calculations

Capacity of plant = 100,000 m/day

Raw material used = Gray Fabrics, Dye Colors, Chemicals
Type of fuel used = Reliance Peat Coke, Lignite / Barmeri Coal
BOILER CALCULATION
HEAT OUTPUT DATA
Quantity of steam generated = 2 TPH
Steam pressure = 8 Kg/cm2
Enthalpy of steam at 8 Kg/cm2 = 659 kcal/kg
Feed water temperature = 65C
Enthalpy of feed water = 65 kcal/kg
Fuel used = Lignite Coal
HEAT INPUT DATA
Quantity of coal consumed = 450 kg/hr
Gross calorific value of coal = 3500 kcal /kg
Boiler Efficiency () = (Q*(H-h))/(q*GCV) * 100
Where
Q= Quantity of steam generated per hour (kg/hr)
q = Quantity of fuel used per hour (kg/hr)
GCV= Gross calorific value of fuel used (kcal/kg)
H= Enthalpy of steam (kcal/kg)
h = Enthalpy of feed water (kcal/kg)
Boiler Efficiency () = (2000 (659-65))/(4503500)*100
= 75.4 %
Evaporation Ratio = (RATE OF STEAM GENERATION )/(RATE OF FUEL CONSUMPTION )
=(2000 (kg )/hr OF STEAM)/(450 kg/hr OF COAL )
= 4.44 kg OF STEAM PRODUCED / kg OF COAL

BOILER EFFICEINCY BY INDIRECT METHOD

Fuel Analysis (in %)
Ash Content in Fuel = 8.63, Moisture in Coal = 31.65, Carbon Content = 41.65, Hydrogen Content= 2.0413, Nitrogen Content = 1.6,
Oxygen Content = 14.48, GCV of Coal = 3500 Kcal/Kg Flue Gas Temperature = 180C, Ambient Temperature = 30C, Percentage of
O2 and Co2 in Flue Gas = 11 & 14, Theoretical Air Requirement.
THE CHEMICAL REACTION ARE
C + O2 ------------------------ CO2
2H2 + O2 -------------------2H2O
S + O2 -------------------- SO2
C + O2 ---------------------CO2
12 + 32 ---------------------- 44
12 kg of carbon requires 32 kg of oxygen to form 44 kg of carbon dioxide. Therefore 1 kg of carbon requires 32/ 12 kg i,e 2.67 kg of
oxygen
41.65 kg C + (41.65 X 2.67) kg O2 ---------------------------- 152.85 kg CO2
2H2 + O2 ------------------------------- 2H2O
4 + 32 ------------------------------- 36
4 kg of hydrogen requires 32 kg of oxygen to form 36 kg of water. Therefore 1 kg of hydrogen requires 32/ 4 kg i,e 8 kg of oxygen

2.0413 kg H2 + (2.0413 X 8) kg O2 ------------------------ 18.37 kg H2O

S + O2 ------------------------------------ SO2
32 + 32 ------------------------------------ 64
32 kg of sulphur requires 32 kg of oxygen to form 64 kg of sulphur dioxide. Therefore 1 kg of sulphur require 32/32 kg i,e, 1 kg of
oxygen .
0 kg S + (0 X 1) kg O2 ------------------------------------------ 0 kg OF SO2
Total Oxygen Required
(111.20 + 16.33 + 0) = 127.53 kg
Oxygen already present in 100 kg fuel = 14.28 kg (from ultimate analysis)
Additional oxygen required = 127.53 14.28 = 113.25kg
Therefore quantity of dry air required = 113.25/0.23 = 492.39 kg OF AIR
(Air Contains 23 % Oxygen By Wt.)
Theoretical air required = 492.39/100
= 4.9239 kg OF AIR /kg OF FUEL

Theoretical CO2 % present in exhaust gases

% CO2 at Theoretical Condition = MOLES OF C
MOLES OF N2 + MOLES OF C

Moles of N2 = WT. OF N2 IN THEORITICAL AIR + WT. OF N2 IN FUEL

MOL. WT. OF N2 MOL. WT. OF N2

Moles of N2 = (4.91 7.7)/28 +0.016/28 = 0.1356

Where Moles of C = (WT.OF C IN FUEL )/(MOL.WT OF C)

= 0.4165/12
= 0.0347
(CO2)t = 0.0347/(0.1332+0.0347)
(CO2)t = 20.37%

Excess air present in exhaust gases

Actual Co2 measured in flue gas = 14%
% Excess air supplied (EA) = 7900 X [( CO2%)t (CO2%)a]
(CO2%)a X[100 (CO2%)t]

= (7900 [20.37-14])/(14 [100-20.37])

= 45.17%

Actual mass of air supplied for combustion

Actual mass of air supplied = [1+ EA/100] X theoretical air
= [1+ 45.17/100] X 4.91
= 7.13 kg of air/kg OF COAL
Actual mass of dry flue gas
Mass of dry flue gas = MASS OF CO2 + MASS OF N2 CONTENT IN THE FUEL + MASS OF N2
IN THE COMBUSTION AIR SUPPLIED + MASS OF OXYGEN IN FLUE GAS
Mass of dry flue gas = (0.4165 44)/12 +0.016+ (7.13 77)/100+((7.13-4.9))/100X23
= 7.54 kg/kg OF COAL

Flue Gas Temperature (Tf) = 180C

Ambient Temperature (Ta) = 30C
% Heat Loss in Dry Flue Gas (L1) = (m Cp(Tf-Ta))/(GCV OF FUEL ) X 100
= (7.54 0.23 (180-30))/3500 X100
L1 = 7.43%
% Heat loss due to formation
of water from h2 in fuel (L2) = (9 H2{584+Cp (Tf-Ta})/(GCV OF FUEL ) X 100
=(9 0.02041 {584+0.45 (180-30))/3500 X 100
L2 = 3.41 %

% Heat Loss Due To Moisture in Fuel (L3) = (M {584+Cp (Tf-Ta)})/(GCV OF FUEL ) X 100
= (0.316 { 584+0.45 (180-30)})/3500 X100
L3 = 5.8 %
% Heat Loss Due To Moisture in Air = (AAS HUMIDITY Cp (Tf-Ta))/(GCV OF FUEL ) X 100
= (7.13 0.0204 0.45 (180-30))/3500 X 100
L4 = 0.28%
% Heat Loss Due To Partial Conversion of C to Co
= %CO X C X 5744
%CO + CO2% GCV OF FUEL

= (0.55 0.4165)/(0.55+14) X 5744/3500 X 100

L5 = 2.58%
Heat Loss Due To Radiation and Convection
= 0.548 X [(Ts/55.55)4-(Ta/55.55)4] + 1.957 X (Ts-Ta) 1.25 X
SQRT OF [(196.85 Vm + 68.9)/68.9]
Where
Vm = wind velocity in m/s
Ts = Surface Temperature (K)
Ta = Ambient Temperature (K)
Surface area of boiler = 32.31m2
= O.548 [(353/55.55)4- (303/55.55)4] + 1.957 X (353-303)1.25((196.853.5+68.9))/68.9)
=1271.48 w/m2
=1271.48 X 0.86
=1093.47 Kcal /m2
TOTAL RADIATION AND CONVECTION LOSS PER HOUR
= 1093.47 X 32.31.
= 35330.01 Kcal
% RADIATION AND CONVECTION LOSS = (35330.01 100)/(3500 450)
L6= 2.24%

Heat loss due to unburnt in fly ash

% ash in coal = 8.63
ratio of bottom ash to fly ash = 90:10
Gcv of fly ash = 452.5 kcal/kg
Amount of fly ash in 1 kg of coal = fly ash % x amount of ash in 1 kg of coal
Total ash %
0.1 x 0.0863
= 0.00863 kg
Heat loss in fly ash = 0.00863 X 452.5
= 3.905 kcal/kg OF COAL
% Heat loss in fly ash = heat loss in fly ash / GCV of coal = 3.905 X 100/3500
L7= 0.11%
% Heat loss due to unburnt in bottom ash
GCV of bottom ash = 800 kcal / kg
Amount of bottom ash in 1 kg of coal = 0.9X 0.0863
= 0.077 kg
Heat loss in bottom ash = 0.077 X 800
= 62.136 kcal / kg OF COAL
% Heat loss in bottom ash = 62.136 X 100 / 3500
L7 =1.77%
BOILER EFFICIENCY BY INDIRECT METHOD
=100-(L1 + L2 + L3 +L4 +L5 +L6 +L7 +L8)
=100-(7.43+3.41+5.8+0.28+2.58+2.24+0.11+1.77)
=76.39%

BOILER FEED PUMP

Rated Data
Motor HP= 5 HP + 5HP
Motor RPM = 2860 RPM
Full Load Current = 7.1 amp
Efficiency = 65%
Measured Data
Measured Current = 3.5 amp AND 3.4 amp
Power Factor = 0.50
Operating Hr = 5 Hr/day
Annual Working Day = 330 days
Power Consumption = (HP 0.746 POWER FACTOR )/(MOTOR EFFICIENCY)
= (5 2 0.746 0.50)/0.65
= 5.73 kWh
Daily electric power consumed = actual power consumption x time of usage/day
= 5.73 X 5
= 28.69kWh/day
Annual electric power consumed = daily consumption x no. of days /year
= 28.69 X 330
= 9468 kWh/yr
Cost of electricity
=9468 kWh/yr. x 4.41 Rs/kWh
=41756Rs/yr.

PROPOSED PUMP
The motor replace with 5 hp ksb kds 527++ pump
Proposed pump data
Flow rate = 14.3 ltr/sec.
Head = 16m
Efficiency = 65%
Specific gravity of water = 1
Power required (P) = (H QK)/(102)
P= Brake power at pump shaft in kW
= Pump efficiency
H =Total heat in meters
Q= Discharge required in LPS
K= Specific gravity of liquid
102 = Constant
P=(16 14.3 1)/(102 0.65)
P= 3.45 kW
Daily consumption (kWh) = Actual power consumed (kW) x time of usage (hrs/ day)
= 3.45 X 5
= 17.25kWh/day
Annual consumption = Daily consumption (kWh/day) x no. of use days/yr
= 17.25 X 330
= 5692.25kWh/yr.
Cost of electricity
= 5692.5 kWh/yr. X 4.41 Rs/kWh
= 25103.925 Rs/yr.
Economics of proposed pump
The cost of 5 hp ksb kds 527++ pump is of 12000/- Rs
Net annual saving = 41756 25103.925
= 16652 Rs.
Simple payback period = (NET COST)/(ANNUAL SAVING ) X 12
= 12000/16652 X 12
= 8.6 MONTHS
BOILER BLOW DOWN PROCESS:
Boiler pressure = 8 kgf/cm2
Boiler rating = 2000kg/hr
Boiler blow down TDS (total dissolved solid) = 4500PPM
Feed water TDS = 500 PPM
% Blow down = (FEED WATER TDS)/(BLOWDOWN TDS-FEED WATER TDS)
= 500/(4500-500)
= 12.5%

If boiler evaporation rate is 2000 kg/hr then required blow down rate is
= (2000 X 12.5 )/100
=250kg/hr
Calculated blow down rate = 250kg/hr
To obtain the energy flow in kW
The blow down rate in kg/s = (250 Kg/hr)/3600
= 0.0694 kg/s
The amount of energy in each kg of blow down sludge, hf AT 8 kg/cm2 = 720kJ/kg
Rate of energy wasted in blow down = 0.0694 X 720
= 49.9kW
Assuming the blow down water is released to a flash steam system operating at 0.5 BAR g. Steam tables may be used to quantify this
energy excess.
Specific enthalpy of water at 0.5 BAR g(1.013 bar + 0.5 bar= 1.51 bar abs) = 468 kJ/kg
Excess energy = energy at 8 bar discharge energy at 1.51 bar = 720kJ/kg 468 kJ/kg=252 kJ/kg
The specific enthalpy of evaporation ( hfg ) at 1.5 bar from steam tables is 2226 kJ/kg
% Flash steam = (hf HIGH PRESSURE-hf LOW PRESSURE )/(hfg LOW PRESSURE ) X 100
% Flash steam = (720-468)/2226 X 100
= 11.3%
Rate of flash steam generation = 250 kg/hr X 11.3 %
= 28.25 kg/hr (0.0078 kg/s)
Total energy per kg of steam = 2694 kJ/kg (hg AT 1.5 BAR)
Energy flow rate in flash steam = 0.0078 kg/s X 2694kJ/kg
=21.14kJ/s
Compare this to the 49.9 kW rate of energy blow down from the boiler
It may be possible to use this flash steam in this it represent almost 43% of the energy flow rate in the blow down and 11.3% of the
water blow down

THERMOPACK (BOILER NO.2)

Capacity = 20, 000, 00 kcal/hr.
Fuel= Reliance peat coke
Avg. coal consumption = 16 TONNE / day.
Pump detail
Rated data
Capacity flow rate (Q) = 160 m3/hr.
Head = 90 m
Pump motor HP =40 HP
Pump motor RPM = 2940 RPM
Full load current = 52 AMP.
Efficiency = 85%
Measured data
Measured current = 53.56 AMP.
Load factor = 1.03
Measured discharge capacity
Brake power = (Q SGH )/
Where
Q= Flow rate m3/hr.
S= Specific gravity
G= Gravity acc. =9.8 m/sec
H= Head in m
= Efficiency
Power = (HP 0.746LOAD FACTOR)/(EFFICIENCY )

=(40 0.7461.033600)/0.85 = (Q 0.72 9.81 90)/0.85

Q= 174 m3/hr.
Heat output
= m Cp T
T = AVERAGE T (DIFFERENCE OF SUPPLY & RETURN TEMPERATURE)
= 174 X 1000 X 0.48 X (220 -200)
=1670400 kcal.
Heat input
Total coal consumption = 666 kg/ hr.
GCV of coal = 3500 kcal /kg
Heat input = 666 X 3500
= 2333333kcal /hr.
Efficiency = (HEAT OUTPUT )/(HEAT INPUT )

=1670400/2333333
= 71 %
THERMOPACK EFFICIENCY BY INDIRECT METHOD
FUEL ANALYSIS (IN %)
ASH CONTENT IN FUEL = 8.63
MOISTURE IN COAL = 31.65
CARBON CONTENT = 41.65
HYDROGEN CONTENT= 2.0413
NITROGEN CONTENT = 1.6
OXYGEN CONTENT = 14.48
GCV OF COAL = 3500 kcal/kg
FLUE GAS TEMPERATURE = 220C
AMBIENT TEMPERATURE = 30C
PERCENTAGE OF O2 AND CO2 IN FLUE GAS = 11.1 & 8.5
THEORITICAL AIR REQUIREMENT
THE CHEMICAL REACTION ARE
C + O2 ------------------------ CO2
2H2 + O2 -------------------2H2O
S + O2 -------------------- SO2
C + O2 ---------------------CO2
12 + 32 ---------------------- 44
12 KG OF CARBON REQUIRES 32 KG OF OXYGEN TO FORM 44 KG OF CARBON DIOXIDE. THEREFORE 1 KG OF CARBON
REQUIRES 32/ 12 kg I,e 2.67 kg OF OXYGEN
41.65 C + (41.65 X 2.67) kg O2 ---------------------------- 152.85 kg CO2
2H2 + O2 ------------------------------- 2H2O
4 + 32 ------------------------------- 36
4 kg OF HYDRIGEN REQUIRES 32 kg OF OXYGEN TO FORM 36 kg OF WATER. THEREFORE 1 kg OF HYDROGEN REQUIRES
32/ 4 kg I,E, 8 kg OF OXYGEN

2.0413 kg H2 + (2.0413 X 8) kg O2 ------------------------ 18.37 kg H2O

S + O2 ------------------------------------ SO2
32 + 32 ------------------------------------ 64
32 kg OF SULPHUR REQUIRES 32 kg OF OXYGEN TO FORM 64 kg OF SULPHUR DIOXIDE. THEREFORE 1 kg OF SULPHUR
REQUIRE 32/32 kg ie, 1 kg OF OXYGEN.
0 kg S + (0 X 1) kg O2 ------------------------------------------ 0 kg OF SO2
TOTAL OXYGEN REQUIRED
(111.20 + 16.33 + 0) = 127.53
OXYGEN ALREADY PRESENT IN 100 kg FUEL = 14.28 kg (FROM ULTIMATE ANALYSIS)
ADDITIONAL OXYGEN REQUIRED = 127.53 14.28 = 113.25kg
THEREFORE QUANTITY OF DRY AIR REQUIRED = 113.25/0.23 = 492.39 kg OF AIR
(AIR CONTAINS 23 % OXYGEN BY WT.)
THEORITICAL AIR REQUIRED = 492.39/100
= 4.9239 kg OF AIR /kg OF FUEL

THEORITICAL CO2 % PRESENT IN EXHAUST GASES

% CO2 AT THEORITICAL CONDITION = MOLES OF C
MOLES OF N2 + MOLES OF C

MOLES OF N2 = WT. OF N2 IN THEORITICAL AIR + WT. OF N2 IN FUEL

MOL. WT. OF N2 MOL. WT. OF N2

MOLES OF N2 = (4.91 7.7)/28 +0.016/28 = 0.1356

WHERE MOLES OF C = (WT.OF C IN FUEL )/(MOL.WT OF C)

= 0.4165/12
= 0.0347
(CO2)t = 0.0347/(0.1332+0.0347)
(CO2)t = 20.37%

EXCESS AIR PRESENT IN EXHUAST GASES

ACTUAL CO2 MEASURED IN FLUE GAS = 8.5%
% EXCESS AIR SUPPLIED (EA) =7900 X [(CO2%)t (CO2%)a]
(CO2%)a X[100 (CO2%)t]

= (7900 [20.37-8.5])/(8.5 [100-20.37])

= 138.54%

ACTUAL MASS OF AIR SUPPLIED FOR COMBUSTION

ACTUAL MASS OF AIR SUPPLIED = [1+ EA/100] X THEORITICAL AIR
= [1+ 138.54/100] X 4.91
= 11.71 kg/kg OF COAL
ACTUAL MASS OF DRY FLUE GAS
MASS O DRY FLUE GAS = MASS OF CO2 + MASS OF N2 CONTENT IN THE FUEL + MASS OF N2
IN THE COMBUSTION AIR SUPPLIED + MASS OF OXYGEN IN FLUE GAS
MASS OF DRY FLUE GAS = (0.4165 44)/12 +0.016+ (7.13 77)/100+((7.13-4.9))/100X23
= 7.54 kg/kg OF COAL
FLUE GAS TEMPERATURE (Tf) = 220C
AMBIENT TEMPERATURE (Ta) = 30C
% HEAT LOSS IN DRY FLUE GAS (L1) = (m Cp(Tf-Ta))/(GCV OF FUEL ) X 100
= (7.54 0.23 (220-30))/3500 X100
L1 = 9.41%
% HEAT LOSS DUE TO FORMATION
OF WATER FROM H2 IN FUEL (L2) = (9 H2{584+Cp (Tf-Ta})/(GCV OF FUEL ) X 100
=(9 002041 {584+0.45 (220-30))/3500 X 100
L2 = 3.51 %

% HEAT LOSS DUE TO MOISTURE IN FUEL (L3) = (M {584+Cp (Tf-Ta)})/(GCV OF FUEL ) X 100
= (0.316 { 584+0.45 (220-30)})/3500 X100
L3 = 5.71 %
% HEAT LOSS DUE TO MOISTURE IN AIR = (AAS HUMIDITY Cp (Tf-Ta))/(GCV OF FUEL ) X 100
= (11.71 0.0204 0.45 (220-30))/3500 X 100
L4 = 0.58%
% HEAT LOSS DUE TO PARTIAL CONVERSION OF C TO CO
= (% CO C)/(% CO+% CO2 ) X 5744/(GCV OF FUEL ) X 100
= (0.55 0.4165)/(0.55+8.5) X 5744/3500 X 100
L5 = 4.15%
HEAT LOSS DUE TO RADIATION AND CONVECTION
= 0.548 X [(Ts/55.55)4-(Ta/55.55)4] + 1.957 X (Ts-Ta)1.25 X
= SQRT OF [(196.85 Vm + 68.9)/68.9]
WHERE
Vm = WIND VELOCITY IN m/s
Ts = SURFACE TEMPERATURE (K)
Ta =AMBIENT TEMPERATURE (K)
= O.548 [(353/55.55)4- (303/55.55)4] + 1.957 X (353-303)1.25((196.853.5+68.9))/68.9)
=1271.48W/m2
=1271.48 X 0.86
=1093.47 Kcal /m2
TOTAL RADIATION AND CONVECTION LOSS PER HOUR
= 1093.47 X 90
= 98412.3 Kcal
% RADIATION AND CONVECTION LOSS = (98412.32 100)/(3500 450)
L6 = 4.22%

HEAT LOSS DUE TO UNBURNT FUEL IN FLY ASH

% ASH IN COAL = 8.63
RATIO OF BOTTOM ASH TO FLY ASH = 90.10
GCV OF FLY ASH = 452.5 kcal/kg
AMOUNT OF FLY ASH IN 1 kg OF COAL = 0.1 X 0.0863
= 0.00863 kg
HEAT LOSS IN FLY ASH = 0.00863 X 452.5
= 3.905 kcal/kg OF COAL
HEAT LOSS IN FLY ASH = 3.905 X 100/3500
L7 = 0.11%
% HEAT LOSS DUE TO UNBURNT IN BOTTOM ASH
GCV OF BOTTOM ASH = 800 kcal / kg
AMOUNT OF BOTTOM ASH IN 1 kg OF COAL = 0.9X 0.0863
= 0.077 kg
HEAT LOSS IN BOTTOM ASH = 0.077 X 800
= 62.136 kcal / kg OF COAL
% HEAT LOSS IN BOTTOM ASH = 62.136 X 100 / 3500
L8 =1.77%
BOILER EFFICIENCY BY INDIRECT METHOD
100-(L1 + L2 + L3 +L4 +L5 +L6 +L7 +L8)
100-(9.41+3.51+5.71+0.58+4.15+4.22+0.11+1.77)
=76.25%

COMPRESSOR DETAIL
RATED DATA COMPRESSOR 1 COMPRESSOR 2
Motor HP 10 HP 10HP
Motor Rpm 1430 RPM 1430 RPM
Full load current 11 AMP 11 AMP
Efficiency 7.3 AMP 7.5 AMP
Measured Data
Measured current 7.3 AMP 7.5 AMP
Power factor 66% 67%
Avg. running hrs/day 4 hrs 6hrs
Annual operating days/hr 330days 330 days

COMPRESSOR 1
Power consumption rating of motor = 10 HP
= 10 X 0.746 KW
= 7.46 KW
Actual power consumed = (POWER CONSUMPTION POWER FACTOR )/(EFFICIENCY OF MOTOR)
= (7.4 0.66)/0.85
= 5.74KW
Daily electric power consumed by the motor = Actual power consumed x time of usage
= 5.74 X 4
=22.98 kWh
Annual electric power used by motor = Daily consumption x no. of days use
= 22.98 X 330
= 7584.56kWh/yr.
Cost of electricity used by motor/yr. = 7584.56 kWh/yr X 4.41 Rs/kWh
= 33447.9 Rs/yr.

COMPRESSOR 2
Power consumption rating of motor = 10 HP
= 10 X 0.746 KW
= 7.46KW
Actual power consumed = (POWER CONSUMPTION POWER FACTOR )/(EFFICIENCY OF MOTOR )
= (7.46 0.67)/0.85
= 5.81 kW
Daily electric power consumed by the motor= Actual power consumed x time of usage
= 5.81 X 6 kWh
= 34.87 kWh
Annual electric power used by motor = Daily consumption x no. of days /yr
= 34.87kWh X 330
= 11507kWh/yr.
Cost of electricity used by month / yr. = 11507 kWh/yr. X 4.41 Rs/yr
= 50748Rs/yr.
PERFORMANCE TEST AND MEASUREMENT
P1= Initial pressure = 5 kg/cm2
P2=Final pressure = 7kg/cm2
Pa= Atmospheric pressure (ABSOLUTE)
Vr= Volume of air receiver and interconnected pipes = 300 ltr = 0.300 m3
t =Time in seconds for pressure to rise from P1 to P2 = 56 SEC.
TC= Temperature correction factor
TR=Air temperature in receiver K = 31C= 304K
Ta=Ambient temperature K= 30C= 303K
TC=(273+Ta)/(273+Tr) = (273+303 )/(273+304 ) = 0.99
Q= (P2-P1)/1.026 X Vr X 60/t XTCX (35.32 FOR m3 TO CUB. FEET)
= (7-5)/1.026 X 0.300 X 60/56 X 0.99 X 35.52
= 21.90 CFM
Specific power consumption
Actual output = 21.90 CFM
Actual consumption = 5.74 kW
= Actual output / actual consumption
=21.90/5.74
=3.81 CFM/kW
%Leakage in the compressor air system
= T/(T+t ) X100
T= 64 SEC.
T= 172 SEC.
= 64/(64+172 ) X 100
= 27%
The quantity of compressed air leakage
Leakage quantity =Percentage leakage x actual output
= 0.27 X 21.90
= 5.91 CFM
Calculate the power lost due to leakage
= Leakage quantity / specific energy
= 5.91 CFM / 3.81 CFM/kW
= 1.549 kW
Daily electric power lost by motor
= Actual power lost x time of usage
=1.549 X 4
6.196 kWh
Annual electric power lost by motor
= 6.196 X 330
= 2044.68 kWh / yr.
Cost of electricity lost by motor /yr.
= 1548.624 kWh/ yr. X 4.41 Rs/kWh
=9017.11 Rs/yr.
PERFORMANCE TEST AND MEASUREMENT OD COMPRESSOR 2
P1= Intial pressure = 4 kg/cm2
P2= Final pressure= 6 kg/cm2
Pa= Atmospheric pressure (ABSOLUTE)
Vr= Volume of air receiver and interconnected pipes= 300 LTR= 0.300 m3
t = Time in second for pressure to rise from P1 to P2= 58 SEC
TC= Temperature correction factor
Tr = Air temperature in receiver K = 31 C= 304K
Ta= Ambient temperature K= 30C= 303K
TC=(273+Ta)/(273+Tr ) = (273+303 )/(273+304 ) = 0.99
Q= (P2-P1)/1.026 X Vr X 60/t X TC X (35.32 FOR m3 TO CU. FEET)
=(6-4)/1.026 X 0.300 X 60/58 X 0.99 X 35.32
Q= 21.53 CFM
Specific power consumption
=Actual output = 21.53 CFM
=Actual consumption = 5.81 kW
=Actual output / actual consumption
=21.53/5.81
3.70 CFM / kW
% Leakage in the compressed air system
% leakage in the system
= T/(T+t) X 100
T= 52 sec
T = 66 sec
=52/(52+66) X 100
= 44 %
The quantity of compressed air leakage
Leakage quantity= Percentage leakage x actual output
= 0.44 X 21.153
= 9.30 CFM
Calculate the power lost due to leakage
=Leakage quantity/ specific energy
= 9.30 CFM / 5.81 CFM/kW
=1.60kW
Daily electric power lost by motor
= Actual power lost x time of usage
= 1.60 X 6
= 9.60 kWh
Annual electric power lost by motor
= 9.60 X 330
= 3168kWh/yr
Cost of electricity lost by motor / yr
= 3168kWh/yr X 4.41 Rs/kWh
= 13970Rs/yr
LIGHNING SYSTEM
MAKE: Crompton greaves/ Aluminum choke
Assumption
1 Daytime use = 12 Hrs
2 Night time use = 12 Hrs
Energy consumption of each fluorescent tube
1 Tube light = 40W
2 Choke = 14W
3 Total = 54 W
Sr. LOCATION NO. OF TUBE USED DAYTIME NO. OF TUBE USED NIGHT TIME
1 Main Gate --- 4
2 D.G.Sets --- 7
3 Boiler house --- 9
4 Zero-Zero M/C 1 2
5 Felt M/C 3 4
6 Fitter room 2 2
7 Stenter 1 2 16
8 Stenter2 2 14
9 Front fitter room 2 7
10 Jet Dyeing M/C - 7
11 Store 4 15
12 Laboratory 4 4
13 F.B. Printing M/C 10 10
14 F.B. Printing M/C2 11 11
15 F.B. Printing M/C3 12 12
16 F.B. Printing M/C4 11 11
17 F.B. Printing M/C5 11 11
18 F.B. Printing M/C6 10 10
19 F.B. Printing M/C7 8 8
20 F.B. Printing M/C8 9 9
21 Miscellaneous - 15
TOTAL 102 185
Daily electric power consumed by tube light in daytime
= Actual power consumed x no. of tube light x time of usage
= (54 W 102 12 hr)/1000
=66kWh/daytime
Annual electric power consumed by tube light
= Daily consumption x no. of days use/yr.
=66kWh X 330
=21780 kWh/yr.
Cost of electricity consumed by tube light
= 21780kWh/yr. X 4.41 Rs/kWh
= 96049.8 Rs/yr.
Daily electric power consumed by tube light in nighttime
=Actual power consumed x no. of tube light x time of usage
= (54 W 185 12)/1000
=119.88kWh/nighttime
Annual electric power consumed by tube light
=Daily consumption x no. of days use /yr.
=119.88 X 330
=39560.4kWh/yr.
Cost of electricity used by tube light
= 39560.4kWh/yr X 4.41 Rs/kWh
=174461.36 Rs/yr.
Case 1
Interlock F.B. Printing M/C tube light
Avg. tube light on one F.B. Printing M/C= 10 NOS.
Total M/C = 8 NOS.
Total no. of tube light = 8 X 10
= 80 NOS.
Approx. hrs saving = 5 hr/day
Annual working days = 330
Unit cost = 4.41/ unit
Annual cost saving= (ACTUAL POWER CONSUMPTION NO.OF TUBELIGHT TIME OF USAGE NO.OF DAYSUNIT COST)/1000
=(54 80 5 330 4.41)/1000
=31434
=31500Rs/yr
Case 2 retrofit the tube light with CFL of 15w
No. of tube light = 56
Daily power consumption of tube light before retrofitting
= Actual power consumed x no. of tube light x time of usage
= (54 56 24)/1000
=72.57kWh/day
Annual electric power used
= Daily consumption x no. of days use / yr
= 72.57 kWh X 330
= 23950kWh/yr
Cost of electricity
= 23950 kWh/yr. X 4.41 Rs/kWh
= 105619.8 Rs/yr.
Daily power consumption of tube light after retrofit with CFL of 15 W
= Actual power consumed x no. of tube light x time of usage
=(15 56 24)/1000
=20.16kWh/DAY
Annual electric power used
= Daily consumption x no. of days use /yr.
= 20.16 X 330
=6652.8kWh/yr
Cost of electricity
= 6652.8 kWh/yr. x 4.41Rs/kWh
29338.84 Rs/yr
Net annual saving = 105619.8- 29338.84
= 76280.9 Rs/yr.
Payback period
=(TOTAL COST)/(ANNUAL SAVING ) X 12
Total cost of CFL = 85 Rs X 56
= 4760 Rs
= 4760/76280.9 X 12
= 0.748 Yr
Case 3 retrofit the tube light with energy efficient tube light of 28 W
No. of tube light =47
Energy consumed by tube = 27W
Energy consumed by choke = 1 W
Total = 28 W
Daily power consumption before retrofit
Daily power consumption of tube light before retrofitting
= Actual power consumed x no. of tube light x time of usage
= (54 47 24)/1000
=60.92kWh/day
Annual electric power used
= Daily consumption x no. of days use / yr
= 60.92 kWh X 330
= 20100kWh/yr
Cost of electricity
= 20100 kWh/yr. X 4.41 Rs/kWh
= 88645Rs/yr.
Daily power consumption after retrofit
=(ACTUAL POWER CONSUMED NO.OF TUBELIGHT TIME OF USAGE )/1000
=(28 47 24)/1000
=31.48kWh/day
Annual electric power consumption
= Daily consumption x no. of days use /Yr.
= 31.58 X 330
= 10421.4kWh/Yr.
Cost of electricity
= 10421.4kWh/yr. X 4.41 Rs/kWh
= 45958.37 Rs/yr.
Net annual saving = 88645-45958
= 42686Rs/yr
Payback period
=(TOTAL COST)/(ANNUAL SAVING ) X 12
Total cost of energy efficient lightning = 500 Rs X 47
= 23500 Rs
= 23500/42686 X 12
= 6.6 MONTH

DETERMINATION OF ELECTRIC MOTOR LOAD

Jet Dyeing machine 1,2
Measured data
V= 414 VOLT
I= 11 AMP
P.F=95%
P=7.4 kW
Rated data
Hp= 10 Hp
Efficiency = 75%
Case1
PI= (V IPF3)/1000
Where
PI=Three phase power in kW
V= RMS VOLTAGE
I= RMS CURRENT
P.F= Power factor
PI=(414 110.951.732)/1000
=7.49 kW
PIR= (HP 0.7457)/
Where
Pir= Input power at full rated
Hp=Name plate rated horse power
= Efficiency at full rated load
=(10 0.7457)/(0.75 )
= 9.94 kW
Load = Pi/Pir X100
Load = Output power as a % of rated power
Pi = Measured three phase power in kW
Pir= Input power at full rated load in kW
Load = 7.49/9.94 X 100
= 74.4%
Case 2
Motor efficiency saving
Replace the standard efficiency (S.E) motor with energy efficient (E.E) motor whose efficiency = 86%
Then
kW saved = 0.746 X [ HP1/(EFFICIENCY )HP2/(EFFICIECNY )]
HP1 =Existing motor load
HP2 = Motor load for new motor
kW saved = 0.746[10/0.75-10/0.86]
= 1.269 KW
Now
Input power at full rated load with 86% efficiency
Pir= (HP X 0.7457)/(EFFICIENCY )
= (10 0.7457)/0.86
= 8.67 kW
Load = 7.49/8.6 X 100
= 86 %
Comment
Most electric motors are designed to runs at 50% to 100% of rated load. In case 1 motor runs at 74.4% which is quiet good. But in case
2 when we replace S.E motor with E.E motor it runs at 86% load which is better
Jet Dyeing machine 3, 4
Measured data
V= 414 volt
I = 13 amp
PF = 77 %
P= 6.4 kW
Rated Data
HP = 10 HP
Efficiency = 75%
PI=(V IPF3)/1000
=(414 130.771.732)/1000
=7.17 kW
Pir=(HP 0.7457)/
= (10 0.7457)/0.75
= 9.94 kW
Load =PI/PIR X 100
= 7.17/9.94 X 100
= 72.1%
Case 1
Motor efficiency saving
Replace the standard efficiency motor (S.E) with energy efficient motor whose efficiency = 86%
KW saved = 0.746X [HP1/EFFICIENCY-HP2/EFFICIENCY]
= 0.746X [10/0.75-10/0.86]
= 1.269 kW
Now input power at full rated load with 86% efficiency
Pir= (HP 0.7457)/EFFICIENCY
= (10 0.7457)/0.86
= 8.69 kW
Load = Pi/Pir X 100
= 7.17/8.67 X 100
= 82%
Case3
Replace the 10 Hp S.E. motor with 8 Hp (E.E) motor then
Motor efficiency saved
kW saved = 0.746 X [HP1/EFFICIENCY-HP2/(EFFICIENCY )]
= 0.746 X [10/0.75-8/0.86]
= 3.004 kW
Now input power at full rated load with 8 HP motor
Pir =HP X 0.7457/(EFFICIENCY )
= 8 X 0.7457/0.86
= 6.93 kW
Load = Pi/Pir X 100
= 7.17/6.93 X 100
= 103 %
Comment
In case1 motor runs at 72.1% which is quiet good .in case 2 when we replace S.E. motor with E.E motor it runs at 82% load which is
better but in case3 when motor is replaced with 8 HP E.E motor.Motor runs at 103 % load which is not feasible
Stenter machine 1
Measured data
V= 431 volts
I= 58.1 amp
PF= 85.1%
P= 42.69 kW
Rated data
HP = 75 HP
Efficiency = 0.75
Pi = (V IPF 3)/1000
= (431 58.10.8511.732)/1000
= 36.90 kW
Pir =HP X 0.7457/EFFICIENCY
= 75 X 0.7457/0.75
= 74.57 kW
Load = Pi/Pir X 100
= 36.90/7457 X 100
= 49.48%
Case 2
Replace the S.E motor with E.E motor when efficiency is 86%
Motor energy saved
kW saved = 0.746 X [(HP1 )/(EFFICIENCY )(HP2 )/(EFFICIENCY )]
= 0.746 X [75/0.75-75/0.86]
= 9.54 kW
Now input power at full rated load with 86% efficiency
Pir =HP X 0.7457/EFFICIENCY
= 75 X (0.7457 )/0.86
= 65.03 kW
Load = Pi/Pir X 100
= 36.90/65.03 X 100
= 56%
Case 3
Replace the 75 HP S.E. motor with 50 HP E.E motor
Motor efficiency saved
kW saved = 0.746 X [HP1/EFFICIENCY-HP2/(EFFICEINCY )]
= 0.746 X [75/0.75-50/0.86]
= 31.22 kW saved
Pir =HP X 0.7457/EFFICIENCY
= 50 X 0.7457/0.86
= 43.35 kW
Load = Pi/Pir X 100
= 36.90/43.35 X 100
= 85.1%
Comment
In case 1 motor runs at 49.48% loading which is not good. in case 2 motor runs at 56% loading but in case 3 motor runs at 85% loading
which is better than case 1 and case 2

STENTER NO. 2
MEASURED DATA
V= 424 VOLTS
I= 76 AMP
PF= 80%
P=51.73 kW
RATED DATA
HP = 75 HP
EFFICIENCY = 75%
Pi = (V I PF 3)/1000
= (424 76 0.80 1.732)/1000
= 44.64 kW
Pir = HP X 0.7457/EFFICIENCY
= 75 X 0.7457/0.75
= 74.57 kW
LOAD = Pi/Pir X 100
= 44.64/75.57 X 100
= 59.86%
CASE 2
REPLACE THE S.E MOTOR WITH E.E MOTOR WHOSE EFFICEINCY IS 86%
MOTOR ENERGY SAVED
kW SAVED = 0.746 X [(HP1 )/(EFFICIENCY )(HP2 )/(EFFICIENCY )]
= 0.746 X [75/0.75-75/0.86]
= 9.54 kW
NOW INPUT POWER AT FULL RATED LOAD WITH 86% EFFICIENCY
Pir =HP X 0.7457/EFFICIENCY
= 75 X (0.7457 )/0.86
= 65.03 kW
LOAD = Pi/Pir X 100
= 44.64/65.03 X 100
= 68.6%
CASE 3
REPLACE 75 HP S.E MOTOR WITH 50 HP E.E MOTOR
MOTOR EFFICIENCY SAVED
kW saved = 0.746 X [HP1/EFFICIENCY-HP2/(EFFICEINCY )]
= 0.746 X [75/0.75-50/0.86]
= 31.22 kW saved
Pir =HP X 0.7457/EFFICIENCY
= 50 X 0.7457/0.86
= 43.35 kW
LOAD = Pi/Pir X 100
= 44.64/43.35 X 100
= 103%
COMMENT
IN CASE 1 MOTOR RUNS AT 59.86% WHICH IS QUIET GOOD . IN CASE 2 MOTOR RUNS AT 68.6% LOAD WHICH IS BETTER
BUT IN CASE 3 MOTOR RUNS AT 103% LOAD WHICH IS NOT FEASIBLE
LOOP MACHINE
MEASURED DATA
V= 423 VOLT
I= 15.47 AMP
PF=95 %
P= 6.35 kW
RATED DATA
HP = 15 HP
EFFIECIENY = 86%

Pi = (V I PF 3)/1000
= (423 15.47 0.95 1.732)/1000
= 10.76 kW
Pir = HP X 0.7457/EFFICIENCY
= 15 X 0.7457/0.86
= 13 kW
LOAD = Pi/Pir X 100
= 10.76/13 X 100
= 82.7%
COMMENT
IN THIS CASE MOTOR RUNS AT 82.7% LOADING WITH 86% EFFICIENCY OF MOTOR SO NEED TO REPLACE THE MOTOR

THRMOPACK
MEASURED DATA
V= 423 VOLT
I= 56.1 AMP
P.F= 86.2%
P= 44.92 kW
RATED DATA
HP = 65 HP
EFFICIENCY = 86%
Pi = (V I PF 3)/1000
= (423 56.1 0.862 1.732)/1000
= 35.42 kW
Pir = HP X 0.7457/EFFICIENCY
= 65 X 0.7457/0.75
= 56.36 kW
LOAD = Pi/Pir X 100
= 35.42/56.36 X 100
= 62.8%
CASE 2
REPLACE THE 65 HP S.E MOTOR WITH 50 HP E.E MOTOR
MOTOR EFFICIENCY SAVED
kW saved = 0.746 X [HP1/EFFICIENCY-HP2/(EFFICEINCY )]
= 0.746 X [65/0.86-50/0.86]
= 13.01 kW saved
Pir =HP X 0.7457/EFFICIENCY
= 50 X 0.7457/0.86
= 43.35 kW
LOAD = Pi/Pir X 100
= 35.42/43.35 X 100
= 81%
COMMENT
IN CASE 1 MOTOR RUNS AT 62.8% LOADING WHICH IS GOOD AND IN CASE 2 MOTOR RUNS AT 81% LOADING WHICH IS
BETTER
COMPRESSOR
MEAUSRED DATA
V= 423 VOLT
I= 10 AMP
P.F= 64.5%
P=5.23 kW
RATED DATA
HP = 10 HP
EFFICIENCY = 75%
Pi = (V I PF 3)/1000
= (423 10 0.645 1.732)/1000
= 4.72 kW
Pir = HP X 0.7457/EFFICIENCY
= 10 X 0.7457/0.86
= 8.67 kW
LOAD = Pi/Pir X 100
= 4.72/8.67 X 100
= 54.4%
CASE 2
REPLACE 10 HP S.E MOTOR WITH 8 HP E.E. MOTOR THEN
MOTOR EFFICIENCY SAVED
kW saved = 0.746 X [HP1/EFFICIENCY-HP2/(EFFICEINCY )]
= 0.746 X [10/0.86-8/0.86]
= 3.04 kW saved
Pir =HP X 0.7457/EFFICIENCY
= 8 X 0.7457/0.86
= 6.9 kW
LOAD = Pi/Pir X 100
= 4.72/6.93 X 100
= 68%
COMMENT
IN CASE 1 MOTOR RUNS AT 54.4% LOADING WHICH IS GOOD BUT IN CASE2 MOTOR RUNS AT 68% LOADING WHICH IS
BETTER