Short type questions and answers

1. List any four important factors involved in deciding final cost of purchased
electricity.
The factors which are involved in deciding final cost of purchased electricity are
• Maximum demand charges, kVA
• Energy Charges, kWh
• TOD Charges, Peak/Non-peak period
• Power factor Charge, P.F
2. What are the principles of energy management?
The principles of energy management involve the following:
i) Procure all the energy needed at the lowest possible price
ii) Manage energy use at highest energy efficiency
iii) Reusing and recycling energy by cascading (waste heat recovery)
iv) Use the most appropriate technology
v) Reduce the avoidable losses
3. What is the need for managerial skills in energy management?
Managerial skills include bringing about awareness, motivating people at all levels,
changing the structure & procedure, monitoring the energy consumption, norms target
setting, etc. Both the organizational and people changes are required. For example, a
mere awareness campaign in an industry on switching off lights, fans and air conditioners
brought about a significant reduction in energy consumption.
4. What do you mean by energy audit?
Energy Audit is defined as “the verification, monitoring and analysis of use of energy
including submission of technical report containing recommendations for improving
energy efficiency with cost benefit analysis and an action plan to reduce energy
consumption”.
5. Give any four bench marking parameters followed in equipment/utility related in
Industries.
i) kWh/ton of refrigeration (on Air conditioning plant)
ii) % thermal efficiency of a boiler plant
iii) kWh/NM3 of compressed air generated
iv) kWh /litre in a diesel power generation plant.
6. List any one energy audit instrument used for power measurement and one for
flue gas measurement along with parameters to be measured?

7. How do you classify energy conservation measures?

Based on energy audit and analyses of the plant, a number of potential energy saving
projects may be identified. These may be classified into three categories:
1. Low cost – high return;
2. Medium cost – medium return;
3. High cost – high return
8. Define ‘energy management’.
The judicious and effective use of energy to maximize profits (minimize the costs) and
enhance competitive positions.

9. List steps involved in pre-audit phase.

Pre-audit phase:
􀂌 Plan and organise
􀂌 Walk through audit
􀂌 Informal interview with plant personnel
10. What are the factors to be considered before procuring fuels for energy
efficiency and economics?
The following factors should be considered before procurement of fuel for energy
efficiency and economics:
o Price at source, transport charge, type of transport
o Quality of fuel
o Energy content
11. What is the objective of energy management?
The objectives of energy management is to achieve and maintain optimum energy
procurement, utilisation throughout the organisation and
a) To minimise energy costs/ waste without affecting production & quality
b) To minimise environmental effects

12. Define the energy audit as per the energy conservation Act 2001?
As per the Energy Conservation Act, 2001, Energy Audit is defined as “the verification,
monitoring and analysis of use of energy including submission of technical report
containing recommendations for improving energy efficiency with cost benefit analysis
and an action plan to reduce energy consumption”.
13. What are fuel substitution and list one example of fuel substitution?
Fuel substitution is substituting existing fossil fuel with more efficient and less cost / less
polluting fuels such as natural gas, biogas, and locally available agro residues. E.g.
Natural gas is increasingly the fuel of choice as fuel and feedstock in fertilizers,
petrochemicals, power and sponge iron industries.
14. What are the base line data that an audit team should collect while conducting
detailed energy audit?
The audit team should collect the following baseline data:
- Technology, processes used and equipment details
- Capacity utilisation
- Amount & type of input materials used
- Water consumption
- Fuel Consumption
- Electrical energy consumption
- Steam consumption
- Other inputs such as compressed air, cooling water etc
- Quantity & type of wastes generated
- Percentage rejection / reprocessing
- Efficiencies / yield
 Long type questions and answers

1.Briefly explain with examples on fuel and energy substitution

Fuel substitution: Substituting existing fossil fuel with more efficient and less cost/less
polluting fuel such as natural gas, biogas and locally available agro-residues.
Energy is an important input in the production. There are two ways to reduce energy
dependency; energy conservation and substitution.
Fuel substitution has taken place in all the major sectors of the Indian economy. Kerosene
and Liquefied Petroleum Gas (LPG) have substituted soft coke in residential use.
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

Few examples of energy substitution

􀂌 Replacement of electric heaters by steam heaters
􀂌 Replacement of steam based hot water by solar systems
2. Distinguish between ‘preliminary energy audit’ and ‘detailed energy audit’?
Preliminary energy audit is a relatively quick exercise to:
􀂌 Establish energy consumption in the organization
􀂌 Estimate the scope for saving
􀂌 Identify the most likely (and the easiest areas for attention)
􀂌 Identify immediate (especially no-/low-cost) improvements/ savings
􀂌 Set a ‘reference point’
􀂌 Identify areas for more detailed study/measurement
􀂌 Preliminary energy audit uses existing, or easily obtained data
Whereas, detailed energy audit
• Provides a detailed energy project implementation plan for a facility, since it evaluates
all major energy using systems.
• Offers the most accurate estimate of energy savings and cost.
• Considers the interactive effects of all projects, accounts for the energy use of all major
equipment, and
• Includes detailed energy cost saving calculations and project cost.
Arrives energy balance based on an inventory of energy using systems, assumptions of
current operating conditions and calculations of energy use. This estimated use is then
compared to utility bill charges.
3. Give a typical energy audit reporting format.
After successfully carried out energy audit energy manager/energy auditor should
report to the top management for effective communication and implementation. A
typical energy audit reporting contents and format are given below. The following
format is applicable for most of the industries. However the format can be suitably
modified for specific requirement applicable for a particular type of industry.
􀂌 Acknowledgement
􀂌 Executive summary - Energy audit options at a glance and recommendations
􀂌 Introduction about the plant
􀂌 Production process description
􀂌 Energy and utility system description
- List of utilities
- Brief description of each utility
􀂌 Detailed process flow diagram and energy and material balance
􀂌 Energy efficiency in utility and process systems
􀂌 Energy conservation options and recommendations
- List of options in terms of no cost / low cost, medium cost, and high investment cost, annual
energy and cost savings, and pay back
- Implementation plan for energy saving measures / projects
􀂌Annexures
4. Write down the steps involved in ‘Energy management Strategy’? (EA)
1. Identify a strategic corporate approach
2. Appoint energy manager
3. Set up an energy monitoring and reporting system
4. Conduct energy audit
5. Prepare an energy management policy statement
6. Prepare and undertake a detailed project implementation plan
7. Implement a staff awareness and training program
8. Annual review
5. List steps involved in ‘detailed energy audit’. (EA)
Pre-audit phase:
􀂌 Plan and organise
􀂌 Walk through audit
􀂌 Informal interview with plant personnel

Audit phase:
􀂌 Primary data collection
􀂌 Conduct survey and monitoring
􀂌 Conduct detailed trials and experiments
􀂌 Analysis of energy use
􀂌 Identification and development of energy conservation opportunities
􀂌 Cost benefit analysis
􀂌 Report preparation and presentation to the plant personnel and management
Post audit phase:
Implementation and follow-ups
6. Draw process flow diagram and list process steps of any
industry. (self study)

7. List down Identification of Energy Conservation

Opportunities.

Ans:
Fuel substitution: Identifying the appropriate fuel for efficient energy conversion
Energy generation :Identifying Efficiency opportunities in energy conversion
equipment/utilitysuch as captive power generation, steam generation in boilers, thermic
fluid heating, optimal loading of DG sets, minimum excess air combustion with
boilers/thermic fluid heating, optimising existing efficiencies, efficienct energy
conversion equipment, biomass gasifiers,
Cogeneration, high efficiency DG sets, etc.
Energy distribution: Identifying Efficiency opportunities network such as
transformers, cables, switchgears and power factor improvement in electrical systems and
chilled water, cooling water, hot water, compressed air, Etc.
Energy usage by processes: This is where the major opportunity for
improvement and many of them are hidden. Process analysis is useful tool for process
integration measures.

8.

Problems on Fuel Substitution

 1. A plant is using 4 tonnes/day of coal to generate steam. The calorific value of the
coal is 4000 kcal/ kg. The cost of coal is Rs. 2,000/tonne. The plant substitutes
coal with rice husks, as a boiler fuel, which has a calorific value of 3000 kcal/ kg
and cost Rs. 700/tonne. Calculate the annual cost savings at 300 days of
operation, assuming that the boiler efficiency decreases from 78% on coal to 72%
on rice husks.
2. A plant is using 6 ton/day of coal in a boiler to generate steam at 72% boiler
efficiency. The gross calorific value of coal is 3300 kCal/kg. The cost of coal is
Rs. 4200/ton . The plant substitutes coal with agro-residue , as a boiler fuel, which
has a gross calorific value of 3100 kCal /kg and costs Rs. 1800/ton. The boiler
efficiency reduces to 68%. Calculate the annual cost savings for 300 days of
operation with agro residue as fuel.

Solution
Useful energy to generate steam by 6 tonnes of coal per day
= 6000 x 3300 x 0.72 = 14256000 kcal/day
To deliver 14256000kcal/day , daily amount of agro residue required
= 142 560 00
3100 x 0.68
= 6763 kg/day
Daily saving = 6000 x 4200 - 6763 x 1800
1000 1000
25200-12173
Rs 13027/-
Annual saving =13027 x 300
=Rs 39,08,100/-

3. Fuel substitution from a high cost fuel to a low cost fuel in boilers is common to
reduce energy bill. For the following situations calculate:
(i) annual reduction in energy costs in Crore Rs.
(ii) annual change in energy consumption in %. (Calorific value of fuels not
required for calculations)

Before substitution:
Steam output = 6 tons/hour
Fuel consumption = 1 ton oil per 13 tons of steam.
Operating hours = 6400 / Year
Fuel costs = Rs.13,000 /ton of oil
Boiler thermal efficiency (yearly average)= 82%
After Substitution:
Steam output = 6 tons/hour
Fuel consumption = 3 tons of waste wood per 13 tons of steam
Fuel costs = Rs.2,000 / ton of waste wood
Boiler thermal efficiency (yearly average) = 74%
Solution
 Oil consumption before substitution was 6 x 6400/13 = 2,953.85 tons/y.
The annual oil costs were 2,953.85 x 13,000= 38,400,050 = Rs 3.84 Crore

Wood consumption after substitution is 6 x 6400x 3/13 =8,861.54 tons/y

The annual waste wood costs are 8,861.54 x 2,000 = 1.77 Crore Rs.
(i) The annual reduction in fuel costs is Rs 2.07 Crore.

(ii) More energy is used because the boiler efficiency drops

the change is 100 x (74-82)/74 = 10.8% more energy

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 = 78%
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
MTOE due to electrical savings = ( 3287 x 10 6 x 860 ) / 10 7
= 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 =

= 3287 x 10 6 kWh

Therefore Avoided Capacity = 3287 x 10 6 /( 0.78 x .80 x 365 x 24 x 1000 )

= 601.3 MW