COC = 2.071

S-9 A jockey pump of a fire hydrant system is analysed for efficiency and following data is
collected:

Flow - 45 m3/hr , Total head – 100 meters, Power drawn by motor– 23.7 kW, Motor
efficiency – 90%
Determine the pump efficiency

Answer

Hydraulic power Q (m3/s) x total head (m) x 1000 x 9.81

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/1000

(45/3600) x 100 x 1000 x 9.81/1000

Hydraulic power 12.26 kW

Power input to pump 23.7 x 0.9

21.33 kW

Pump efficiency 12.26/21.33

57.5 %

S-10 A 22 kW rated motor driving a lube oil pump is drawing a constant power of 19 kW at
90% efficiency. If the motor is replaced with an energy efficient motor which operates
at 93 % efficiency, find out the annual energy savings at 7000 hours of operation/year.
If the investment is Rs. 30,000/- find out the payback period at Rs.5/kWh energy
charges.
Answer
kW output 19 x 0.9
Energy savings kW output x [1/New - 1/Old]

17.1 [1/0.9 – 1/0.93] x 7000 kWh

4290 kWh/year

30,000 /(4290 x Rs.5)

1.4 years
16.8 months

……. End of Section - II …….

Section – III: LONG DESCRIPTIVE QUESTIONS Marks: 5 x 10 = 50

(i) Answer all Five questions

(ii) Each question carries Ten marks

L-1. List down 10 energy conservation opportunities in a Compressed air system:

▪ Ensure air intake to compressor is not warm and humid by locating

compressors in well-ventilated area or by drawing cold air from outside.
Every 40C rise in air inlet temperature will increase power consumption by 1
percent.

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▪ Clean air-inlet filters regularly. Compressor efficiency will be reduced by 2

percent for every 250 mm WC pressure drop across the filter.

▪ Keep compressor valves in good condition by removing and inspecting

once every six months. Worn-out valves can reduce compressor efficiency
by as much as 50 percent.

▪ Install manometers across the filter and monitor the pressure drop as a
guide to replacement of element.

▪ Minimize low-load compressor operation; if air demand is less than 50

percent of compressor capacity, consider change over to a smaller
compressor or reduce compressor speed appropriately (by reducing motor
pulley size) in case of belt driven compressors.

▪ Consider the use of regenerative air dryers, which uses the heat of
compressed air to remove moisture.

▪ Fouled inter-coolers reduce compressor efficiency and cause more water

condensation in air receivers and distribution lines resulting in increased
corrosion. Periodic cleaning of inter-coolers must be ensured.

▪ Compressor free air delivery test (FAD) must be done periodically to check
the present operating capacity against its design capacity and corrective
steps must be taken if required.

▪ If more than one compressor is feeding to a common header, compressors

must be operated in such a way that only one small compressor should
handle the load variations whereas other compressors will operate at full
load.

▪ The possibility of heat recovery from hot compressed air to generate hot air
or water for process application must be economically analyzed in case of
large compressors.

▪ Consideration should be given to two-stage or multistage compressor as it

consumes less power for the same air output than a single stage
compressor.

▪ If pressure requirements for processes are widely different (e.g. 3 bar to 7

bar), it is advisable to have two separate compressed air systems.

▪ Reduce compressor delivery pressure, wherever possible, to save energy.

▪ Provide extra air receivers at points of high cyclic-air demand which permits
operation without extra compressor capacity.

▪ Retrofit with variable speed drives in big compressors, say over 100 kW, to
eliminate the `unloaded’ running condition altogether.

▪ Keep the minimum possible range between load and unload pressure
settings.

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▪ Automatic timer controlled drain traps wastes compressed air every time the
valve opens. So frequency of drainage should be optimized.

▪ Check air compressor logs regularly for abnormal readings, especially

motor current cooling water flow and temperature, inter-stage and discharge
pressures and temperatures and compressor load-cycle.

▪ Compressed air leakage of 40- 50 percent is not uncommon. Carry out

periodic leak tests to estimate the quantity of leakage.

▪ Install equipment interlocked solenoid cut-off valves in the air system so

that air supply to a machine can be switched off when not in use.

▪ Present energy prices justify liberal designs of pipeline sizes to reduce

pressure drops.

▪ Compressed air piping layout should be made preferably as a ring main to

provide desired pressures for all users.

▪ A smaller dedicated compressor can be installed at load point, located far

off from the central compressor house, instead of supplying air through
lengthy pipelines.

▪ All pneumatic equipment should be properly lubricated, which will reduce

friction, prevent wear of seals and other rubber parts thus preventing energy
wastage due to excessive air consumption or leakage.

▪ Misuse of compressed air such as for body cleaning, agitation, general floor
cleaning, and other similar applications must be discouraged in order to
save compressed air and energy.

▪ Pneumatic equipment should not be operated above the recommended

operating pressure as this not only wastes energy bus can also lead to
excessive wear of equipment’s components which leads to further energy
wastage.

▪ Pneumatic transport can be replaced by mechanical system as the former

consumed about 8 times more energy. Highest possibility of energy savings
is by reducing compressed air use.

▪ Pneumatic tools such as drill and grinders consume about 20 times more
energy than motor driven tools. Hence they have to be used efficiently.
Wherever possible, they should be replaced with electrically operated tools.

▪ Where possible welding is a good practice and should be preferred over

threaded connections.

▪ On account of high pressure drop, ball or plug or gate valves are preferable
over globe valves in compressed air lines.

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L-2. A fan is driven by a motor through a belt pulley system. The input power to the
fan is 40 kW for a 2500 Nm3/hr fluid flow. The motor speed is 2990 RPM and
its pulley diameter is 200 mm. The fan pulley diameter is 300 mm. If the flow is
to be reduced by 20% by changing the fan pulley size, what should be the
diameter of the fan pulley and what will be the power input to the fan ?

Answer

Ratio of fan pulley to motor pulley = 300/200 = 1.5

Motor speed = 2990 RPM

Existing fan speed = 2990/1.5

= 1993 RPM

Flow delivered at 1993 RPM = 2500 Nm3/hr

Flow at 20 % reduction = 2500 – 500 = 2000 Nm3/hr

Corresponding fan speed required = (2000/2500) x 1993

= 1594 RPM

New fan pulley size = (2990/1594) x 200 mm

= 375 mm

Power drawn = (P1/P2) = (Q1/Q2)3

= (40/P2) = (2500/2000)3

P2 = 20.48 kW

L-3. Draw a sketch of centrifugal pump (head vs flow) characteristic curve incorporating
the following. (Draw separate sketches for each of the conditions)

a) System resistance curve (with static and dynamic head) and show the
operating point
b) Effect of throttling the pump on head and flow
c) Effect of pump speed reduction on head and flow
d) Effect of impeller diameter reduction on head and flow
Answer

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System resistance Effect of throttling

Pump curve with lower speed Pump curve with lower impeller diameter

L-4. A chemical plant has a contract demand of 2500 kVA with the power supply company.
The average maximum demand of the plant is 2100 kVA at a power factor of 0.95.
The maximum demand is billed at the rate of Rs.300/kVA. The minimum billable
maximum demand is 75 % of the contract demand. An incentive of 0.5 % reduction in
energy charges component of electricity bill are provided for every 0.01 increase in
power factor over and above 0.95. The average energy charge component of the
electricity bill per month for the company is Rs.11 lakhs.

The plant decides to improve the power factor to unity. Determine the power factor
capacitor kVAr required, annual reduction in maximum demand charges and energy
charge component. What will be the simple payback period if the cost of power factor
capacitors is Rs.800/kVAr.

Answer

kW drawn 2100 x 0.95 =

1995 kW

Kvar required to improve power factor from kW ( tan 1 – tan 2)

0.95 to 1
kW ( tan (cos-1) – tan (cos-2)
1995 ( tan (cos- ) – tan (cos- )
1995 (0.329 - 0)
656.36 kVAr

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Cost of capacitors @Rs.800/kVAr Rs.5,25,088

Maximum demand at unity power factor 1995/1 = 1995 kVA

75 % oc contract demand 1875 kVA

Reduction in Demand charges (2100 – 1995) 105 kVA x Rs.300
Rs.31500 x 12
Rs.3,78,000

Percentage reduction in energy charge from 2.5 %

0.95 to 1 @ 0.5 % for every 0.01 increase
Monthly energy cost component of the bill Rs.11,00,000
Reduction in energy cost component 11,00,000 x (2.5/100)
Rs.27,500/month
Annual reduction Rs.27,500 x 12
Rs.3,30,000

Savings in electricty bill Rs.7.08,,000

Investment Rs.5,25,088
Payback period 5,25,088/7,08,000
0.74 years or 9 months

L -5 A cooling tower is operating at a capacity of 31,00,000 kcal/hr and a range of 6 oC. The
cooling tower pump has a positive suction of 2 m and the discharge pressure shows
3.8 kg/cm2. The measured motor power is 72 kW and the operating efficiency of the
motor is 92%. Find out the efficiency of the pump.

Answer
Pump flow rate 31,00,000/6
516.6 m3/hr

otal head 38 – 2 = 36 m

Hydraulic power (516.6/3600) x 36 x 9.81

50.6kW

Pump input power 72 x 0.92

66.24 kW

Pump efficiency 50.6/66.24

76 %

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……. End of Section – III ……

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