Energy Engineering and Management

Energy Engineeringand Management

New Delhi-1100012011

AMLAN CHAKRABARTIProfessor and Head

Department of Electrical EngineeringNarula Insitute of Technology

Kolkata

ENERGY ENGINEERING AND MANAGEMENTAmlan Chakrabarti

© 2011 by PHI Learning Private Limited, New Delhi. All rights reserved. No part of this bookmay be reproduced in any form, by mimeograph or any other means, without permission inwriting from the publisher.

ISBN-978-81-203-4233-0

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,New Delhi-110001 and Printed by Raj Press, New Delhi-110012.

v

CONTENTSCONTENTSCONTENTSCONTENTSCONTENTS

Preface ................................................................................................................................................... xiAcknowledgements ............................................................................................................................. xiii

1 INTRODUCTION TO GLOBAL ENERGY SCENARIO ................................1–3

1.1 Global Energy Requirements ........................................................................................ 11.2 Depletion of Conventional Energy Resources .......................................................... 11.3 Availability of Non-conventional Energy Sources ................................................... 21.4 Fallouts of Energy Usage .............................................................................................. 21.5 Application of Carbon Credit ...................................................................................... 3Exercises ....................................................................................................................................... 3

2 TECHNOLOGY AND CONSIDERATIONS FORELECTRICAL AND FUEL ENERGY .................................................................4–10

2.1 Electrical Energy ............................................................................................................. 42.1.1 The Evolution of Electric Power ........................................................................ 42.1.2 Power Plant Locations ........................................................................................ 42.1.3 Electric Power Network...................................................................................... 52.1.4 Designed Capacities ............................................................................................ 62.1.5 Electric Power Storage ........................................................................................ 6

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2.2 Fuel Energy ...................................................................................................................... 62.2.1 Fossil Fuels ........................................................................................................... 62.2.2 Coal ........................................................................................................................ 72.2.3 Coal Analysis ....................................................................................................... 72.2.4 Properties of Coal ................................................................................................ 82.2.5 Heating Value of Coal ......................................................................................... 92.2.6 Fuel Oil .................................................................................................................. 92.2.7 Natural and Petroleum Gas ............................................................................... 92.2.8 Combustion Reactions ...................................................................................... 10

Exercises ..................................................................................................................................... 10

3 ENERGY COSTS OF FOOD, FUEL, MATERIALS,GOODS AND SERVICES .................................................................................11–13

3.1 Energy Cost of Food .................................................................................................... 113.2 Energy Cost of Fuel ...................................................................................................... 123.3 Energy Cost of Goods and Services ......................................................................... 12Exercises ..................................................................................................................................... 13

4 ENERGY ANALYSIS AND THERMODYNAMICS ....................................14–20

4.1 Fundamentals of Thermodynamics (Relationship between Heat and Work)... 144.1.1 The First Law ..................................................................................................... 144.1.2 The Second Law................................................................................................. 15

4.2 Carnot Cycle .................................................................................................................. 164.3 Rankine Cycle ................................................................................................................ 164.4 Energy Balance .............................................................................................................. 18

4.4.1 Heat Balance for Steam Process ...................................................................... 184.5 Energy Balance of Steam Generator ......................................................................... 18Exercises ..................................................................................................................................... 20

5 ENERGY ANALYSIS OF ‘REAL’ INDUSTRIAL SYSTEMS—FACTORIES .........................................................................................................21–58

5.1 Process System Optimization ..................................................................................... 215.1.1 Different States of Water and its Relationship with Pressure and

Temperature ....................................................................................................... 215.1.2 The Mollier Chart .............................................................................................. 22

5.2 Electrical System Optimization .................................................................................. 265.2.1 Electricity Rate Tariff ........................................................................................ 265.2.2 Key to Reduction in Electrical Energy Consumption .................................. 265.2.3 Methods to Improve Plant Power Factor ....................................................... 285.2.4 Load Management ............................................................................................ 285.2.5 Conduction Loss ................................................................................................ 295.2.6 Switching Loss ................................................................................................... 305.2.7 Magnetic Loss .................................................................................................... 31

Contents ❖ vii

5.2.8 Harmonics Compensation ............................................................................... 315.2.9 Motor Control .................................................................................................... 315.2.10 Lighting Energy Saving .................................................................................... 335.2.11 Other Energy Savings ....................................................................................... 37

5.3 Cogeneration .................................................................................................................. 375.3.1 Theory and Practice .......................................................................................... 375.3.2 Cogeneration Technologies .............................................................................. 405.3.3 Basic Thermodynamic Cycles .......................................................................... 40

5.4 Heating, Ventilation and Air Conditioning Systems............................................. 425.4.1 Principles of Heat Pump .................................................................................. 425.4.2 Liquid Chilling Units ........................................................................................ 435.4.3 Gas Cooling Technology .................................................................................. 455.4.4 Air Conditioning Systems ................................................................................ 475.4.5 Economizer Cycle .............................................................................................. 475.4.6 Heat Recovery System ...................................................................................... 485.4.7 Cold Storage ....................................................................................................... 48

5.5 Principles of Heat Transfer ......................................................................................... 495.5.1 Modes of Heat Transfer .................................................................................... 495.5.2 Conduction through a Flat Surface ................................................................. 505.5.3 Conduction through a Cylindrical Surface .................................................... 515.5.4 Heat Transfer by Radiation .............................................................................. 515.5.5 Heat Transfer by Convection ........................................................................... 525.5.6 Finned-tube Heat Exchanger ........................................................................... 525.5.7 Shell and Tube Heat Exchanger ...................................................................... 535.5.8 Heat Loss from a Vessel or Tank ..................................................................... 53

Exercises ..................................................................................................................................... 57

6 ENERGY ANALYSIS OF REAL INDUSTRIAL SYSTEMS—TRANSPORTATION SYSTEMS .....................................................................59–63

6.1 Energy Conservation in Transportation ................................................................... 596.1.1 Pattern of Energy Consumption ..................................................................... 596.1.2 Emission Targets for Transportation .............................................................. 60

6.2 New Technologies ........................................................................................................ 616.3 Progress in Clean Diesel Technology ....................................................................... 62

6.3.1 Areas of Improvement ...................................................................................... 626.3.2 Fuel ...................................................................................................................... 626.3.3 Engine ................................................................................................................. 626.3.4 Exhaust Systems ................................................................................................ 626.3.5 Cleaning the Tailpipe ........................................................................................ 63

Exercises ..................................................................................................................................... 63

7 ENERGY ANALYSIS OF REAL INDUSTRIAL SYSTEMS—BUILDINGS .........................................................................................................64–72

7.1 Energy Consumption in Buildings ............................................................................ 647.2 Construction Cost vs Life Cycle Cost ....................................................................... 64

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7.3 Building Design—Walls and Roof ............................................................................ 657.4 Heating Ventilation and Air Conditioning (HVAC) Systems ............................. 677.5 Water Supply Systems ................................................................................................. 687.6 Lighting Systems ........................................................................................................... 697.7 Building Data Loggers and Advanced Controls .................................................... 717.8 The Energy Conservation Act, 2001 ......................................................................... 727.9 National Building Code of India, 2005 .................................................................... 72Exercises ..................................................................................................................................... 72

8 PRINCIPLES AND OBJECTIVES OF ENERGY MANAGEMENT ..........73–79

8.1 Introduction.................................................................................................................... 738.2 Energy Planning ............................................................................................................ 738.3 Energy Staffing .............................................................................................................. 748.4 Energy Organization .................................................................................................... 748.5 Energy Requirement ..................................................................................................... 758.6 Energy Costing .............................................................................................................. 758.7 Energy Budgeting ......................................................................................................... 758.8 Energy Monitoring ....................................................................................................... 758.9 Energy Consciousness .................................................................................................. 768.10 Energy Conversions...................................................................................................... 768.11 Energy Efficient Equipment ........................................................................................ 768.12 Energy Management Professionals ........................................................................... 768.13 Environment Pollution due to Energy Use ............................................................. 77

8.13.1 Components of Pollution ................................................................................. 778.13.2 Harmful Effects of Pollution ............................................................................ 788.13.3 Measures Taken to Combat Pollution ............................................................ 788.13.4 Possible Future Measures ................................................................................. 78

8.14 Evaluation of Alternative Energy Sources ............................................................... 79Exercises ..................................................................................................................................... 79

9 DESIGN OF ENERGY MANAGEMENT PROGRAMMES .......................80–85

9.1 Saving Energy and Implementation of Energy Conservation ............................. 809.2 Principles of Energy Management ............................................................................ 809.3 Need for Energy Management Programme ............................................................ 819.4 Agenda for Organization Structure .......................................................................... 829.5 Role of Energy Manager/Plant Engineer ................................................................ 839.6 Implement Energy Conservation Actions ................................................................ 849.7 Continuing Energy Conservation Efforts ................................................................. 84Exercises ..................................................................................................................................... 85

10 PROCEDURES FOR ENERGY ANALYSIS AND AUDIT .........................86–89

10.1 Categories of Energy Audit ........................................................................................ 8610.2 Types of Energy Audit ................................................................................................ 87

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10.3 Ventilation Audit .......................................................................................................... 8810.4 Measuring and Detection Instruments for Energy Survey .................................. 8810.5 Scope of Energy Audit ................................................................................................ 89Exercises ..................................................................................................................................... 89

11 SOCIAL AND ECONOMIC COST BENEFITS ............................................90–97

11.1 Social and Economic Pressures .................................................................................. 9011.2 Benefits of Energy Management ................................................................................ 9111.3 Energy Accounting and Analysis .............................................................................. 92

11.3.1 Cost per Unit of Energy .................................................................................... 9211.3.2 Energy Efficiency ............................................................................................... 9211.3.3 Weather Impact on Energy Consumption ..................................................... 9211.3.4 Volume Mix Impact on Energy Consumption .............................................. 9211.3.5 Pollution Control Impact on Energy Consumption ..................................... 9311.3.6 Other Impacts on Energy Consumption ........................................................ 9311.3.7 Life Cycle Costing ............................................................................................. 93

11.4 Energy Management in Deregulated Environment ............................................... 9511.5 Energy Pricing ............................................................................................................... 9611.6 Sustainable Development ............................................................................................ 97Exercises ..................................................................................................................................... 97

12 MEASURES FOR ENERGY CONSERVATION .........................................98–107

12.1 Energy Conservation Checklist .................................................................................. 9812.2 Potential Energy Conservation Opportunities in Boilers ...................................... 9812.3 Potential Energy Conservation Opportunities in Chilled Water Plants

and Central Air-Conditioning Systems .................................................................. 10012.4 Potential Energy Conservation Opportunities in Compressors and Fans ...... 10012.5 Potential Energy Conservation Opportunities in Heat Pumps

and Cooling Systems .................................................................................................. 10112.6 Potential Energy Conservation Opportunities in Water Heaters

and Coolers .................................................................................................................. 10112.7 Potential Energy Conservation Opportunities in HVAC Systems ................... 10412.8 Potential Energy Conservation Opportunities in Lighting Systems ................ 10612.9 Potential Energy Conservation Opportunities in Motors and

Transformers ................................................................................................................ 106Exercises ................................................................................................................................... 107

Appendix A: Questions and Answers on Energy Management ......................109–150

Appendix B: Problems on Energy Management ................................................151–180

Appendix C: Multiple Choice Questions on Energy Management .................181–199

Appendix D: Case Studies on Energy Management ..........................................200–246

Index ...........................................................................................................................247–249

xi

PREFACEPREFACEPREFACEPREFACEPREFACE

Five years ago, I decided to quit my long industrial career of twenty-five years and became anacademic. The first challenge faced by me in this new career was choosing an elective subjectfor the final semester of the undergraduate programme of electrical engineering. Incidentally,this dilemma was for the first batch of the undergraduate electrical engineering students ofNarula Institute of Technology. I had a number of options from the syllabus of West BengalUniversity of Technology. Since I had an electrical engineering and industrial engineeringbackground and long years of experience in design and development of energy control centres,I picked up ‘Energy Management and Audit’ as an elective subject and offered it to the students.There were a couple of more choices, but all the students decided to pursue this elective subject.Most probably, influenced by my thoughts, the students could feel the opportunity for a bettercareer path through this elective subject.

The next challenge was to find a suitable textbook on the subject. This turned out to berather a serious problem. I could not find any book written by an Indian author. Of course, therewere a number of foreign books on the subject, but more available even in most reputedtechnical libraries of Kolkata. After consistent follow-up, I managed to place a prepaid order onthe website of a large foreign publisher. Since the delivery was expected to be delayedconsiderably, I resorted to teaching from the self-compiled material. Towards this effort, I mustacknowledge the guidance received from Dr. A.M. Roy, former Professor, Bengal Engineering& Science University, Prof. Tapas Kumar Sengupta, JIS College of Engineering, and Mr. M.K.Lahiri, an Industrial consultant. My book was conceived during this compilation process. It isorganized around 40 lectures to be covered over a semester with teaching period of four months.

xii ❖ Preface

It is now a class-tested material over five even semesters during the period 2006–2010 and hasundergone several revisions too. The book has been designed to be a text for final year B.Tech.students, M.Tech. students, and MBA students. Case studies and processes have been includedfor utilizing the book for training the employees of an industry where energy managementprogramme is getting implemented. Substantial attention has been given to questions and answersrequired for Certification Examination of Bureau of Energy Efficiency, Government of India.

As an academician and practising professional, my emphasis is more on mathematical andgraphical representations rather than textual explanations. I have made a sincere attempt tomatch every theoretical explanation with its mathematical or graphical representation. I shall begrateful to the readers for suggestions to improve the contents of the book. The reader can emailtheir suggestions to amlanc@hotmail.com

Amlan Chakrabarti

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ACKNOWLEDGEMENTSACKNOWLEDGEMENTSACKNOWLEDGEMENTSACKNOWLEDGEMENTSACKNOWLEDGEMENTS

At the outset, I express my gratitude to my mother, my wife and my daughter for their support,inspiration and tolerance during the process of writing this book. I am particularly appreciativeof the graphics skills of my daughter who considerably improved their quality befiting of atextbook.

I thank my colleagues at the Electrical Engineering Department, Narula Institute ofTechnology for their help and assistance rendered during the compilation of this book.

Most of all, I am indebted to the Management of JIS Group for providing me with anopportunity, environment and time without which it would not have been possible for me towrite this book.

I also acknowledge the excellent presentation and meticulous editing and proof-readingwork executed by the editing and production teams of PHI Learning.

Energy Engineering and Management

Publisher : PHI Learning ISBN : 9788120342330 Author : Chakrabarti

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