Energy Eff Thermal Utilities All Papers

Paper EM2 Energy Manager Set A
NATIONAL CERTIFICATION EXAMINATION 2004

FOR
ENERGY MANAGERS
PAPER EM2: Energy Efficiency in Thermal Utilities
Date: 22.05.2004 Timings: 1400 - 1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
o Please check that this question paper contains 6 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

177

Answer all 50 questions

178

Each question carries one mark

179

Put a () tick mark in the appropriate box in the answer book
1. Excess air can be derived by measuring the percentage of in the flue gas.
a) CH4 b) N2 c) CO d) CO2
2. Which of the following fuel requires the least amount of excess air for complete
combustion?
a) furnace oil b) LDO c) coal d) natural gas
3. LPG consists of one of the following

a) Methane b) Butane c) Hexane d) Iso-Octane
4. Suitable atomizing viscosity of furnace oil for use in LAP/MAP burners is

a) 100 Redwood seconds-1 b) 300 Redwood Seconds-1
c) 600 Red wood seconds-1 d) 400 Redwood Seconds-1

5. Stoichiometric air to fuel ratio for Indian coals used in thermal power plants is in the
range
a) below 3 b) 8 - 10 c) 3 - 6 d) 10 - 14
6. Element in fuel oil responsible for corrosion is

a) Carbon b) Sulphur c) Hydrogen d) Chlorine
7. A system in which a package type boiler operates with a FD fan is called

a) Natural draft b) Forced draft c) Induced draft d) Balanced draft
_______________________ 1
Bureau of Energy Efficiency
8. Steam generation in a boiler is 26 tonnes in 2 hours. Fuel consumption in the same
period is 1 tonnes per hour. The evaporation ratio is
a) 10 b) 12 c) 13 d) 26
9. The limiting temperature to which the flue gases can be cooled is influenced by
percentage of
a) Carbon in fuel b) Hydrogen in fuel c) Sulphur in fuel d) Ash in fuel
10. Economizer in boiler is used to extract heat from flue gases for pre-heating
a) blow down b) fuel oil c) air for combustion of fuel d) feed water
11. Concentration of solids in boiler drum is controlled by

a) steam venting b) blow down c) steam trap d) excess air
12. Major heat loss in an oil fired boiler is accounted by

a) surface radiation loss b) stack loss
c) un-burnt carbon loss d) blow down loss

13. At which of the following pressure, the enthalpy of evaporation of steam will be
highest
a) 2 kgs/cm2 b) 8 kgs/cm2 c) 12 kgs/cm2 d) 20 kgs/cm2
14. Which of the steam trap operates on the principle of difference in density between
steam and condensate
a) thermodynamic b) inverted bucket c) thermostatic d) none of the above
15. Steam mains should be run with a falling slope of in the direction of steam flow for
effective line condensate drainage
a) 125 mm in 30 metres b) 250 mm in 30 metres
c) 50 mm in 30 meteres d) 350 mm in 30 metres

16. Heat loss through openings in furnaces is directly proportional to
a) fourth power of absolute temperature b) square of absolute temperature
c) absolute temperature d) fourth power of temperature

17. Furnace wall heat loss does not depend on
a) temperature of external surface b) temperature of air around the furnace
c) emissivity of external wall surfaces d) stock to be heated

18. The efficiency of a stand alone gas turbine without any heat recovery system will be
in the range of
a) 10 15 % b) 15 20 % c) 20 25 % d) 35 40 %
19. Which of the following influences energy savings when ceramic coating is applied on
furnace hot side
a) conductivity b) convective heat transfer coefficient
c) emissivity d) factor for total radiation
_______________________ 2
20. Which of the following is not a property of ceramic fibre insulation.

a) low thermal conductivity b) light weight
c) high heat capacity d) thermal shock resistant

21. Fuel bed temperature in a FBC boiler is about
a) 550 oC b) 900oC c) 1400 oC d) 1700 oC
22. Low combustion temperature in FBC boilers results in reduced formation of

a) SOx b) NOx c) CO2 d) O2
23. A major advantage of PFBC boilers compared to conventional pulverised coal fired
boiler is
a) less ash removal b) low excess air
c) low radiation loss d) much smaller size

24. Which of the following industry may not be ideal for adoption of co-generation system
a) fertilizer b) pulp & paper c) refinery d) foundry
25. Ceramic recuperators can withstand gas side temperature up to

a) 400oC b) 1300oC c) 1000oC d) 1700o C
26. The waste heat recovery equipment in a combustion system will be more economical
when the exit flue gases are at a temperature of
a) 200oC b) 400oC c) 600oC d) 800oC
27. Which among the following uses a sealed working fluid for heat recovery
a) heat pipe b) recuperator c) heat wheel d) thermocompressor
28. The device that upgrades a low temperature heat source to a higher temperature
sink is called
a) heat pipe b) heat pump c) plate heat exchanger d) economizer
29. Which of the following equipment requires electricity for its operation
a) thermocompressor b) heat pump c) heat pipe d) economizer
30. The average reduction of flue gas temperature by . results in an efficiency

increase of the boiler by 1% point
a) 12oC b) 22oC c) 32oC d) 42oC
31. The equipment used to upgrade a low pressure steam to a higher pressure steam is
known as
a) heat pump b) thermocompressor c) heat pipe d) heat wheel
32. Which of the following boiler has the largest permissible boiler drum TDS
concentration
a) low pressure water tube boiler b) high pressure water tube boiler
c) lancashire boiler d) package and economic boiler
_______________________ 3
33. A power plant which uses first a gas turbine followed by a steam turbine for power
generation is called
a) topping cycle b) combined cycle
c) Brayton cycle d) bottoming cycle

34. The Gross Calorific Value of furnace oil, LSHS and LDO is of the order of
a) 5,000 kilo calorie per kg b) 8,000 kilo calorie per kg.
c) 10,000 kilo calorie per kg d) 13,000 kilo calorie per kg

35. A co-generation system is also known as
a) reversible system b) re-generation system
c) combined heat and power system d) Brayton cycle system

36. Which of the following will not conserve energy in a furnace
a) preheating combustion air b) charge preheating
c) optimizing excess air d) addition of more burners

37 Regenerators are widely used in
a) reheating furnaces b) heat treatment furnaces
c) baking ovens d) glass melting furnaces

38. The efficiency of a re-heating furnace, operating at 10 tonnes per hour consuming
furnace oil of 460 kg/hour for reheating the stock from 40 oC to 1100oC. (Specific heat
of material is 0.13 kCal/kg0C) is about
a) 20 b) 30 c) 40 d) 50
39. What is the major energy loss in an oil fired reheating furnace?
a) loss due to evaporation of moisture in fuel b) skin losses
c) sensible heat loss in flue gas d) heat loss through openings

40. Which of the following does not contribute to efficient use of steam
a) superheated steam for indirect process heating
b) insulation of steam pipe lines

c) reducing the work to be done by steam d) providing dry steam for process
41. The purpose of venting air from steam systems is because air is a
a) dilutant b) inert substance
c) good conductor d) insulator

42. Steam is used as a heat transfer medium in an industry because of the following
main factor
a) water is easily available b) steam can be transported
c) releases maximum heat during heat transfer at a fixed temperature

d) none of the above
43. The coefficient of thermal expansion of refractory material should be
a) very high b) high c) medium d) low
_______________________ 4
44. High emissivity coatings are most effective when applied on

a) inner surface of furnace b) outer surface of furnace
c) refrigeration pipings d) none of the above

45. Alumina is a type of refractory.
a) acid b) neutral c) basic d) none of the above
46. The efficiency of a typical FBC boiler would be around

a) 90% b) 80% c) 70% d) 40%
47. In FBC boiler the combustion is carried out at a temperature

a) closer to steam temperature
b) below ash fusion temperature of fuel used

c) at adiabatic combustion temperature
d) at and above ash fusion temperature
48. In a CFBC boiler the capture and recycling of bed materials is accomplished by
a) cyclone b) back filter c) settling chamber d) scrubber system
49. The equipment having the highest efficiency in case of conventional power plant is
a) boiler b) electric generator c) cooling tower d) steam or gas turbine
50. The major limitation of metallic recuperator is

a) limitation of handling SOx, NOx gases.
b) manufacturing difficulty of the required design
c) limitation of reduced life for handling temperature above 1000 oC
. End of Section I .
Section II: SHORT DESCRIPTIVE QUESTIONS Marks: 10 x 5 = 50
0 Answer all Ten questions

0.0 Each question carries Five marks
S-1. List some applications using ceramic fibre.
S-2. What are the important aspects to be considered for retrofitting a conventional
boiler to FBC technology?
S-3. Explain what is meant by a combined cycle.
_______________________ 5
S-4. List at least five important parameters to be considered before installing a

cogeneration system.
S-5. What is a heat pipe? How does it work?
S-6. Explain the meaning of dryness fraction of steam.
S-7. How is percentage of excess air level calculated from data obtained from a flue
gas analysis of boilers or furnaces?
S-8. What is meant by wall losses of a furnace? How can they be minimized?
S-9. Explain the importance of deaeration of boiler feed water.
S-10. In a boiler drum the permissible TDS is 2000 ppm, permissible make up water
is 10 per cent of feed water and TDS of feed water is 200 ppm. Find out the
blow down percentage?
. End of Section II .
Section III: LONG DESCRIPTIVE QUESTIONS Marks: 5 x 10 = 50
(i) Answer all Five questions

0 Each question carries Ten marks
L-1. (i) Explain why the furnace efficiency is low in comparison to a typical steam
boiler efficiency.
0 A furnace of 12 tonnes/ hr output consumes 900 kg/hr of fuel oil.
Calculate the furnace efficiency by assuming specific heat of the stock
material as 0.15 kcal/kgoC, stock material heated from 90oC to 1250oC,
and GCV of fuel oil as 11500 kcal/kg.
L-2. Discuss four major energy conservation opportunities in a boiler system?
L-3. Describe any five properties of ceramic fibre from the point of view of their uses
in furnace.
L-4. Discuss advantages of condensate and flash steam recovery in steam systems.
L-5. What is meant by heat- to- power ratio in a cogeneration system? Show in a
sketch three different modes in which a single steam turbine can be used for
cogeneration.
. End of Section III .
_______________________ 6
nd
2 NATIONAL CERTIFICATION EXAMINATION - 2005
FOR
ENERGYMANAGERSANDENERGYAUDITORS
MODELTESTSERIESA
PAPER2:ENERGYEFFICIENCYINTHERMALUTILITIES
Duration: 3 HRS Max. Marks: 150
0 Please check that this question paper contains 65 questions
1 The question paper is divided into three sections
2 All questions in all three sections are compulsory
3 All parts of a question should be answered at one place

5888 Answer all 50 questions
5889 Each question carries one mark
1. Proximateanalysisoffuelisdeterminationofpercentageof
a) Carbon,hydrogen,nitrogen,sulphur,moisture
b) Fixedcarbon,ash,volatilematter,moisture
c) Highercalorificvalue
d) Lowercalorificvalue
2. Ultimateanalysisoffuelisdeterminationofpercentageof
a) Carbon,Hydrogen,Nitrogen,SulphurandMoisture
b) Fixedcarbon,ash,volatilematterandmoisture
c) Highercalorificvalue
d) Lowercalorificvalue
3. Spontaneouscombustionisaphenomenoninwhich
a) Allthefuelburnsinstantaneouslyproducinghighenergyrelease
b) Fuelburnswithlessair
c) Coalburstsintoflamewithoutanyexternalignitionsourcebutbyitself
duetogradualincreaseintemperatureasaresultofheatreleasedby
combinationofoxygenwithcoal
d) Explosionoccursinfurnace
Paper-2/Model Test Series-A Page 1 of 18
4. O2 contentinatmosphericaironvolumebasisis
a) 21%
b) 23%
c) 30%
d) 40%
5. ThethreeTsforgoodcombustionare
a) Temperature,time,andturbulance
b) Totalair,truefuel,andturbulance
c) Thoroughmixing,totalairandtemperature
d) Totalair,time,andTemperature
6. Pulverisedfuelisusedfor
a) Betterburning
b) Morecalorificvalue
c) Lessradiationloss
d) Easeofhandling
7. Condensateatpressureof4kg/cm2and1600Ctemperaturewhenexposedto
atmospherewill
a) Boil
b) Flashi.e.getconvertedintosteam
c) Remainasitwas
d) Cooldown
8. Thelatentheatofsteamwithincreasesofpressure
a) Remainssame
b) Increases
c) Decreases
d) Behavesunpredictably
9. Fyriteapparatusisusedfor
a) Gravimetricanalysisofthefluegas
b) Volumetricanalysisofthefluegas
c) Massflowofthefluegas
d) Measuringsmokedensityoffluegases
23 Firetubeboilersarethoseinwhich
23 Fluegasespassthroughtubesandwateraroundit
24 Waterpassesthroughthetubesandfluegasesaroundit
25 Forcedcirculationtakesplace
26 Tubesarelaidvertically

11. Thehighpressureboilerisoneproducingsteamatapressuremorethan
a) Atmosphericpressure
b) 5kg/cm2
c) 20kg/cm2
d) 75kg/cm2
12. Inforcedrecirculationtypeboiler
a) Heatingtakesplaceatbottomandthewatersuppliedatbottomgets
convertedintothemixtureofsteambubblesandhotwaterwhichriseto
drum
b) Waterissuppliedindrumandthroughdowncomerslocatedinatmospheric
conditionitpassestothewaterwallandrisestodrumintheformofmixture
ofwaterandsteam
c) Feedpumpisemployedtosupplementnaturalcirculationinwaterwalltype
furnace
d) Thewaterisconvertedintosteaminone passwithoutanyrecirculation
13. Thebalancedraftfurnaceisoneusing
a) Induceddraftfanandchimney
b) Induceddraftfanandforceddraftfan
c) Forceddraftfanandchimney
d) Anyoneoftheabove
14. Whichtypeof Steamtrapoperatesontheprincipleofdifferenceintemperature

betweensteamandcondensate:
a)Thermodynamictrapb)InvertedBucket c)Thermostatictrapd)Noneof
theabove
15. Flashsteamcanberecoveredfrom
a) Superheatedsteamb)saturatedsteam c)highpressurecondensated)
condensateatatmosphericpressure
16. Thepurposeofventingairfromsteamsystemsisbecauseairisa
a)insulatorb)goodconductor c)dilutant d)inertsubstance
17. Thetemperatureofsuperheatedsteam,expressedasdegreesabovesaturation
correspondingtothepressure,isreferredtoasthedegreeof
a)sensibleheat b)superheat c)latentheat d)subcooling
18. Asteamtrapisadevice,whichdischarges
a)condensateb)steamc)effluentd)TDS
19. Basedonmodeofchargingofmaterial,furnacescanbeclassifiedinto
a)Batch&ContinuousFurnace b)Combustion&electricFurnace
c)Recuperativeandregeneratived)Forgingandheattreatmentfurnace
20. Thefurnacetemperaturemaintainedforabatchtype,rerollingmillfurnaceis
o o o o
a)1200 C b)900 C c)1500 Cd)1000 C
21. Heattransferinareheatingfurnaceisachievedbywhichmethod
a)Conduction b)Convection c)Radiation d)Alloftheabove
22. Whatisthetypicalthermalefficiencyforalowtemperaturebatchtypefurnace
o
operatingat540980 C?
a)2030% b)1020% c)1525%d)510%
23. Amongthefollowingwhichoneistheidealpressureforafurnace.
a)+2mmWc b)5mmWc c)+10mmWc d)10mmWc
24. Arecuperatorisusedtopreheat
a)Water b) Stock c) Combustionair d)Fluegas
25. Amongthefollowing,whichoneimprovesefficiencyofafurnace
a)Chargepreheating b)Preheatingcombustionair
c)ReducingWallloss d) Alltheabove
26. Glassmineralwoolcanbeappliedfortemperaturerangeapplicationupto
a) 9500C
0
b) 500C
c) 12000C
d) 7500C
27. Theinsulationthicknessforwhichthetotalcostisminimumiscalled
a) Minimuminsulationthickness
b) Cheapestinsulationthickness
c) Economicthickness
d) Noneoftheabove
28. SiO2%inasilicabrickwillbeatleast:
a) 43%
b) 23%
c) 93%
d) 63%
29. Ceramicfiberismanufacturedbyblendingandmelting:
a) Magnesia&Silica
b) Alumina&Magnesia
c) Alumina&Silica
d) Silica&Chromite
30. Theheatstoredinaceramicfibreliningsystemisgenerallyintherangeof
a) 270400Kcal/m2
b) 27004000Kcal/m2
c) 2700040000Kcal/m2
d) 2740Kcal/m2
31. Highertheheattransfercoefficient,thesurfaceheatlosswillbe
a) Lower
b) Higher
c) Nochange
d) Cannotsay
32. Anexampleoforganicinsulationis
a) Mineralwool
b) CalciumSilicate
c) Polyurethane
d) Noneofthese
33. Theunitofthermalconductivityis
a) W/m20C
b) W0C/m2
0
c) W/mC
d) W0C/m
34. FluidizedbedcombustionhaseffectonSO XandNOXemission.
a)Increased b)Reduced c)Nil d)noneofthethem
35. WhatisusedinfluidizedbedboilertocontrolSulfurDioxideandNitrogen
oxideemissions.
a)Charcoal b)Limestone c)Sand d)Silica
36. Thevelocityof fluidizedairinaAFBCboileris

a)1.23.7m/s b)3.79m/sc)912m/sd)Noneofthem
37. InacoalfiredAFBC,Clinkerformationoccurswhenbedtemperatureexceeds

o o o o
a)850 C b)950
C c)1000 C d)800 C

38. ThecoalsizeforoverbedfeedinginaAFBCboiler?
a)<1mm b)610mm c)1014mm d)>10mm
39. FlyashinaFBCboilerisintherangeof
a)20% b)30% c)40% d)Noneoftheabove
40. ThecombustionairinaCFBCissuppliedatapressureincomparison
tobubblingbedcombustors
a)Lower b)Higher c)Similar d)Veryhigh
41. APFBCsystemcandrivewhichtypeofturbine
a)Gasturbine b)Steamturbinec) bothGas&Steamturbine
d)NeitherGasnorSteamturbine.
42. ExcessairquantityrequiredinaFBCboilerisoftheorderof
a)2025% b)1015% c)1520% d)>30%
43. CHPis
a) Collectivehorsepower
b) CollectiveheatandPower
c) CombinedheatandPower
d) Combinedhorsepower
44. Whichofthefollowingcogenerationoptionstobeusedifuserrequiresthermal
energyattwodifferenttemperature?
a) Backpressureturbine
b) Fullycondensingturbine
c) Extractioncondensingturbine
45. Whatisthegeneralelectricalconversionefficiencyofdieselengine
a) 1328%
b) 2338%
c) 3348%
d) 4358%`

46. Theaverageheattopowerratioofafertilizerindustrywouldbe
a) 0.5
b) 1
c) 2
d) 3
47. Thetemperatureofthegasthatentersthegasturbineisaround
0
a) 900C
b) 4000C
c) 2000C
d) 1500C
48. Theefficiencyofstandalonegasturbinewillbeintherangeof
a) 3540%
b) 2025%
c) 1520%
d) 1015%
49. Thedeviceusedtoupgradealowerpressuresteamtoahigherpressuresteamis
called
a) heatpumpb)thermocompressorc)heatpiped)heatwheel
0 Adeviceusedtocompressalowpressuresteamtoahighpressuresteamiscalled
a)heatpumpb)heatpipec)thermocompressor d)economizer
Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 10 x 5 = 50
(i) Answer all Ten questions
(ii) Each question carries Five marks

0 Whatisdraftincombustionsystem?Explainbrieflythedifferenttypesofdraft.
Thefunctionofdraftinacombustionsystemistoexhausttheproductsofcombustionintothe
atmosphere.ThedraftcanbeclassifiedintotwotypesnamelyNaturalandMechanicalDraft.
NaturalDraft
Itisthedraftproducedbyachimneyalone.Itiscausedbythedifferenceinweightbetweenthe
columnofhotgasinsidethechimneyandcolumnofoutsideairofthesameheightandcross
section.
MechanicalDraft
Itisdraftartificiallyproducedbyfans.Threebasictypesofdraftsthatareapplied

are,
BalancedDraft:Forceddraft(FD)fan(blower)pushesairintothefurnaceandaninduceddraft(I
D)fandrawsgasesintothechimneytherebyprovidingdrafttoremovethegasesfromtheboiler.
InducedDraft:Aninduceddraftfandrawsenoughdraftforflowintothefurnace,causingtheproductsof
combustiontodischargetoatmosphere
ForcedDraft:TheForceddraftsystemusesafantodelivertheairtothefurnace, forcingcombustion
productstoflowthroughtheunitandupthestack.
0 Whatarethecomparativeadvantagesanddisadvantagesoffiretubeandwatertubeboilers?
S.No. Parameters Firetubeboilers Watertubeboilers

a. Rateofsteamgeneration Lessrapid Morerapid
b. Suitabilityforpowerplants Unsuitable Suitable.Allmajor
powerplantsare
basedonthese
c. Operatingsteampressure Limitedto Canwellexceed
25kgf/cm2 125kgf/cm2
d. Chancesofexplosion Less More
e. Riskofdamagedueto Muchmore Muchless
explosion
f. Watertreatment Notvery Requiredasscaling
necessaryas willleadtotube
minorscaling bursting
wouldnotgo
farenoughto
cause
overheatingand
tubebursting
g.. Floorspacerequirement Much Less
h. Cost&construction Higher Muchless

problem
i. Transportation Inconvenient Comparatively
duetolargesize easier
oftheshell
j. Skillrequiredforefficient Less More
operation
0 Howwaterhammerisproducedinapipingsystemandhowitcanbeeliminated?
Awaterhammerinasteamsystemiscausedbycondensatecollectionintheplantorpipeworkpickedup
bythefastmovingsteamandcarriedalongwithit.Whenthis

collectionhitsobstructionssuchasbends,valves,steamtrapsorsomeotherpipefittings,it
islikelytocauseseveredamagetofittingsandequipmentandresultinleakingpipejoints.
Theproblemofwaterhammercanbeeliminatedbypositioningthepipessothatthereisa
continuousslopeinthedirectionofflow.Aslopeofatleast12mminevery3metresis
necessary,asalsoanadequatenumberofdrainpointsevery30to50metres.
0 Whatdoyouunderstandbyreducingtheworktobedonebysteam?
Ifanyproductistobedriedsuchasinalaundry,apresscouldbeusedtosqueezeasmuchwater
aspossiblebeforebeingheatedupinadryerusingsteam.Whenthesteamreachestheplace
whereitsheatisrequired,itmustbeensuredthatthesteamhasnomoreworktodothanis
absolutelynecessary.Airheaterbatteries,forexample,whichprovidehotairfordrying,willuse
thesameamountofsteamwhethertheplantisfullyorpartlyloaded.So,iftheplantisrunning
only at 50 per cent load, it is wasting twice as much steam (or twice as much fuel) than
necessary.
Alwaysusethemosteconomicalwaytoremovingthebulkofwaterfromthewetmaterial.Steamcan
then be used to complete the process. For this reason, hydroextractors, spin dryers, squeeze or
calendarrolls,presses,etc.areinitiallyusedinmanydryingprocessestoremovethemassofwater.
0Whatarethevariouslossesthatoccursinafurnace?
Answer:
Thevariouslossesthatoccursinafurnaceare:
0Heatstorageinthefurnacestructure.
1Lossesfromthefurnaceoutsidewallsorstructure.
2Heattransportedoutofthefurnacebytheloadconveyors,fixtures,etc.
3Radiationlossesfromopenings,hotexposedparts,etc.
4Heatcarriedbythecoldairinfiltrationintothefurnace.
5Heatcarriedbytheexcessairusedintheburners.
0 Mentionfiverequirementsofarefractorymaterial.
Refractories:
0 Abilitytowithstandhightemperatures
1 Abilitytowithstandsuddenchangesoftemperatures
2 Abilitytowithstandactionofmoltenmetalslag,glass,hotgases,etc.
3 Abilitytowithstandloadatserviceconditions.
4 Abilitytowithstandloadandabrasiveforces
0 Whataretheadvantagesoffluidizedbedcombustion?
Fluidizedbedcombustionhasemergedasaviablealternativeandhassignificant

advantagesoverconventionalfiringsystemandoffersmultiplebenefitscompactboilerdesign,fuel
flexibility,highercombustionefficiencyandreducedemissionofnoxiouspollutantssuchasSOXand
NOX.Thefuelsburntintheseboilersincludecoal,washeryrejects,ricehusk,bagasseandother
agriculturalwastes.
0 WriteashortnoteonFuelFeedingsysteminaAFBCboiler
1.FuelFeedingSystem:
Forfeedingfuel,sorbentslikelimestoneordolomite,usuallytwomethodsarefollowed:under
bedpneumaticfeedingandoverbedfeeding.
UnderBedPneumaticFeeding:
Ifthefueliscoal,itiscrushedto16mmsizeandpneumaticallytransportedfromfeedhopperto
thecombustorthroughafeedpipepiercingthedistributor.Basedonthecapacityboiler,the
numberoffeedpointsisincreased,asitisnecessarytodistributethefuelintothebeduniformly.
OverBedFeeding:
Thecrushedcoal,610mmsizeisconveyedfromcoalbunkertoaspreaderbyascrewconveyor.The
spreaderdistributesthecoaloverthesurfaceofthebeduniformly.Thistypeoffuelfeedingsystem
accepts over size fuel also and eliminates transport lines, when compared to underbed feeding
system.
0 Mentionthreecircumstances,wherecogenerationislikelytobemostattractive.
0.0 Thedemandforbothsteamandpowerisbalancedi.e.consistentwiththerangeof
steam:poweroutputratiosthatcanbeobtainedfromasuitablecogenerationplant.
0.1 Asingleplantorgroupofplantshassufficientdemandforsteamandpowerto
permiteconomiesofscaletobeachieved
Peaksandtroughsindemandcanbemanagedor,inthecaseofelectricity,adequatebackupsuppliescan
beobtainedfromtheutilitycompany.
0 Whatarethedirectandindirectbenefitsofwasteheatrecovery?
DirectBenefits:
Recovery of waste heat has a direct effect on the efficiency of the process. This is reflected by
reductionintheutilityconsumption&costs,andprocesscost.
IndirectBenefits:

Reductioninpollution:Anumberoftoxiccombustiblewastessuchascarbonmonoxidegas,sour
gas,carbonblackoffgases,oilsludge,Acrylonitrileandotherplasticchemicalsetc,releasingto
atmosphereif/whenburntintheincineratorsservesdualpurposei.e.recoversheatandreducesthe
environmentalpollutionlevels.
Reductioninequipmentsizes:Wasteheatrecoveryreducesthefuelconsumption,which
leadstoreductioninthefluegasproduced.Thisresultsinreductioninequipmentsizes
ofallfluegashandlingequipmentssuchasfans,stacks,ducts,burners,etc.
Reduction in auxiliary energy consumption: Reduction in equipment sizes gives additional

benefits in the form of reduction in auxiliary energy consumption like electricity for fans,
pumpsetc
Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 5 x 10 = 50
0 Answer all Five questions

23 Howthecoalispulverized,andwhataretheadvantagesofpulverizedcoalfiringsystems?
Itistwostageprocess
I.Stage:
Rawandlumpcoaliscrushedtoaparticlesizenotmorethan1525mminthecrusher
IIStage:
Crushedcoalisdeliveredintorawcoalbunkersandfromhereitistransferredtogrinding
millsthatgrindthefeedintothefinalparticlesof2003000meshsize.Duringgrindinghot
airisblownthroughthefueltodryittoimpartgoodfluidityofthecoaldust.
23 Pulverizationbringsaboutalargeincreaseinsurfaceareaperunitmassofsolidfuel.
Sincecombustionisasurfacereaction,greatertheextentofcoalsurfaceavailable,higher
willbetherateofcombustion.Hereinliesthesuccessofpulverizedcoalfiredsystems.
24 Lessexcessairisrequiredforcompletecombustionbecauseofgreatersurfaceareaoffuelexposed.
25 Highercombustionairtemperaturesensurehighercycleefficiency.
26 Agoodrangeofcoalrightfromanthracitetopeatcanbesuccessfullyburnt
27 Bettercombustioncontrolenablesthesystemtorespondquicklytoextensiveloadvariation.

23 Betterresponsetoinstrumentcontrolonauto
Steam
lossvs
24 Largeamountofheatreleasemakesitverysuitableforsuperthermalpowerstationswheretherateof
steamgenerationisashighas2000t/h.
25 Slaggingandclinkeringproblemsarelow
26 Carryoverofunburntfueltoashispracticallynil
27 Ashhandlingproblemlow
28 Canoperatesuccessfullyincombinationwithgasandoilfiredsystems
29 Coldstartupofboilersisveryrapidandefficient
30 Lessfurnacevolumeisrequired
31 Lowbankingloss
2 Listdownthevariousenergyconservationopportunitiesavailableinasteamsystem?
1.AvoidingSteamLeakages
Steamleakageisavisibleindicatorofwaste
andmustbeavoided.Ithasbeenestimated
thata3mmdiameterholeonapipeline
2
carrying7kg/cm steamwouldwaste33KL
offueloilperyear.Steamleaksonhigh
pressuremainsareprohibitivelycostlier
thanonlowpressuremains.Anysteam
leakagemustbequicklyattendedto.Infact,
theplantshouldconsideraregular
surveillanceprogrammeforidentifying
leaksatpipelines,valves,flangesandjoints.
Indeed,bypluggingallleakages,onemay
besurprisedat
theextentoffuelsavings,whichmayreachupto
5%ofthesteamconsumption
inasmallormediumscaleindustryorevenhigherininstallationshavingseveralprocess
departments.
2.ProvidingDrySteamforProcess
Thebeststeamforindustrialprocessheatingisthedrysaturatedsteam.Wetsteamreduces
totalheatinthesteam.Alsowaterformsawetfilmonheattransferandoverloadstrapsand
condensateequipment.Superheatedsteamisnotdesirableforprocessheatingbecauseit
givesupheatatarateslowerthanthecondensationheattransferofsaturatedsteam.
Itmustberememberedthataboilerwithoutasuperheatercannotdeliverperfectlydry
saturatedsteam.Atbest,itcandeliveronly95%drysteam.Thedrynessfractionofsteam
dependsonvariousfactors,suchasthelevelofwatertobeapartofthesteam.Indeed,even
assimpleathingasimproperboilerwatertreatmentcanbecomeacauseforwetsteam.

Assteamflowsthroughthepipelines,itundergoesprogressivecondensationduetothelossof
heattothecoldersurroundings,Theextentofthecondensationdependsontheeffectivenessof
thelagging.Forexample,withpoorlagging,thesteamcanbecomeexcessivelywet.
Sincedrysaturatedsteamisrequiredforprocessequipment,dueattentionmustbepaidtotheboiler
operationandlaggingofthepipelines.
Wetsteamcanreduceplantproductivityandproductquality,andcancausedamageto
mostitemsofplantandequipment.Whilstcarefuldrainageandtrappingcanremove
mostofthewater,itwillnotdealwiththewaterdropletssuspendedinthesteam.To
removethesesuspendedwaterdroplets,separatorsareinstalledinsteampipelines.
3.UtilisingSteamattheLowestAcceptablePressurefortheProcess
Astudyofthesteamtableswouldindicatethatthelatentheatinsteamreducesasthe
steampressureincreases.Itisonlythelatentheatofsteam,whichtakespartinthe
heatingprocesswhenappliedtoanindirectheatingsystem.Thus,itisimportantthat
itsvaluebekeptashighaspossible.Thiscanonlybeachievedifwegoinforlower
steampressures.Asaguide,thesteamshouldalwaysbegeneratedanddistributedat
Figure3.20TemperatureControlforDirectly
thehighestpossiblepressure,bututilizedataslowapressureaspossiblesinceitthen
hashigherlatentheat. InjectedSteam
However,itmayalsobeseenfromthesteamtablesthatthelowerthesteampressure,thelower
willbeitstemperature.Sincetemperatureisthedrivingforceforthetransferofheatatlower
steampressures,therateofheattransferwillbeslowerandtheprocessingtimegreater.In
equipmentwherefixedlossesarehigh(e.g.bigdryingcylinders),theremayevenbeanincrease
insteamconsumptionatlowerpressuresduetoincreasedprocessingtime.Thereare,however,
severalequipmentincertainindustrieswhereonecanprofitablygoinforlowerpressuresand
realizeeconomyinsteamconsumptionwithoutmateriallyaffectingproductiontime.
Therefore,thereisalimittothereductionofsteampressure.Dependingontheequipment
design,thelowestpossiblesteampressurewithwhichtheequipmentcanworkshouldbe
selectedwithoutsacrificingeitheronproductiontimeoronsteamconsumption.
4.ProperUtilizationofDirectlyInjectedSteam
Theheatingofaliquidbydirectinjectionofsteamisoftendesirable.Theequipmentrequiredis
relativelysimple,cheapandeasytomaintain.Nocondensaterecoverysystemisnecessary.The
heatingisquick,andthesensibleheatofthesteamisalsousedupalongwiththelatentheat,
makingtheprocessthermallyefficient.Inprocesseswheredilutionisnotaproblem,heatingis
donebyblowingsteamintotheliquid(i.e)directsteaminjectionisapplied.Ifthedilutionofthe
tankcontentsand

agitationarenotacceptableintheprocess(i.e)directsteamagitationarenotacceptable,
indirectsteamheatingistheonlyanswer.
Ideally,theinjectedsteamshouldbecondensedcompletelyasthebubblesrisethroughthe 2
liquid.Thisispossibleonlyiftheinletsteampressuresarekeptverylowaround0.5kg/cm
2

andcertainlynotexceeding1kg/cm .Ifpressuresarehigh,thevelocityofthesteambubbles
willalsobehighandtheywillnotgetsufficienttimetocondensebeforetheyreachthesurface.
Figure3.20showsarecommendedarrangementfordirectinjectionofsteam.
Alargenumberofsmalldiameterholes(2to5mm),facingdownwards,shouldbedrilledonthe
separatepipe.Thiswillhelpindissipatingthevelocityofbubblesintheliquid.Athermostaticcontrol
ofsteamadmittedishighlydesirable
5.MinimisingHeatTransferBarriers
Themetalwallmaynotbetheonlybarrierinaheattransferprocess.Thereislikelytobeafilmofair,
condensateandscaleonthesteamside.Ontheproductsidetheremayalsobebakedonproductor
scale,andastagnantfilmofproduct.
Agitationoftheproductmayeliminatetheeffectofthestagnantfilm,whilstregularcleaningonthe
productsideshouldreducethescale.
Regularcleaningofthesurfaceonthesteamsidemayalsoincreasetherateofheat
transferbyreducingthethicknessofanylayerofscale,however,thismaynotalwaysbe
possible.Thislayermayalsobereducedbycarefulattentiontothecorrectoperationof
theboiler,andtheremovalofwaterdropletscarryingimpuritiesfromtheboiler.
6.ProperAirVenting
Whensteamisfirstadmittedtoapipeafteraperiodofshutdown,thepipeisfullofair.
Furtheramountsofairandothernoncondensablegaseswillenterwiththesteam,although
theproportionsofthesegasesarenormallyverysmallcomparedwiththesteam.Whenthe
steamcondenses,thesegaseswillaccumulateinpipesandheatexchangers.Precautions
shouldbetakentodischargethem.Theconsequenceofnotremovingairisalengthy
warmingupperiod,andareductioninplantefficiencyandprocessperformance.
Airinasteamsystemwillalsoaffectthesystemtemperature.Airwillexertitsownpressurewithin
thesystem,andwillbeaddedtothepressureofthesteamtogiveatotalpressure.Therefore,the
actualsteampressureandtemperatureofthesteam/airmixturewillbelowerthanthatsuggestedby
apressuregauge.
Ofmoreimportanceistheeffectairhasuponheattransfer.Alayerofaironly1mmthickcanoffer
thesameresistancetoheatasalayerofwater25mthick,alayerofiron2mmthickoralayerof
copper15mmthick.Itisveryimportantthereforetoremoveairfromanysteamsystem.
Automaticairventsforsteamsystems(whichoperateonthesameprincipleasthermostaticsteam
traps)shouldbefittedabovethecondensatelevelsothatonlyairorsteam/airmixturescanreach
them.Thebestlocationforthemisattheendofthe

steammains.
7.InsulationofSteamPipelinesandHotProcessEquipments
Heatcanbelostduetoradiationfromsteampipes.Asanexamplewhilelaggingsteampipes,itis
commontoseeleavingflangesuncovered.Anuncoveredflangeisequivalenttoleaving0.6
metreofpipelineunlagged.Ifa0.15msteampipediameterhas5uncoveredflanges,there
wouldbealossofheatequivalenttowasting5tonsofcoalor3000litresofoilayear.Thisis
usuallydonetofacilitatecheckingtheconditionofflangebutatthecostofconsiderableheatloss.
Theremedyistoprovideeasilydetachableinsulationcovers,whichcanbeeasilyremovedwhen
necessary.Thevariousinsulatingmaterialsusedarecork,Glasswool,RockwoolandAsbestos.
23 Describewithasketchaboutcontinuoussteelreheatingfurnace.
Themainfunctionofareheatingfurnaceistoraisethetemperatureofapieceofsteel,typicallyto
o o
between900 Cand1250 C,untilitisplasticenoughtobepressedorrolledtothedesiredsection,size
orshape.Thefurnacemustalsomeetspecificrequirementsandobjectivesintermsofstockheating
rates for metallurgical and productivity reasons. In continuous reheating, the steel stock forms a
continuousflowofmaterialandisheatedtothedesiredtemperatureasittravelsthroughthefurnace.
AllfurnacespossessthefeaturesasshowninFigure
0 Arefractorychamberconstructedofinsulatingmaterialsforretainingheatatthehighoperating
temperatures.

0Ahearthtosupportorcarrythesteel.Thiscanconsistofrefractorymaterialsoranarrangementof
metallicsupportsthatmaybewatercooled.
1Burnersthatuseliquidorgaseousfuelstoraiseandmaintainthetemperatureinthechamber.
Coalorelectricitycanbeusedforreheating.Amethodofremovingthecombustionexhaust
gasesfromthechamber.
2Amethodofintroducingandremovingthesteelfromthechamber.
3Thesefacilitiesdependonthesizeandtypeoffurnace,theshapeandsizeofthesteelbeingprocessed,
andthegenerallayoutoftherollingmill.
4Commonsystemsincluderollertables,conveyors,chargingmachinesandfurnacepushers.
2
0 Anuninsulated100mmpipeof200mlengthcarriessteamat10kg/cm
0 .Thesurfacetemperature
measured is 165 C. Find out the annual cost saving achieved by insulating
0 it with 50 mm.
insulatingmaterial,whichwillbringthesurfacetemperaturedownto60 C.Theboilerefficiency
is85%andthefueloil(withGCVof10000Kcal/kg)costisRs.14000/tonneandambientair
0 o
temperatureis30 Candambienttemperatureis30 Candannualoperatinghouris8000hours.
Ts = 1650C
Ta = 300C
(TT)
xT T
s a
Existingheatloss10
s a
20
(16530)
S1=10 x16530=2261.25kCal/hr.m2
20
(6030)
Heatlossinmodifiedsystem(S2)=10 x6030
20
=345kCal/hr.m2
Existingpipedimension = 100mm&200mlength
Existingsurfacearea(A1) = 3.14x0.1x200 = 62.8m2

Surfaceareaafterinsulation = 3.14x0.2x200 = 125.6m2
Totalheatlossinexistingsystem = 62.8x2261.25 = 142006.5Kcal/hr.
Totalheatlossinmodifiedsystem= 125.6x345 = 43332Kcal/hr
Reductioninheatloss = 142006.543332 =98674.5Kcal/hr.
Totalannualheatloss = 98674.5x 8000
5
0 7893.96x10 Kcal
Calorificvalueoffuel = 10000Kcal/kg
BoilerEfficiency = 85%
Annualfueloilsaving = 7893.9x105/1000 x0.8
= 92869kg/year
Annualcostsaving = 92869x14000
1000
Annualcostsaving = Rs.13,00,166/
0 WritedownindetailabouttenmajoradvantagesofFBCboilersystem
0.768 HighEfficiency
FBCboilerscanburnfuelwithacombustionefficiencyofover95%irrespectiveofash
content.FBCboilerscanoperatewithoverallefficiencyof84%(plusorminus2%).
0.769 ReductioninBoilerSize
High heat transfer rate over a small heat transfer area immersed in the bed result in overall size
reductionoftheboiler.
0.770 FuelFlexibility
FBCboilerscanbeoperatedefficientlywithavarietyoffuels.Evenfuelslikeflotationslimes,
washerrejects,agrowastecanbeburntefficiently.Thesecanbefedeitherindependentlyorin
combinationwithcoalintothesamefurnace.
0.771 AbilitytoBurnLowGradeFuel
FBCboilerswouldgivetheratedoutputevenwithinferiorqualityfuel.Theboilerscanfire
coalswithashcontentashighas62%andhavingcalorificvalueaslowas2,500kcal/kg.
Evencarboncontentofonly1%byweightcansustainthefluidisedbedcombustion.
0.772 AbilitytoBurnFines
Coalcontainingfinesbelow6mmcanbeburntefficientlyinFBCboiler,whichisverydifficultto
achieveinconventionalfiringsystem.
0.773 PollutionControl
SO2formationcanbegreatlyminimisedbyadditionoflimestoneordolomitefor
highsulphurcoals.3%limestoneisrequiredforevery1%sulphurinthecoalfeed.Lowcombustiontemperature
eliminatesNOxformation.
0.774 LowCorrosionandErosion
Thecorrosionanderosioneffectsarelessduetolowercombustiontemperature,softnessofashandlow
particlevelocity(oftheorderof1m/sec).
0.775 EasierAshRemovalNoClinkerFormation

o
Sincethetemperatureofthefurnaceisintherangeof750900 CinFBCboilers,evencoalof
lowashfusiontemperaturecanbeburntwithoutclinkerformation.Ashremovaliseasierasthe
ashflowslikeliquidfromthecombustionchamber.Hencelessmanpowerisrequiredforash
handling.
0LessExcessAirHigherCO2inFlueGas
TheCO2inthefluegaseswillbeoftheorderof1415%atfullload.Hence,theFBCboilercan
operateatlowexcessaironly2025%.
1SimpleOperation,QuickStartUp
Highturbulenceofthebedfacilitatesquickstartupandshutdown.Fullautomationofstartupand
operationusingreliableequipmentispossible.

Paper 2 Set A

FOR
ENERGY MANAGERS & ENERGY AUDITORS
Question Papers & Model solutions to the Question Papers
PAPER 2: Energy Efficiency in Thermal Utilities
Date: 28.05.2004 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
0 Please check that this question paper contains 7 printed pages

2
3
Each question carries one
mark
4
Put a () tick mark in the
appropriate box in the answer book
1. 0
Specific heat in kCal/kg - C of fuel oil is in the range of
a) 0.15 0.20 b) 0.22 0.28 c) 0.29 0.32 d) none of the above
2. Grade B Indian coal has a energy content range (in kcal/kg) of

a) 3360-4200 b) 4200-4900 c) 4940-5600 d) 5600-6200
3. Which is the common coal firing system used in Indian thermal power plants?
a) pulverized coal firing b) stoker firing c) fluidized bedd) pressurized bed
4. Which of the following fuel requires maximum air for stochiometric combustion?
a) Butane b) Propane c) Hydrogen d) Coal
5. Stochiometric air required for combustion of Bagasse is about

a) 13.7 b) 3.2 c) 6 d) 18
6. Which fuel releases the most energy per kg on complete combustion

a) Carbon b) Sulphur c) Nitrogen d) Hydrogen
0 How many kg of CO2 are produced in complete combustion of 16 kg of Methane?
a) 42 b) 44 c) 16 d) none of the above

_________________________ 1
Paper 2 Set A
8. In flue gas the theoretical CO2 is 15.5% and measured CO2 is 11% by volume. The
percentage of excess air will be
a) 40.9% b) 38.7 % c) 240.9 % d) 140.9 %
9. Evaporation ratio (steam to fuel ratio) of an oil fired efficient boiler is in the range of
a) 5 - 6 b) 13 14 c) 1 - 3 d) 7 9
10. A rise in conductivity of boiler feed water indicates

a) drop in the total dissolved solids in boiler water
b) more steam generation c) greater purity of feed water

d) rise in the total dissolved solids in boiler water
11. De-aeration of boiler feed water is referred to as

a) removal of dissolved gases b) removal of silica from feed-water
c) removal of TDS from feed-water d) phosphate treatment of feed-water

0
12. Pre-heating of combustion air in an oil fired furnace by 20 C will save about ___% of
fuel
a) 0.3 b) 1 c) 1.5 d) 0.6
13. To drain condensate from main steam line, the following type of trap is a suitable
trap.
a) float b) bimetallic
c) thermodynamic d) none of the above

0
14. Increase in stack gas temperature of 22 C due to tube fouling or other causes will
increase oil consumption in an oil fired boiler by about.
a) 1% b) 2% c) 3% d) 4%
15. Water hammer in a steam system is caused by

a) collected condensate hitting obstructions b) leaking pipe joints
c) slow moving steam d) continuous slope in direction of flow

16. Which data is not required to calculate boiler efficiency by the indirect method
a) steam flow rate b) stack gas temperature
c) ambient temperature d) energy content of fuel

17. Latent heat at the critical point of a steam phase diagram is
a) infinite b) 540 kCal/kg c) zero d) none of the above
18. Increase of steam pressure has the following effect on steam:

a) steam temperature goes up and enthalpy of evaporation goes down
b) steam temperature and enthalpy of evaporation go down

c) steam temperature goes up and enthalpy of evaporation goes up
d) specific volume goes down and enthalpy of evaporation goes up
0 Scale losses in reheating furnaces will increase with
a) decrease in excess air b) decrease in furnace temperature

c) increase with excess air d) are not correlated to temperature
_________________________ 2

Paper 2 Set A
20. An air film inside a steam pipe, made of steel may be _______ times more resistant
to heat transfer than the steam pipe.
a) 200 1000 b) 1500 3000 c) 4000 8000 d) 8000 16000
21. The best steam for indirect heating in most industrial process is
a) as dry as possible b) super heated steam
c) wet steam d) as wet as possible
22. Pressure drop through a steam pipe is inversely proportional to
a) diameter b) square of diameter c) fifth power of diameter d) cube of diameter
23. In an oil fired burner, the excess air level _____ towards the highest turndown ratio
for efficient combustion.
a) decreases b) increases c) not affected d) none of the above
24. What is the most effective way to avoid ambient air infiltration into a continuous
furnace
a) close all openings b) increase the chimney height
c) operate at about 90% capacity d) reduce negative pressure inside the furnace
25. Black body radiation is
a) linear proportional to temperature
b) proportional to the fourth power of the temperature of the body

c) proportional to the fourth power of the absolute temperature of the body
d) proportional to the square of the body surface area
26. Steam at 6 bar has a sensible heat of 159.33 kCal/ kg and latent heat of 498.59 kCal/
kg. If the steam is 95% dry than the total enthalpy is
a) 625 kCal/ kg b) 649.95 kCal/ kg c) 553 kCal/ kg d) 633 kCal/ kg
27. In which type of furnace operation is a low mass ceramic fiber insulation most
suitable to reduce specific fuel consumption
a) batch type furnace b) continuous Hoffmann tunnel kiln
c) rotary high temperature furnace d) low temperature furnace

0
28. Which loss is the highest in a typical re-heating furnace operating at 1300 C?
a) flue gas loss b) wall loss c) necessary opening loss d)cooling water loss
29. In a batch type furnace the following energy efficiency measure would be the most
controversial
a) increasing the insulation at the hot temperature side
b) increasing the insulation at the outer surface of the furnace
c) pre-heating the combustion air
d) reducing excess air.
0 Pick the wrong statement. The thermal efficiency of a furnace increases by
a) preheating combustion air b) increasing the excess air flow rate

c) reducing the surface heat loss d) minimizing the CO loss and un-burnt losses
_________________________ 3
Paper 2 Set A
31. The most economic insulation is the thickness where ..

a) depreciation costs of insulation and energy cost due to losses are the same
b) the sum of energy cost due to losses and insulation depreciation cost is
minimum
c) energy losses are minimized
d) energy cost due to losses are minimized.
32. Which of the four refractories has the highest melting point temperature?
a) Lime (CaO) b) Silica (SiO2 ) c) Titania (TiO2 ) d) Alumina (Al2 O3 )
33. The emissivity of refractory material.

0
a) increases sharply above 1000 C
b) will be more or less independent of temperature
c) will increase with increasing temperature
d) will decrease with increasing temperature
34. High emissivity coatings are applied on

a) outer surface of furnace b) refrigeration piping
c) inner surface of furnace d) none of the above

35. The heat loss rate from a surface is expressed in
a) Watt 2 0 2 0 d) Joules
b) Watt/m K c) Watt/m C
36. Which statement is incorrect

a) higher density refractory has a lower thermal conductivity
b) a higher emissivity means higher radiation of heat

c) a higher emissivity means lower absorption of heat
d) a black colored body radiates more than a glossy white colored one.
37. Fluidized bed combustion takes place in a temperature range of
0 0 0 0 0 0
a) 600 C - 700 C b) 850 C - 950 C c) above 1000 C d) about 500 C
38. The low combustion temperatures in fluidized bed combustion boilers results in
minimal formation of
a) NOx d) CO
b) NOx and SOx c) CO2
39. SOx emissions in a FBC boiler fired with high sulfur coal are controlled by adding
____ to the bed
a) Magnesia b) Limestone c) Sand d) Silica
40. In circulating fluidized bed combustion boilers most of the heat transfer takes place
a) inside the combustion zone b) bed tubes
c) outside of the combustion zone d) super heater tubes
41. In glass industry waste heat is used for power generation. This type of cogeneration
is called
a) topping cycle b) bottoming cycle
c) gas turbine cycle d) none of the above.

23 The unit for heat-to-power ratio of a CHP plant is
a) kWth / kW e b) BTU / kWc) kCal / kW d) kWhth / kWe
_________________________ 4
Paper 2 Set A
43. Which CHP system has the smallest heat to power ratio with the least flexibility to
increase or reduce the ratio?
a) back pressure turbine b) combined cycle
c) extraction condensing steam turbine d) reciprocating engine

44. Air compressor alone consumes about ______ of the energy generated in a gas
turbine
a) 20-30% b) 30-40% c) 40-50% d) 50-60%
45. Regenerators utilizing waste heat are widely used in

a) cement industry b) pulp and paper
c) glass melting furnaces d) aluminium
46. Heat wheels are mostly used in a situation of.
a) high temperature exhaust gases
b) heat exchange between large masses of air having small temperature
differences
c) heat transfer between a liquid and gas d) corrosive gases
47. A heat pipe can transfer up to ____ times more thermal energy than copper
a) 10 b) 20 c) 50 d) 100
0
48. An economizer raises the boiler feed water by 60 C and therefore saves
approximately ___ % of fuel.
a) 5 b) 10 c) 15 d) 20
49. A shell and tube heat exchanger is most suitable if

a) a liquid is heating another liquidb) a gas is heating another gas
c) a gas is heating a liquid d) the hot gas is loaded with dust

23 The working fluid of a steam thermo-compressor is
a) air b) low pressure steam c) high pressure steam d) water
-------- End of Section - I ---------

24 Each question carries Five marks
S-1 (i) State the stochiometric combustion equation for Methane.

23 how many kg of Carbon Dioxide are generated by complete combustion of
1 kg of Methane?
24 how many kg of water are generated by complete combustion of 1 kg of
Methane?
23 CH4 + 2O2 = CO2 + 2H2 O
_________________________ 5
Paper 2 Set A
23 16 kg + 64 kg = 44 kg + 36 kg i.e. 2.75 kg of CO2 from 1 kg of

Methane
24 2.25 kg of water from 1 kg of Methane.
S-2 Assume the stochiometric (theoretical) air to fuel ratio of furnace oil is 14. The
burner operates at 20% excess air. Calculate the mass of stack gas
generated from combustion of one kg of oil.
Mass of air + mass of fuel = mass of stack gas

1.2 x 14 + 1 = 17.8 kg
S-3 (i) Explain the difference between a water tube and a fire tube boiler.
23 In what pressure range have water tube boilers an advantage over fire
tube boilers and why?
0 In a fire tube boiler combustion gases are inside small fire tubes,
which are bundled, and the water to be heated is outside. In a
water tube boiler the water is flowing inside tube bundles and the
combustion gases are flowing around the water tubes. (3 marks)
1 At steam pressures of more than 20 bar and larger capacities
water tube boilers are preferred, because the thickness of a fire
boiler shell would be very thick and heavy to withstand the
pressure.
S-4 (i) Explain the meaning of hf , hfg and hg in a water and steam system
(ii) Write down the equation for hg if the steam is wet and contains 4%
moisture.
0 hf = enthalpy of saturated water

hfg = enthalpy of evaporation of saturated water to saturated
steam hg = enthalpy of saturated steam
5888 hg = hf + 0.96 hfg
S-5 A furnace output is 5000 kg/hour of billets. Thermal efficiency is claimed to be

o o
25% Specific heat of billet is 0.12 kcal/kg- C. Billets enter the furnace at 40 C
o
and leave at 1200 C. Calculate the hourly oil consumption in liter if GCV of oil
is 9,200 kCal/liter.
(i) Efficiency = heat absorbed in the stock =

0.25 heat in fuel
= 5000 x 0.12 (1200- 40) = 0.25

Liter x 9,200
Liter = 302.6 liter of oil per hour.
S-6 In selection of a refractory which physical, chemical and other properties of a

refractory are important?
23 melting or softening point

24 bulk density,
25 porosity
_________________________ 6
Paper 2 Set A
0 thermal conductivity
1 creep at high temperature
2 capital costs
S-7 List advantages of fluidized bed combustion boiler over fixed grate boiler.
0 efficiency is not so much affected when firing higher ash fuels

1 better fuel flexibility
2 burns low grade fuels
3 burns fines
4 reduces NOx formation
5 may reduce SOx formation through additives
6 no clinker formation
7 no soot blowing
8 quicker response to changing demand
S-8 What parameters are analyzed in a proximate analysis of coal?
The elements analyzed in proximate analysis of coal are (i) ash, (ii)
moisture, (iii) volatile matter and (iv) fixed carbon content on a (v)
percentage weight basis.
S-9 Draw a sketch of an extraction-condensing turbine cogeneration system.
S-10 A firm wants to recover the waste heat in a flue gas stream of 2000 kg/hour.
0
from a furnace. Specific heat of flue gas is 0.25 kcal/kg C.
0 calculate the heat recovered if the heat exchanger has an efficiency of

0 0
98% and temperature of flue gas drops from 800 C to 250 C across
the heat exchanger.
0
1 How many liters of water per hour can be heated by 50 C from this
waste stream?
(i) Heat transferred to water = 2,000 x 0.98 x0.25 x (800 250)

= 269,500 kCal / hour
(ii) Solve for liter the equation 269,500 = liter x 1 kCal x 50

liter = 5,390 liters / hour.
_________________________ 7
Paper 2 Set A
-------- End of Section - II ---------

L-1 It is proposed to replace an oil-fired boiler of 10 tons per hour with a coal fired
boiler of equivalent capacity. With the help of the data provided find out the
following:
23 the annual oil consumption in tons per year?

24 the annual coal consumption in tons per year?
25 estimate annual fuel cost savings in Crore rupees
26 simple pay back period of the project, assuming the coal fired boiler
costs Rs.1.5 Crore and annual repair and maintenance costs is 25%
of capital cost.
27 What additional data could be added for working out a more realistic
simple pay back period?
Operation data
Heat content of steam - 660 kCal/kg.

0
Feed water inlet temperature - 60 C
Daily operating hours - 24
Number of days / year - 300
Efficiency of oil fired boiler - 82%
Efficiency of coal fired - 72%
Cost of oil - Rs.13/- kg.
Cost of coal - Rs.2 /kg.
GCV of oil 10,000 kCal/kg
GCV of coal 4,200 kCal/kg.
5888 the hourly oil consumption is = 10,000 kg x(660-60) = 731.7 kg/h

10,000 kCal x 0.82
it follows 731.7 x 24 x 300/1000 = 5,268 tons per year
0 the hourly coal consumption is = 10,000 kg x (660-60) = 1,984 kg/h

4200 x 0.72
it follows 1,984 x 24 x300/1000 = 14,285 tons/year
0 (5,268 x13,000 14,285 x 2000)/10,000,000 = Rs 3.99 Cr

1 Simple pay back period 1.5/(3.99-0.25 x 1.5) = 0.41 years
0 The simple payback period in fact cannot be calculated with these

few simplistic assumptions because when switching from oil to
coal there are additional costs and benefits such as
(a) labour (b) coal processing (c) avoided R & M of oil operation
(d) salvage value of oil boiler
_________________________ 8
Paper 2 Set A
L-2 (i) draw the steam phase diagram in a coordinate system with temperature as (y-
axis) and enthalpy as (x-axis)
(ii) explain the major regions of the diagram.
(i)
5888 Comments
5888 to the left of the tilted dome is the liquid region

5889 under the dome is the two phase region, which means
wet steam
5890 to the right of the dome is the superheat steam region
5891 o the highest point of the dome is the super critical point at
374 C and 221 bar
5892 above the critical point is the super critical region where
steam has no well defined boiling points.
5893 at any point on the dome curve the first x-coordinate B is
enthalpy of the saturated liquid, the second x-coordinate C is the
enthalpy of the saturated steam and the width C-B is the enthalpy
of evaporation from saturated water to saturated steam .
L-3 An energy manager recommends to his superior that in an already well

functioning boiler the oil be mixed and should contain 20% water by weight.
The manager claims:
0 this would reduce fuel costs

1 boiler efficiency would also improve
Agree or disagree and support your decision by argumentation as well as

some calculations. Assume that 1 kg of feed water requires about 600 kCal to
evaporate.
(i) One should disagree because 1 kg of furnace oil is replaced by a

mixture of 0.8 k of oil and 0.2 kg of water. Even if water costs are
_________________________ 9
Paper 2 Set A
assumed to be zero 1 kg of oil-water mixture cannot cost less than 80%

of 1 kg oil.
(ii) One should disagree because this means energy in the oil is
required to evaporate additional 0.2 kg of water and heat the water
vapor (steam) up to the furnace flue gas temperature. This energy is not
any longer available to generate steam. The thermal efficiency is
therefore reduced and not improved.
To heat up and evaporate 1 kg of water about 600 kCal of energy are

required. In other words 120/8000 = 1.5% of the energy in the oil-water
mixture are needed to evaporate this water. This energy is not any
longer available to generate steam. Consequently the boiler efficiency is
reduced by at least 1.5 %.
L-4 (i) state two examples of heat pump applications

0 in which situation are heat pumps most promising?
1 draw the schematics of a heat pump system
2 briefly discuss each process stage
5888 (a) space heating system, (b) use in plastic factory where chilled
water is used to cool injection moulding machines, (c) drying
applications such as maintaining dry atmosphere in storage and drying
compressed air
5889 In a situation when both the cooling and heating capabilities of

the cycle can be used in combination
(iii)
_________________________ 10
Paper 2 Set A
23 Step 1: in the evaporator the heat is extracted to boil the

circulating working fluid
Step 2: the evaporated working fluid is compressed in a
compressor rising working fluid temperature and pressure
Step 3: the heat is delivered to the condenser
Step 4: the pressure of the working fluid is reduced in a throttling
valve and condensate returned to the compressor
L-5 On the topic of waste heat recovery boilers, explain the following:
0 Which are typical applications of waste heat boilers?

1 How do they differ from ordinary steam boilers?
2 In what temperature range do they operate?
0
3 Is it more energy efficient to generate hot water of 80 C or
saturated steam at 6 bar in a waste heat boiler? Explain
0 Typical applications are to recover waste heat from medium

temperature waste gas streams such as (a) gas turbines, (b)
incinerators, (c) furnaces.
1 Waste heat boilers are of the water tube type. The hot gases pass
over a number of parallel tubes. There is no radiation section but heat
transfer is accomplished by convection only. Some have finned water
tubes to increase heat transfer
2 Gas temperatures are low to medium (400 C to 800 C)
3 It is more energy efficient to generate hot water at 80 C than

saturated steam at 6 bar because more heat can be extracted from the
waste heat stream. In the case of steam generation the waste gas
temperature can only be lowered to about 180 C while in the case of
hot water the waste heat temperature can be lowered to about 130 or
even lower if no excessive Sulfur compounds are present in the flue
gas.
-------- End of Section - III ---------

_________________________ 11
nd
2 NATIONAL CERTIFICATION EXAMINATION 2005
FOR
ENERGYMANAGERSANDENERGYAUDITORS
MODELTESTSERIESB

1. Bombcalorimeterisusedtodetermine
a) Highercalorificvalueatconstantvolume
b) Lowercalorificvalueatconstantvolume
c) Highercalorificvalueatconstantpressure
d) Lowercalorificvalueatconstantpressure
2. Forcombustionofafuel,followingisessential
a) Correctfuelairratio
b) Properignitiontemperature
c) O2tosupportcombustion
d) Allthethreeabove
3. Theeconomizerisusedinboilersto
a) Increasethermalefficiencyofboiler
b) Toheatfeedwaterbybleedsteam
c) Extractheatfromtheexhaustfluegases
d) Increasefluegastemperature
4 O2contentinatmosphericaironweightbasisis
23 21%
24 23%
25 30%
26 70%
Paper-2/Model Test Series-B Page 1 of 17

5. Incompletecombustioncanbebestjudgedby
a) Smokychimneyexit
b)Excessairinfluegases
c)Measuringcarbonmonooxideinfluegases
d)Measuringtemperatureoffluegasesatexitoffurnace
6. Calorificvalueofcoalisoftheorderof
a) 200400Kcal/kg
b) 8001200Kcal/kg
c) 20004000Kcal/kg
d) 50008000Kcal/kg
7. Thedrysaturatedsteamatverylowpressure(510kg/cm2)whenthrottledto
atmospherewillbecome
a) Wet
b) Superheated
c) Remaindrysaturated
d) Dry
8. Theincreaseinpressure
a) Lowerstheboilingpointofaliquid
b) Raisestheboilingpointofaliquid
c) Doesnotaffecttheboilingpointofaliquid
d) Reducesitsvolume
9. Watertubeboilersarethoseinwhich
a) Fluegasespassthroughtubesandwateraroundit
b) Waterpassesthroughthetubesandfluegasesaroundit
c) Forcedcirculationtakesplace
d) Tubesarelaidvertically
10. A packagedboilerisoneinwhichvariouspartslikefiringequipment,fans,
feedpumpsandautomaticcontrolare:
a) Suppliedbysamemanufacturerlooseandassembledatsite
b) Suppliedmountedonasinglebase
c) Purchasedfromseveralpartiesandpackedtogetheratsite
d) Doesnotexist
5888 Innaturalcirculationtypeboiler
23 Heatingtakesplaceatbottomandthewatersuppliedatbottomgetsconverted
intothemixtureofsteambubblesandhotwaterwhichrisetodrum.
24 Waterissuppliedindrumandthroughdowncomerslocatedinatmosphericconditions
itpassestothewaterwallandrisestodrumintheformofmixtureofwaterandsteam
25 Feedpumpisemployedtosupplementnaturalcirculationinwaterwalltype

furnace
d) Thewaterisconvertedintosteaminonepasswithoutanyrecirculation
12. ThermalefficiencyofwellmaintainedoilfiredboilerbasedonGCVwillbeof
theorderof
a) 40%
b) 50%
c) 85%
d) 94%
13. Boilersteamgenerationparametersareexpressedby
a) Tons/hr.ofsteam
b) Pressureofsteaminkg/cm2
c) TemperatureofsteaminoC
d)Alloftheabove
14. Maximumenergylossinaboileroccursdueto
a) Unburnt carboninash
b) Incompletecombustion
c) Ashcontent
d) Fluegases
15. Atwhichofthesepressuresthelatentheatofthesteamwillbeminimum
2 2 2 2
a)2kg/cm b)8kg/cm c)12kg/cm d)15kg/cm

16. Theheatwhichisrequiredtochangethetemperatureofwaterfrom25oCto
o
100 Ciscalled
a)LatentHeat b)SensibleHeat c)SuperHeatd)SpecificHeat
17. Laggingofsteampipesisdoneprimarilytoprevent
a)Heatloss b)Steamleaksc)Highnoised)Pipedamages
18. Bimetallictrapisatypeof
a)thermodynamictrapb)InvertedBucketc)Thermostatictrapd)noneofthe
above
19. Asteamtrapisadevice,whichdischarges
a)condensate b)steam c)effluent d)TDS
0 Flashsteamfromthecondensatecanbeseparatedinanequipmentcalled
a)Steamtrapb)flashvessel c)strainer d)noneoftheabove

21. Generallymeltingfurnacesforsteel,castironare
a)Forgingfurnace b)ArcFurnace c)InductionFurnaced)Bothb&c
22. Inaforgingfurnace,thefurnacetemperatureismaintainedat
o
a) 1200C b)900 C
o o
c)1500 C
o
d)1000 C
23. Inacontinuoussteelreheatingfurnace,productisheatedupto
o o c) 400500oC o
a)1100 C b)9001250C d)700800 C
24. WhatisthepercentageofexcessairwhenO2influegasis8%?
a)30%b)61% c) 75% d)69%
25. Sensibleheatlossinafurnacecanbereducedby
a)Reducingexcessair b)Reducingoutgoingfluegastemperature
c)Botha&b d)Neitheranorb
26. Whichcanreducewalllossesinafurnace.
a)Regeneratorb)Recuperator c)CeramicFibre d)None
27. Radiationlossisdirectlyproportionalto
3 4 2 d) T
a)T b)T
c)T
28. Thermalconductivityofamaterial,withincreaseintemperaturewill
a) Increase
b) Decrease
c) Nochange
d)Firstdecrease&thenincreases
29. Thetotalcostcurvevisvisinsulationthicknesswill
a) Decreaselineally
b) Firstreduceandthenincrease
c) Firstincreaseandthenreduce
d) Straightline
0 Zirconiumdioxideisstabilizedbyincorporating:
0 Calcium
1 Magnesium
2 Lime&Magnesium
3 Lime

31. Emissivityisameasureofamaterialsabilityto
a) Absorbheat
b) Radiateheat
c) Absorb&radiateheat
d) Noneoftheabove
32. Thelowthermalconductivityofceramicfibreisadvantageousasitwillleadto
a) Lesserliningthickness
b) Reducedcost
c) Easeofmaterialhandling
d) Noneofthethese
33. Thethermalconductivitywillgenerallywithincreasein
temperature
a) Increase
b) Decrease
c) Nochange
d) Decreasefirstandthenincrease
34. Whichofthefollowingisnotusedforhightemperature(325&above)
insulationapplication
a) Calciumsilicate
b) Mineralfibre
c) Ceramicfibre
d) Magnesia
35. Thefluidizationdependsontheandairvelocity.
a)WaterPressureb)Temperature c)ParticleSized)Particletype
36. Whatisnotatypeoffluidizedbedcombustion?
a)TFBC b)AFBC c)PFBC d)CFBC
37. ThebeddepthinaAFBCboilerisnormallyintherangeof
a) 0.91.5m b)1.5m1.9m c)1.5m2.5md)0.4m0.9m
38. WhatcouldbethebedmaterialinaFBCboiler?
a)Sandb)CrushedRefractoryc)Ash d)Alltheabove
23 HeatTransferinsidethebedofaFBCboilerdependsupon
a)Particlesize b)bedtemperature c)Botha&b d)neitheranorb

40. Percentageof airsuppliedthroughbottomofaCFBCboileris
a)2030% b)1020% c)3040% d)6070%
41. ThebedvesselinaPFBCisoperatedatpressure
a)Upto60ata b) Upto 40ata c)Upto30ata d)Upto16ata
42. BoilersizeinaPFBCsystemisreducedbecauseof
a)HighTemperature b)LowTemperature c)HighPressure
d)LowPressure
43. ThecombustionefficiencyinaFBCboilerisoftheorderof
a)6070% b)7080% c)8084% d)>95%
44. Cogeneration hasthefollowingadvantagesexcept

a) Increasesystemefficiency
b) Reducefuelconsumption
c) ReduceGHGemission
d) IncreaseCO2generation
45. Whatisthemaximumefficiencyofasteamturbine
a) 34%
b) 17%
c) 68%
d) Noneoftheabove
46. Whichofthefollowingcogenerationsystemhasmaximumheattopowerratio?
a) Gasturbine
b) Combinedcycle
c) Backpressuresteamturbine
d) Reciprocatingengine
47. Theshortfallinelectricaloutputcanmetby
a) Feedingmorefuel
b) Operatingthesysteminoverloadcondion
c) Importingpower
d)Noneoftheabove
23 Thefuelthatisgenerallyusedinagasturbinesare
0 Furnaceoil
1 Residualoil
2 Producergas
3 Naturalgas

49. Typicalapplicationofabottomingcycleis
a) Cement
b) Brewery
c) Noneofthese
d) Fertilizer
50. Forevery22oCreductioninfluegastemperaturebypassingthroughan
economizerthereisapproximately____savingoffuel.
a)3%b)5%c)1%d)7%
23Answer all Ten questions

23 Whatarethevarioustypesofcombustioncontrolsandbrieflyexplain?
Combustioncontrolsassisttheburnerinregulationoffuelsupply,airsupply,(fuelto
airratio),andremovalofgasesofcombustiontoachieveoptimumboilerefficiency.
Varioustypesofcombustioncontrolsinuseare:
On/OffControl
Thesimplestcontrol,ON/OFFcontrolmeansthateithertheburnerisfiringatfullrateoritisOFF.This
typeofcontrolislimitedtosmallboilers.
High/Low/OffControl
SlightlymorecomplexisHIGH/LOW/OFFsystemwheretheburnerhastwofiringrates.The
burneroperatesatslowerfiringrateandthenswitchestofullfiringasneeded.Burnercanalso
reverttolowfiringpositionatreducedload.Thiscontrolisfittedtomediumsizedboilers.
ModulatingControl
Themodulatingcontroloperatesontheprincipleofmatchingthesteampressuredemandby
alteringthefiringrateovertheentireoperatingrangeoftheboiler.Modulatingmotorsuse
conventionalmechanicallinkageorelectricvalvestoregulatetheprimaryair,secondaryair,
andfuelsuppliedtotheburner.Fullmodulationmeansthatboilerkeepsfiring,andfueland
airarecarefullymatchedoverthewholefiringrangetomaximizethermalefficiency.
23 WhatarethetypesofBlowdownandbrieflyexplaineachofthem?

Conventionalmethodsforblowingdowntheboilerdependontwokindsofblowdown
intermittentandcontinuous.
Theintermittentblowndownisgivenbymanuallyoperatingavalvefittedtodischargepipe
atthelowestpointofboilershelltoreduceparameters(TDSorconductivity,pH,Silicaand
Phosphatesconcentration)withinprescribedlimitssothatsteamqualityisnotlikelytobe
affected.Inintermittentblowdown,alargediameterlineisopenedforashortperiodof
time,thetimebeingbasedonathumbrulesuchasonceinashiftfor2minutes.
Incontinuousblowdownthereisa steadyandconstantdispatch of smallstreamof

concentratedboilerwater,andreplacementbysteadyandconstantinflowoffeedwater.
ThisensuresconstantTDSandsteampurityatgivensteamload.Onceblowdownvalve
issetforagivenconditions,thereisnoneedforregularoperatorintervention.
5888 Whatarethetypesofsteamtrapsandbrieflyexplainabouttheirprincipleofoperation?
Therearethreebasictypesofsteamtrapintowhichallvariationsfall,
Thermostatic (operated by changes in fluid temperature) The temperature of saturated

steam is determined by its pressure. In the steam space, steam gives up its enthalpy of
evaporation(heat),producingcondensateatsteamtemperature.Asaresultofanyfurtherheat
loss,thetemperatureofthecondensatewillfall.Athermostatictrapwillpasscondensatewhen
thislowertemperatureissensed.Assteamreachesthetrap,thetemperatureincreasesandthe
trapcloses.
Mechanical (operated by changes in fluid density) This range of steam traps

operates by sensing the difference in density between steam and condensate. These
steamtrapsinclude'ballfloattraps'and'invertedbuckettraps'.Inthe'ballfloattrap',the
ball rises in the presence of condensate, opening a valve which passes the denser
condensate. With the 'inverted bucket trap', the inverted bucket floats when steam
reachesthetrapandrisestoshutthevalve.Bothareessentially'mechanical'intheir
methodofoperation.
Thermodynamic (operated by changes in fluid dynamics) Thermodynamic steam traps rely

partlyontheformationofflashsteamfromcondensate.Thisgroupincludes'thermodynamic','disc',
'impulse'and'labyrinth'steamtraps.
0 Whatismeantbyairventingandwhatisitspurpose?
Whensteamisfirstadmittedtoapipeafteraperiodofshutdown,thepipeisfullofair.Further
amountsofairandothernoncondensablegaseswillenterwiththesteam,althoughtheproportions
ofthesegasesarenormallyverysmallcomparedwiththesteam.Whenthesteamcondenses,these
gaseswillaccumulateinpipes

and heat exchangers. Precautions should be taken to discharge them. The consequence of not
removing air is alengthy warming up period, and a reduction inplant efficiency and process
performance.
Airinasteamsystemwillalsoaffectthesystemtemperature.Airwillexertitsownpressurewithin
thesystem,andwillbeaddedtothepressureofthesteamtogiveatotalpressure.Therefore,the
actualsteampressureandtemperatureofthesteam/airmixturewillbelowerthanthatsuggestedby
apressuregauge.
Ofmoreimportanceistheeffectairhasuponheattransfer.Alayerofaironly1mmthickcanoffer
thesameresistancetoheatasalayerofwater25mthick,alayerofiron2mmthickoralayerof
copper15mmthick.Itisveryimportantthereforetoremoveairfromanysteamsystem.
Automaticairventsforsteamsystems(whichoperateonthesameprincipleasthermostatic
steamtraps)shouldbefittedabovethecondensatelevelsothatonlyairorsteam/air
mixturescanreachthem.Thebestlocationforthemisattheendofthesteammains.
0 Giveatleast3characteristicsofanefficientfurnace
Furnaceshouldbedesignedsothatinagiventime,asmuchofmaterialaspossiblecanbeheatedto
anuniformtemperatureaspossiblefuelandlabour.Toachievethisend,thefollowingparameterscan
beconsidered.
0 Determinationofthequantityofheattobeimpartedtothematerialorcharge.
1 Liberationofsufficientheatwithinthefurnacetoheatthestockandovercomeallheatlosses.
2 Transferofavailablepartoftheheatfromthefurnacegasestothesurfaceoftheheatingstock.
5888 What are the major points to be considered before selecting refractories in a
furnace?
5888Emissivityofwalls
5889 Conductivityofrefractories
5890 Wallthickness
5891 Whetherfurnaceorkilnisoperatedcontinuouslyorintermittently.
0Whatisbubblingfluidizedbed?
Whenanevenlydistributedairorgasispassedupwardthroughafinelydividedbedof
solidparticlessuchassandsupportedonafinemesh,theparticlesareundistributedat
low velocity. As air velocity is gradually increased, a stage is reached when the
individualparticlesaresuspendedintheairstreamthebediscalledfluidized.
Withfurtherincreaseinairvelocity,thereisbubbleformation,vigorousturbulence,

rapidmixingandformationofdensedefinedbedsurface.Thebedofsolidparticlesexhibitsthe
propertiesofaboilingliquidandassumestheappearanceofafluidbubblingfluidizedbed.
0 Brieflyexplainthetoppingcycle&bottomingcycle.
Acogenerationsystemcanbeclassifiedaseitheratoppingorabottomingcycleonthebasisofthe
sequenceofenergyuse.Inatoppingcycle,thefuelsuppliedisusedtofirstproducepowerandthen
thermalenergy,whichisthebyproductofthecycleandisusedtosatisfyprocessheatorother
thermalrequirements.
BottomingCycle:
Inabottomingcycle,theprimaryfuelproduceshightemperaturethermalenergyandtheheatrejected
fromtheprocessisusedtogeneratepowerthrougharecoveryboilerandaturbinegenerator.
23 Whatarethetwoimportantparametersthatyouwillconsiderbeforedevelopingawasteheatrecovery
system?
1.Understandingtheprocess
UnderstandingtheprocessisessentialfordevelopmentofWasteHeatRecoverysystem.Thiscanbe
accomplishedbyreviewingtheprocessflowsheets,layoutdiagrams,pipingisometrics,electricaland
instrumentationcableductingetc.Detailreviewofthesedocumentswillhelpinidentifying:
23 Sourcesandusesofwasteheat
24 Upsetconditionsoccurringintheplantduetoheatrecovery
25 Availabilityofspace
26 Anyotherconstraint,suchasdewpointoccurringinanequipmentsetc.
Afteridentifyingsourceofwasteheatandthepossibleuseofit,thenextstepistoselectsuitableheat
recoverysystemandequipmentstorecoverandutilisethesame.
2.EconomicEvaluationofWasteHeatRecoverySystem
Itisnecessarytoevaluatetheselectedwasteheatrecoverysystemonthebasisoffinancial
analysissuchasinvestment,depreciation,paybackperiod,rateofreturnetc.Inadditionthe
adviceofexperiencedconsultantsandsuppliersmustbeobtainedforrationaldecision.
5888 Whatisaheatpipeandhowitfunctionsasawasteheatrecoverydevice?
TheHeatPipecomprisesofthreeelementsasealedcontainer,acapillarywickstructureanda
workingfluid.Thecapillarywickstructureisintegrallyfabricatedintotheinteriorsurfaceof
thecontainertubeandsealedundervacuum.Thermalenergyappliedtotheexternalsurfaceof
theheatpipeisinequilibriumwithitsownvapourasthecontainertubeissealedunder
vacuum.Thermalenergyappliedtotheexternalsurfaceoftheheatpipecausestheworking
fluidnearthesurfaceto

evaporateinstantaneously.Vapourthusformedabsorbsthelatentheatofvapourisationandthis
partoftheheatpipebecomesanevaporatorregion.Thevapourthentravelstotheotherendthe
pipewherethethermalenergyisremovedcausingthevapourtocondenseintoliquidagain,
therebygivingupthelatentheatofthecondensation.Thispartoftheheatpipeworksasthe
condenserregion.Thecondensedliquidthenflowsbacktotheevaporatedregion.

0 Explainsomeoftheenergyconservationopportunitiesavailableinaboilersystem.
Thevariousenergyefficiencyopportunitiesinboilersystemcanberelatedtocombustion,heat
transfer,avoidablelosses,highauxiliarypowerconsumption,waterqualityandblowdown.
1.StackTemperature
Thestacktemperatureshouldbeaslowaspossible.However,itshouldnotbesolowthat
watervaporintheexhaustcondensesonthestackwalls.Thisisimportantinfuels
containingsignficantsulphuraslowtemperaturecanleadtosulphurdewpointcorrosion.
Stacktemperaturesgreaterthan200Cindicatespotentialforrecoveryofwasteheat.
2. FeedWaterPreheatingusingEconomiser
o
Typically,thefluegasesleavingamodern3passshellboilerareattemperaturesof200to300 C.
Thus,thereisapotentialtorecoverheatfromthesegases.Thefluegasexittemperaturefroma
o
boilerisusuallymaintainedataminimumof200 C,sothatthesulphuroxidesinthefluegasdo
notcondenseandcausecorrosioninheattransfersurfaces.Whenacleanfuelsuchasnaturalgas,
LPG or gas oil is used, the economy
o
of heat recovery must be worked out, as the flue gas
temperaturemaybewellbelow200 C.
Thepotentialforenergysavingdependsonthetypeofboilerinstalledandthefuelused.Fora
o
typicallyoldermodelshellboiler,withafluegasexittemperatureof260 C,aneconomizer
o o
couldbeusedtoreduceitto200 C,increasingthefeedwatertemperatureby15 C.
3. CombustionAirPreheat
Combustionairpreheatingisanalternativetofeedwaterheating.Inordertoimprovethermal
o
efficiencyby1%,thecombustionairtemperaturemustberaisedby20 C. Mostgasandoil
burnersusedinaboilerplantarenotdesignedforhighairpreheatstemperatures.
4. IncompleteCombustion

Incompletecombustioncanarisefromashortageofairorsurplusoffuelorpoordistributionof
fuel.Itisusuallyobviousfromthecolourorsmoke,andmustbecorrectedimmediately.
Inthecaseofoilandgasfiredsystems,COorsmoke(foroilfiredsystemsonly)withnormal
or high excess air indicates burner system problems. A more frequent cause of incomplete
combustionisthepoormixingoffuelandairattheburner.Pooroilfirescanresultfromimproper
viscosity,worntips,carbonizationontipsanddeteriorationofdiffusersorspinnerplates.
5. ExcessAirControl
Excessairisrequiredinallpracticalcasestoensurecompletecombustion,toallowforthenormal
variationsincombustionandtoensuresatisfactorystackconditionsforsomefuels.Theoptimum
excessairlevelformaximumboilerefficiencyoccurswhenthesumofthelossesduetoincomplete
combustionandlossduetoheatinfluegasesisminimum.Thislevelvarieswithfurnacedesign,
typeofburner,fuelandprocessvariables.Itcanbedeterminedbyconductingtestswithdifferentair
fuelratios.Controllingexcessairtoanoptimumlevelalwaysresultsinreductioninfluegaslosses;
forevery1%reductioninexcessairthereisapproximately0.6%riseinefficiency.
6. RadiationandConvectionHeatLoss
Theexternalsurfacesofashellboilerarehotterthanthesurroundings.Thesurfacesthusloseheattothe
surroundingsdependingonthesurfaceareaandthedifferenceintemperaturebetweenthesurfaceandthe
surroundings.
Theheatlossfromtheboilershellisnormallyafixedenergyloss,irrespectiveoftheboiler
output.Withmodernboilerdesigns,thismayrepresentonly1.5%onthegrosscalorificvalueat
fullrating,butwillincreasetoaround6%,iftheboileroperatesatonly25percentoutput.
7. AutomaticBlowdownControl
Uncontrolledcontinuousblowdownisverywasteful.Automaticblowdowncontrolscanbeinstalledthatsense
2
andrespondtoboilerwaterconductivityandpH.A10%blowdownina15kg/cm boilerresultsin3%
efficiencyloss.
8. ReductionofScalingandSootLosses
Inoilandcoalfiredboilers,sootbuildupontubesactsasaninsulatoragainstheattransfer.Any
suchdepositsshouldberemovedonaregularbasis.Elevatedstacktemperaturesmayindicate
excessivesootbuildup.Alsosameresultwilloccurduetoscalingonthewaterside.Highexit
gastemperaturesatnormalexcessairindicatepoorheattransferperformance.Thiscondition
canresultfromagradualbuildupofgassideorwatersidedeposits.Watersidedepositsrequire
areviewofwatertreatmentproceduresandtubecleaningtoremovedeposits.Anestimated1%
o
efficiencylossoccurswithevery22 Cincreaseinstacktemperature.

0 ExplainindetailtheworkingofThermodynamicandThermostatictypeofsteamtrap?
Thermodynamic
Thethermodynamictrapisanextremelyrobuststeamtrapwithasimplemodeofoperation.The
trapoperatesbymeansofthedynamiceffectofflashsteamasitpassesthroughthetrap,asdepicted
inFigure.Theonlymovingpartisthediscabovetheflatfaceinsidethecontrolchamberorcap.
Onstartup,incomingpressureraisesthedisc,andcoolcondensateplusairisimmediatelydischarged
fromtheinnerring,underthedisc,andoutthroughthreeperipheraloutlets(only2shown,Figure.i).
Hotcondensateflowingthroughtheinletpassageintothechamberunderthediscdropsinpressureand
releasesflashsteammovingathighvelocity.Thishighvelocitycreatesalowpressureareaunderthe
disc,drawingittowardsitsseat(Figure.ii).
Atthesametime,theflashsteampressurebuildsupinsidethechamberabovethedisc,forcing
itdownagainsttheincomingcondensateuntilitseatsontheinnerandouterrings.Atthispoint,
theflashsteamistrappedintheupperchamber,andthepressureabovethediscequalsthe
pressurebeingappliedtotheundersideofthediscfromtheinnerring.However,thetopofthe
discissubjecttoagreaterforcethantheunderside,asithasagreatersurfacearea.
Eventuallythetrappedpressureintheupperchamberfallsastheflashsteamcondenses.
Thediscisraisedbythenowhighercondensatepressureandthecyclerepeats(Figure.iv).

Thermostatic
Thermalelement thermostatic traps are temperature actuated.

Onstartupthethermalelementisinacontractedpositionwith
the valve wideopen, purging condensate, air, and other
noncondensablegases.Asthesystemwarmsup,heatgenerates
pressureinthethermalelement,causingittoexpandandthrottle
theflowofhotcondensatethroughthedischargevalve.
Whensteamfollowsthehotcondensateintothetrap,the
thermalelementfullyexpands,closingthetrap.Ifcondensate
entersthetrapduringsystemoperation,itcoolstheelement,
contractingitofftheseat,andquicklydischargingcondensate.
ThermostaticTrap
Thermostatictrapsaresmall,lightweight,andcompact.Onetrapoperatesoverextremelybroad
pressureandcapacityranges.Thermalelementscanbeselectedtooperatewithinarangeofsteam
temperatures.Insteamtracingapplicationsitmaybedesirabletoactuallybackuphotcondensatein
thelinestoextractitsthermalvalue.
3 Whatarevariousfurnacelosses?Describeatleastthreetypesoflosses.

Thermalefficiencyofprocessheatingequipment,suchasfurnaces,ovens,heaters,and
kilnsistheratioofheatdeliveredtoamaterialandheatsuppliedtotheheatingequipment.
Thepurposeofaheatingprocessistointroduceacertainamountofthermalenergyintoa
product,raisingittoacertaintemperaturetoprepareitforadditionalprocessingorchange
itsproperties.Tocarrythisout,theproductisheatedinafurnace.Thisresultsinenergy
lossesindifferentareasandformsasshowninsankeydiagramfigure.Formostheating
equipment,alargeamountoftheheatsuppliediswastedintheformofexhaustgases.
HeatlossesinindustrialheatingFurnaces
WallLosses:
Additionalheatlossestakeplacewhilethefurnaceisinproduction.Wallortransmissionlosses
arecausedbytheconductionofheatthroughthewalls,roof,andflooroftheheatingdevice.
Oncethatheatreachestheouterskinofthefurnaceandradiatestothesurroundingareaoris
carriedawaybyaircurrents,itmustbereplacedbyanequalamounttakenfromthecombustion
gases.Thisprocesscontinuesaslongasthefurnaceisatanelevatedtemperature.
Radiation(Opening)Losses:
o
Furnacesandovensoperatingattemperaturesabove540 Cmighthavesignificantradiation
losses.Hotsurfacesradiateenergytonearbycoldersurfaces,andtherateofheattransfer
increaseswiththefourthpowerofthesurfacesabsolutetemperature.Anywhereoranytime
thereisanopeninginthefurnaceenclosure,heatislostbyradiation,oftenatarapidrate.
WastegasLosses:
Wastegasloss,alsoknownasfluegasorstackloss,ismadeupoftheheatthatcannotberemovedfromthe
combustiongasesinsidethefurnace.Thereasonisheatflows

fromthehighertemperaturesourcetothelowertemperatureheatreceiver.
0
0 Thesurfacetemperatureof100dia150mlongpipeis100 C.AsanEnergyAuditor
whichinsulationthicknessyouwillsuggestfrom50mm,75mm,100mmifthesurfacetemperaturebythese
0 0 0
insulation is 70 C, 55 C, 50 C respectively and the incremental cost required for every 25mm insulation is
Rs.10000/.Theboiler
efficiencyis85%andGCVofcoal5000Kcal./kg.andcostoffuelisRs.4000/ton.Theambientairtemperatureis
o
30 C.Annualhoursofoperationis8000hrs.
Existingheatloss,(S1) =(10+10030)(10030)
20
2
=(10+3.5)x70=945Kcal/hr.m
Heatlosswith50mminsulation = (10+7030)(7030)
(S2) 20
= 480Kcal/hr.m2
Heatlosswith75mminsulation = (10+5530)(5530)
(S3) 20
= 281Kcal/hr.m
2
Heatlosswith100mminsulation = (10+ 5030) (5030)
(S4) 20
= 2 2
220Kcal/hr.m =47.1m
ExistingsurfaceareaA = 3.14x0.1x150
Surfacearewith50mminsulation = 3.14x0.2x150 2
=94.2m
2
Surfacearewith75mminsulation = 3.14x0.25x150=117.75m
Surfacearewith100mminsulation= 3.14x0.3x 150=141.3m
2
AnnualHeatlossinexistingsystem= 47.1x945 x8000

(H1) = 3560.7x10 Kcal
5
Annualheatlosswith50mminsulation= 94.2x480x8000
(H2) = 5
3617x10 Kcal
Annualheatlosswith75mm = 117.75x281x8000
Insulation(H3) = 2647x10
5 Kcal
Annualheatlosswith100mm = 141.3x220x8000
Insulation = 2486x105kCal
Heatlosswith50mminsulationishigherandisruledout
Heatlosswith100mminsulationthicknessishigherthantheheatlosswith75mminsulationthickness.
Hencethesuggestedinsulationthicknessis75mm.
0 Withthehelpofsketchexplainbackpressureturbineandextractioncondensingturbine&theircomparative
advantages.

BackPressureTurbine:
InthistypesteamenterstheturbinechamberatHighPressureandexpandstoLoworMedium
Pressure.Enthalpydifferenceisusedforgeneratingpower/work.Dependingonthepressure(or
temperature)levelsatwhichprocesssteamisrequired,backpressuresteamturbinescanhave
differentconfigurationsasshowninFigure.
ExtractionCondensingturbine:
Inthistype,steamenteringatHigh/MediumPressureisextractedatanintermediatepressure
intheturbineforprocessusewhiletheremainingsteamcontinuestoexpandandcondenses
inasurfacecondenserandworkisdonetillitreachesthecondensingpressure(vacuum).
Extractioncondensingturbine

Paper 2 Set B

FOR
Question Papers & Model solutions to the Question Papers
0 Please check that this question paper contains 7 printed pages


(i)Answer all 50 questions
(ii)Each question carries one mark

(iii) Put a () tick mark in the appropriate box in the answer book
1. The working fluid of a steam thermo-compressor is

a) air b) low pressure steam c) high pressure steam d)
water
2. A shell and tube heat exchanger is most suitable if
a) a liquid is heating another liquid b) a gas is heating another gas
c) a gas is heating a liquid d) the hot gas is loaded with dust

0
3. An economizer raises the boiler feed water by 60 C and therefore saves
approximately ___ % of fuel.
a) 5 b) 10 c) 15 d) 20
4. A heat pipe can transfer up to ____ times more thermal energy than copper
a) 10 b) 20 c) 50 d) 100
0 Heat wheels are mostly used in a situation of.
0 high temperature exhaust gases

1 heat exchange between large masses of air having small temperature
differences
c) heat transfer between a liquid and gas d) corrosive gases
_________________________ 1
Paper 2 Set B
6. Regenerators utilizing waste heat are widely used in

a) cement industry b) pulp and paper
c) glass melting furnaces d) aluminium
7. Air compressor alone consumes about _____ of the energy generated in a gas
turbine
a) 20-30% b) 30-40% c) 40-50% d) 50-60%
8. Which CHP system has the smallest heat to power ratio with the least flexibility to
increase or reduce the ratio?
a) back pressure turbine b) combined cycle
9. The unit for heat-to-power ratio of a CHP plant is

a) kWth / kW
e
b) BTU / kW c) kCal /kW d) kWhth / kWe
10. In glass industry waste heat is used for power generation. This type of cogeneration
is called
a) topping cycle b) bottom cycle
c) gas turbine cycle d) none of the above.
11. Pick the wrong statement. The thermal efficiency of a furnace increases by
12. The most economic insulation is the thickness where..
a) depreciation costs of insulation and energy cost due to losses are the same
b) the sum of energy cost due to losses and insulation depreciation cost is
minimum
c) energy losses are minimized
d) energy cost due to losses are minimized.
13. Which of the four refractories has the highest melting point temperature?
a) Lime (CaO) b) Silica (SiO ) c) Titania (TiO2 ) d) Alumina (Al2 O3 )
2
14. The emissivity of refractory material.

0
a) increases sharply above 1000 C
b) will be more or less independent of temperature

c) will increase with increasing temperature
d) will decrease with increasing temperature
15. High emissivity coatings are applied on

a) outer surface of furnace b) refrigeration piping
c) inner surface of furnace d) none of the above
23 The heat loss rate from a surface is expressed in

2 0 2 0
a) Watt b) Watt/m K c) Watt/m C d) Joules
_________________________ 2

Paper 2 Set B
17. Which statement is incorrect

a) higher density refractory has a lower thermal conductivity
b) a higher emissivity means higher radiation of heat

c) a higher emissivity means lower absorption of heat
d) a black colored body radiates more than a glossy white colored one.
18. Fluidized bed combustion takes place in a temperature range of
0 0 0 0 0 0
a) 600 C - 700 C b) 850 C - 950 C c) above 1000 C d) about 500 C
19. The low combustion temperatures in fluidized bed combustion boilers results in
minimal formation of
a) NOx b) NOx and SOx c) CO2 d) CO
20. SOx emissions in a FBC boiler fired with high sulfur coal are controlled by adding
____ to the bed
a) Magnesia b) Limestone c) Sand d) Silica
21. In circulating fluidized bed combustion boilers most of the heat transfer takes place
a) removal of dissolved gases b) removal of silica from feed water
c) removal of TDS from feed water d) phosphate treatment of feed water

0
23. Pre-heating of combustion air in an oil fired furnace by 20 C will save about ___% of
fuel
a) 0.3 b) 1 c) 1.5 d) 0.6
24. To drain condensate from main steam line, the following type of trap is a suitable
trap.
a) float b) bimetallic
c) thermodynamic d) none of the above
0
25. Increase in stack gas temperature of 22 C due to tube fouling or other causes will
increase oil consumption in an oil fired boiler by about.
a) 1% b) 2% c) 3.5% d) 4%
26. Water hammer in a steam system is caused by

a) collected condensate hits obstructions b) leaking pipe joints
c) slow moving steam d) continuous slope in direction of flow

0 Which data is not required to calculate boiler efficiency by the indirect method
a) steam flow rate b) stack gas temperature

c) ambient temperature d) energy content of fuel
_________________________ 3
Paper 2 Set B

a) infinite b) 540 kCal/kg c) zero d) none of the above
29. Increase of steam pressure has which of the following effect on steam
a) steam temperature goes up and enthalpy of evaporation goes down
b) steam temperature and enthalpy of evaporation go down

c) steam temperature goes up and enthalpy of evaporation goes up
d) specific volume goes down and enthalpy of evaporation goes up
30. Scale losses in reheating furnaces will increase with
a) decrease in excess air b) decrease in furnace temperature
c) increase with excess air d) are not correlated to temperature
31. An air film inside in a steam pipe may be _______ times more resistant to heat
transfer then the steel the steam pipe is made of.
a) 200 1000 b) 1500 3000 c) 4000 8000 d) 8000 16000
32. The best steam for indirect heating in most industrial process is
a) as dry as possible b) super heated steam
c) wet steam d) as wet as possible
33. Pressure drop through a steam pipe is inversely proportional to
a) diameter b) square of diameter c) fifth power of diameter d) cube of
diameter
34. In an oil fired burner, the excess air level _____ towards the highest turndown ratio
for efficient combustion.
a) decreases b) increases c) not affected d) none of the above
35. What is the most effective way to avoid ambient air infiltration into a continuous
furnace
a) close all openings b) increase the chimney height
c) operate at about 90% capacity d) reduce negative pressure inside the

furnace
36. Black body radiation is

a) linear proportional to temperature
b) proportional to the fourth power of the temperature of the body

c) proportional to the fourth power of the absolute temperature of the body
d) proportional to the square of the body surface area
37. Steam at 6 bar has a sensible heat of 159.33 kCal/ kg and latent heat of 498.59 kCal/
kg. If the steam is 95% dry than the total enthalpy is
a) 625 kCal/ kg b) 649.95 kCal/ kg c) 553 kCal/ kg d) 633 kCal/ kg
0 In which type of furnace operation is a low mass ceramic fiber insulation most
suitable to reduce specific fuel consumption
a) batch type furnace b) continuous Hoffmann tunnel kiln

_________________________ 4
Paper 2 Set B
c) rotary high temperature furnace d) low temperature furnace

0
39. Which loss is the highest in a typical re-heating furnace operating at 1300 C?
a) flue gas loss b) wall loss c) necessary opening loss d)cooling
water loss
40. In a batch type furnace the following energy efficiency measure would be the most
controversial
a) increasing the insulation at the hot temperature side
b) increasing the insulation at the outer surface of the furnace
c) pre-heating the combustion air d) reducing excess air.
0
41. Specific heat in kCal/kg - C of fuel oil is in the range of
a) 0.15 0.20 b) 0.22 0.28 c) 0.29 0.32 d) none of the above
42. Grade B Indian coal has a energy content range (in kcal/kg) of
a) 3360-4200 b) 4200-4900 c) 4940-5600 d) 5600-6200
43. Which is the common coal firing system used in Indian thermal power plants?
a) pulverized coal firing b) stoker firing c) fluidized bedd) pressurized bed
a) Butane b) Propane c) Hydrogen d) Coal
45. Stochiometric air required for combustion of Bagasse is about

a) 13.7 b) 3.2 c) 6 d) 18
46. Which fuel releases the most energy per kg on complete combustion
a) Carbon b) Sulphur c) Nitrogen d) Hydrogen
47. How many kg of CO2 are produced in complete combustion of 16 kg of Methane?

48. Theoretical CO2 of a fuel in % is 15.5. The measured CO2 in the stack gas is 11% by
volume. The percentage of excess air will be
a) 40.9% b) 38.7 % c) 240.9 % d) 140.9 %
49. Evaporation ratio (steam to fuel ratio) of an oil fired efficient boiler is in the range of
a) 5 - 6 b) 13 14 c) 1 - 3 d) 7 9
0 A rise in conductivity of boiler feed water indicates

b) more steam generation c) greater purity of feed water d)
rise in the total dissolved solids in boiler water
-------- End of Section - I ---------

_________________________ 5
Paper 2 Set B

S-1 (i) State the stochiometric combustion equation for Hydrogen and Carbon.
5888 How many kg of water are generated by complete combustion of 1 kg of
Hydrogen?
5889 How many kg of Carbon Dioxide are generated by complete combustion
of 1 kg of Carbon?
(i) 2H2 + O2 = 2H2 O or H2 + O2 = H20

4 + 32 = 36 (only for reference and further calculation)
C + O2 = CO2
12 + 32 = 44 (only for reference and further calculation)
0 36/4 = 9 kg of water are generated for each kg of Hydrogen (

1 44/12 = 3.67 kg of Carbon Dioxide are generated for each kg of
Carbon.
S-2 Assume the stochiometric (theoretical) air to fuel ratio of furnace oil is 13.8. The
burner operates at 15% excess air. Calculate the mass of stack gas generated
from combustion of one kg of oil.
0 Mass of air + mass of fuel 0 mass of stack gas

0 x 13.8 + 1 1 16.87 kg
S-3 (i) Explain the difference between the indirect and direct method of boiler efficiency
evaluation
(ii) State both equations.
(i) The difference is that in the direct method two major flows (steam and
fuel flow) must be measured to calculate the energy streams for steam as
useful output and energy input from the fuel. The direct method does not
identify or measure energy losses. In the indirect method no flow
measurements are necessary and this method identifies and measures
major losses and estimates not so major losses.
(direct) = Heat output x 100 in %

Heat input
A more precise formulation is to replace heat output by useful heat

output or absorbed heat.
In the indirect method the losses are either measured or estimated and
subtracted from 100.
_________________________ 6
Paper 2 Set B
(indirect) = 100 sum of losses in %.
S-4 Explain why group trapping is not recommended with steam traps.
0 group trapping normally causes water logging

1 group trapping causes loss of output
2 pressure in the various steam spaces will be different, i.e. pressure
at the drain outlet of a heavily loaded unit will be less than in the
case of one that is lightly loaded. Since the traps discharge
condensate due to differential pressure, the condensate from the
heavily loaded one finds it difficult to reach the trap.
S-5 A reheating furnace output is 5 tons/hour. Thermal efficiency is claimed to be 20%.

o o
Specific heat of billet is 0.12 kcal/kg C. Billets enter the furnace at 50 C and
o
leave at 1200 C. Calculate the hourly oil consumption in liter if GCV of oil is
9,000 kCal/liter.
Efficiency = heat absorbed in the stock = 0.20 = 5000 x 0.12 (1200-50)

heat in the fuel liter x 9,000
it follows, oil consumption is 383.3 liter/hour
S-6 How does high emissivity coating in a furnace chamber helps in reducing energy
consumption?
23 promotes rapid and efficient transfer of heat

24 more uniform heating
25 extended life of refractory
26 for intermitted furnaces or where rapid heating is required such
coating has reduced energy consumption by 8% to 20%.
S-7 (i) Which sources of heat can be recovered from a 2 MW reciprocating

engine cogeneration system? and
(ii) What is roughly the temperature level of these waste streams?
(i) There are essentially two work streams such as a) exhaust gas b)
coolers for water, air and oil
0
(ii) The temperature level of the exhaust gas streams are about 350 C -
0 0
450 C from exhaust gas and above 100 C from cooling water.
S-8 (i) list prime movers for cogeneration, and
(ii) state the one with the highest efficiency.

(i) list of prime movers
a) steam turbine back pressure
b) steam turbine extracting and condensing

c) gas turbine
d) reciprocating engine
_________________________ 7
Paper 2 Set B
(ii) the back pressure steam turbine cogeneration system is the most
efficient if 100% of the back pressure exhaust steam is used.
S-9 Calculate the blow down rate in kg/hr from a boiler with an evaporation rate of 5
tons/hr, if the maximum permissible TDS in the boiler water is 4000 ppm and with
15% make up water addition. The feed water TDS is 300 ppm
Blowdown (%) = (feedwater TDS in %) x (% Makeup)

Permissible TDS in Boiler Feedwater TDS
= 300 x 15/(4000-300) = 1.22% or 5000 x 1.22/100 = 60.8 kg/hr
(OR)
Blowdown (%) = feedwater TDS x % Makeup

Maximum Permissible TDS in Boiler water
Blowdown (%) = 300 x 15 = 1.13% or 5000 x 1.13/100 = 56.5 kg/hr

4000
(Marks are to be awarded if the candidates have worked out the solution based on
any one of the above formula.)
S-10 A firm wants to recover waste heat in a flue gas stream of 1800 kg/hour from a
0
furnace. Specific heat of flue gas is 0.23 kCal/kg C.
23 calculate the heat recovered if the heat exchanger has an efficiency of

0 0
97% and temperature of flue gas drops from 900 C to 220 C across the
heat exchanger.
0
24 How many liters of water per hour can be heated by 40 C from this waste
stream?
(i) Heat transferred to water = 1,800 x 0.97 x 0.23 x (900 220)

= 273,074.4 kCal/hour
(ii) Solve for 273,074.4 = litres x 1 x 40
It follows 6827 litres per hour.
-------- End of Section - II ---------
(i) Answer all Five questions

(ii) Each question carries Ten marks
_________________________ 8
Paper 2 Set B
L-1 It is proposed to replace an oil-fired boiler of 10 tons per hour with a coal fired boiler
of equivalent capacity. With the help of the data provided find out the following:
5888 the annual oil consumption in tons per year?

5889 the annual coal consumption in tons per year?
5890 estimate annual fuel cost savings in Crore rupees
5891 simple pay back period of the project, assuming the coal fired boiler costs
Rs.1.5 Crore and annual repair and maintenance costs of the coal fired
boiler are 25% of capital cost.
5892 Comment about accuracy of the calculated payback period.
Operation data
Heat content of steam 760 kCal/kg.

0
Feed water inlet temperature 70 C
Daily operating hours 24
Number of days / year 280
Efficiency of oil fired boiler 80%
Efficiency of coal fired 74%
Cost of oil Rs.14/- kg.
Cost of coal Rs.1.4 kg.
GCV of coal 4,400 kCal/kg.
0 the hourly oil consumption is 10,000 kg x(760-70) = 862.5 kg/h

10,000 kCal x 0.80
it follows 862.5 x 24 x 280/1000 = 5796 tons per year
0 the hourly coal consumption is 10,000 kg x (760-70) = 2,119 kg/h

4,400 x 0.74
it follows 2,119 x 24 x280/1000 = 14240 tons/year
0 Savings (5796 x14,000 14240 x 1,400)/10,000,000 = Rs 6.12 Cr
1 Simple pay back period 1.5/(6.12-0.25 x 1.5) = 0.26 years
2 The dynamic payback period in fact cannot be calculated with these

few simplistic assumptions because when switching from oil to coal there
are additional labor and coal processing cost, which do not exist for oil. In
addition the avoided repair and maintenance costs of the oil operation
should be added. Note, that arguing the simple payback period method is
inaccurate because of the time value of money is a wrong statement in this
context where payback is in any case shorter than 1 year.
L-2 (i) Explain why dry saturated steam is preferred over wet or super heated steam for
industrial process heating
_________________________ 9
Paper 2 Set B
0 Complete the enthalpy

equation hg = ? for wet steam and name the variables.
1 Why should one use dry
steam at the lowest possible pressure for indirect steam heating.
(i) (a) Superheated steam gives up heat at a slower rate then saturated
steam.
(b) wet steam has a lower heat content than dry steam.
(c) dry steam condenses quickly and provides a faster heat transfer (3
marks)
(ii) hg = hf + X.hfg
hf = enthalpy of saturated water at a given pressure
hfg = enthalpy of evaporation of saturated water to saturated
steam hg = enthalpy of saturated steam
X= dryness fraction of wet steam
(iii) The latent heat of steam increase with reduction of steam pressure and
only latent heat takes part in the indirect heating process.
L-3 Explain incomplete combustion with reference to
(i) causes of incomplete combustion

(ii) the products of incomplete combustion
(i) In general the three T apply: Temperature in the combustion chamber

should be high enough to ignite and maintain combustion, Turbulence
helps for good mixing of fuel and oxygen and enough Time should be given
to the fuel in the combustion chamber
The causes of incomplete combustion may be either of a chemical/kinetic

or a physical nature.
Major causes of physical nature are insufficient atomization of oils, wrong

sizing of coal, wrong pressure of oil, combustion flame coming too close to
a colder surface and therefore freezing the chemical reaction, worn out
burner nozzles, insufficient preheating of oil. In general bad mixing of fuel
and combustion air and not enough turbulence.
The major chemical cause for incomplete combustion is insufficient

amount of combustion air and therefore implicitly not enough oxygen to
burn Carbon and Hydrogen to CO 2 and H2O . The amount of combustion air
must be more then the stochiometric or theoretical air for Carbon and
Hydrogen.
(ii) The products of incomplete combustion are Carbon Monoxide (CO), as

well as fine Carbon or soot, and liquid Higher Hydrocarbons.
L-4 (i) State the general equation for heat loss from a hot wall or pipe surface.
23 Name each variable and state SI - units of these variables
_________________________ 10
Paper 2 Set B
23 Where does the thermal conductivity of the wall or pipe structure enter in
this equation?
23 H = h x A x (Th Ta)
24 variables and units
H = heat loss in Watt (=Joules/s and therefore a heat loss rate)

2o 2o
h = heat (or film heat) transfer coefficient in W/m K (same as W / m C)
2
A = outer surface in m
Th = hot surface temperature in degree Centigrade
Ta = ambient (surroundings) temperature in degree Centigrade
(iii) Thermal conductivity of the wall does enter this equation through Th
the hot surface temperature but not through h.
(OR)
S = [10 + (Ts-Ta)/20] x (Ts-Ta)
Where
2
23 =Surface heat loss in kCal/hr m
Ts = Hot surface temperature in K
Ta = Ambient temperature in K
(OR)
t 273 4 t 2 2734
Qax(tt )5/4 4.88Ex

1

1 2
100 100
where Q: Quantity of heat released (kCal/hr)

a : factor regarding direction of the surface of natural convection ceiling = 2.8,
side walls = 2.2, hearth = 1.5
tl : temperature of external wall surface of the furnace (C)
t2 : temperature of air around the furnace (C)
E: emissivity of external wall surface of the furnace
L-5 (i)Draw the schematic for a 2 MW internal combustion engine used as

cogeneration system to generate power and hot water by cold water.
0 0
23 How many cubic meters of water can be heated from 30 C to 60 C per
hour if the power generation unit has an efficiency of 40% for the
generation of electricity without the waste heat recovery components and
82% with the waste heat recovery component. Assume a fuel oil
consumption of 220 gram/kWh electricity at an output of 1.8 MW and
_________________________ 11
Paper 2 Set B
(i)
(ii) Total fuel energy available is 0.22 x 10,000 x 1,800 = 3,960,000 kCal/h
Fuel energy per hour converted to electricity is 0.4 x 0.22 x 10,000 x 1800 =
1,584,000 kCal/h.
Fuel energy loss neither converted to electricity nor warm water 0.18 x 0.22
x10,000 x1,800 = 712,800 kCal/h
Fuel energy available to heat water 3,960,0001,584,000712,800= 1,663,200 kCal/h

Consequently 1,663,200 / [(60-30)x1000] = 55 cubic meters of water per hour
_________________________ 12
Paper 2
Model Question Paper-2006
NATIONAL CERTIFICATION EXAMINATION

FOR


25 Put a () tick mark in the appropriate box in the answer book
1. Which of the following fuel needs preheating for pumping from storage tank
a) LSHS b) Furnace Oil
c) Heavy Fuel Stock d) All of the above
2. Pour point of the fuel is the .
a) Lowest temperature at which it will flow when cooled from high temperature
b) High temperature at which it will flow when heated from low temperature
c) Lowest temperature at which it will solidify when cooled from high temperature
d) Highest temperature at which it will solidify when cooled from high temperature
3. Sulfur content is lowest in
a) LSHS b)LDO c) Furnace oil d) Kerosene
4. Calorific value of fuel is highest in

a) Furnace oil b) LSHS c) LDO d) Anthracite coal
5. Spontaneous combustion can be prevented by
a) Allowing more ventilation of air
b) Spraying water over the leaps of coal
c) Both a and b
d None of the above
6. Higher the sulphor content in the fuel, Dew point temperature will
a) decrease b) increase
c) same d) No impact
7. Which of the following is recommended for pumping light fuel oil
a) Diaphragm Pump
b) Gear Pump
c) Centrifugal Pump
d) All of the above
8. High ash content will
a) Increase the handling cost
b) Causes clinkering and Slagging
c) Reduces boiler capacity
d) All of the above
23 Blending of coal means
23 Mixing of excessive fines with large lumps of coal
24 High GCV coal with Low GCV coal
25 Both a and b
26 Mixing high sulphor content with low sulphor content
_________________________ 1
NPC-AIP 2006
Paper 2
10. Moisture content is less in

a) Deoiled Bran b) Paddy Husk c) Saw Dust d)Coconut Shell
o
11. The atomization temperature of 105 C is recommended for
a) LAP Burner c) HAP Burner
b) MAP Burner d) All of the above
12. The ash fusion temperature for typical Indian coal is
o o
a) 1700 C b) 1300 C
o o
c) 1100 C d) 900 C
13. The temperature of flue gas is high in
a) Two pass Boiler
b) Three Pass Boiler
c) Both a and b
d) None of the above
14. Steam pipes comes under IBR Inspection if
2
a) Steam pressure exceeds 5.5kg/m and internal diameter exceeds 250mm
2
b) Steam pressure exceeds 3.5kg/m and internal diameter exceeds 254mm
2
c) Steam pressure exceeds 1.5 5kg/m and internal diameter exceeds25mm
15. Pulverized coal is crushed into
a) 50 to 55% is below 75 microns
b) 60-65% is below 75 microns
c) 70-75% is below 75 microns
d) 90-95% is below 75 microns
16 Suspension burning as well as Grate burning takes place in
a) Chain Grate Stoker boiler
b) Spreader Stoker boiler
c) Pulverized fuel boiler
d) Fluidized Bed boiler
17 For complete combustion 1kg sulfur needs theoretically
a) 5.45kg of air
b) 4.35kg of air
c) 3.45kg of air
18 Highest permissible TDS limit is allowed for
a) Economic boiler
b) Water tube boiler
c) Smoke tube boiler
d) Lancashire boiler
19 What is the % of Excess air if CO2% measured is 7.5 and theoretical CO2 is 15%
a) 50% b) 75%
c) 100%d) None of the above
20. The TDS level by Softening process method for boiler water treatment may be
a) reduced
b) increased
c) Both a and b
23 Semi permeable membrane will allow to
23 Flow of minerals and molecules only
24 Flow of water molecules only
25 Both a and b
26 None of the above
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NPC-AIP 2006
Paper 2
22 The operating Excess air percentage is high in

a) Spreader Stoker coal fired boiler
b) Oil fired boiler
c) Bagasse fired boiler
d) Wood fired boiler
23 Boiler replacement may be recommended if boiler is
a) Old and inefficient
b) Over sized for present conditions
c) Not designed for ideal loading conditions
d) All of the above
24 Specific volume of steam increases
a) With increasing pressure
b) With decreasing pressure
c) Does not changes with pressure
25 Latent heat at 1 atm pressure is
a) Zero b) 540 kcal/kg c) Infinite d) None of the above
26 From the steam header, condensate is to be drained for every
a) 10 meter length steam pipe line
b) 20 meter length steam pipe line
c) 30 meter length steam pipe line
d) 50 meter length steam pipe line
27 It is preferable to choose the type of.. trap for draining condensate from steam
header pipeline is
a) TD Trap b) Inverted Bucket Trap
c) a or b d) Float trap
28 Saturated steam will flow at velocity of
a) Upto 40 km/hr b) Upto 70 km/hr
c) Upto 100 km/hr d) Upto 140 km/hr
29 Flash steam can be identified by following
a) Steam blows out continuously in a blue stream
b) Steam blows out continuously in a white stream
c) Steam blows out in Blue
d) Steam blows out in white intermittently
30 Self Recuperative burner used to
a) Preheat the fuel oil
b) Preheat the combustion air
c) Both a and b
31 A Refractory property, PCE is called
a) Preheated cone equivalent
b) Pyrometric cone equivalent
c) Pressurized Cone equilibrium
32 Higher the bulk density of a given refractory, increases
a) its volume stability
b) its heat capacity
c) its resistance to slag penetration
d) All of the above
33 Cold crushing strength is high for
a) Clay refractory b) High Alumina refractory
c) Diatomite solid grade d) Silica refractory
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NPC-AIP 2006
Paper 2
34 Out of 3 Ts of combustion, the fluidized bed combustion mostly utilizesand

.for good combustion
a) Time and Temperature
b) Temperature and turbulence
c) Time and turbulence
35 The size of crushed coal for CFBC boiler
a) 1-10 mm b) 3-12 mm
c) 6-10 mm d) 5-12 mm
36 The overall conversion efficiency of PFBC boiler is higher by ----- % over
conventional power plant
a) ) 2-5% b) 3-6% c) 4-7% d) 5-8%
37 Which of the following is not dependency factor for in bed heat transfer of FBC Boiler
a) Particle size
b) Bed temperature
c) Bed pressure
d) Primary air velocity
38 The amount of fly ash to be handled in FBC boiler is
a)Low when compared to conventional boiler
b)Medium when compared to conventional boiler
c)High when compared to conventional boiler
d)Same when compared to conventional boiler
39 Which of the Cogen system can offer a minimum range of heat to power ratios
a) Back pressure steam turbine
b) Combined Cycle
c) Gas turbine
d) DG sets
40 Cogeneration system is most suitable for

a) Sugar Industry b) Foundry
c) Automobile Engineering d) Oil extraction Industry
41 Best suited fuel for Gas turbine
a) HSD b) Naphtha
c) LSHS d) Kerosene
42 Which of the following gives max electrical efficiency
a) Large gas turbine
b) Reciprocating engines
c) Condensing steam turbine
d) Back pressure steam turbine
o
23 A 2000 kg/hr flue gas is exhausted from DG set at 400 C. Specific heat is 0.25
o
kcal/kg. Ambient temperature is 30 C. What is the Heat available in the flue gas?
23 2,00,000 kcal/hr
24 1,85,000 kcal/hr
25 8,00,000 kcal/hr
26 1,00,000 kcal/hr
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NPC-AIP 2006
Paper 2
44 Heat recovery from the Dryer exhaust air is a good application of.in industry
a) Heat Pump b) Heat Wheels c) Economizer d) Refrigerator
45 Thermo compressor is used for

a) Recovery of flue gas at low temperature
b) Recovery Flash steam from condensate
c) Recovery Vapour from hazards chemical process
d) All of the above
46 The maximum efficiency possible for sensible heat recovery in heat wheel is
a) 25% b) 50%
c) 85% d) 95%
47 HP HE means
a) Heat Pump Heat Exchanger
b) Heat Pipe Heat Exchanger
c) High Pressure Heat Exchanger
48 Ceramic recuperators can be used when the exhaust flue gas temperature available
a) Upto 600 b) 600 to 1000
o
c) More than 1300 Cd) None of the above
49 Maximum Heat transfer occurred in heat treatment furnace process is by
a) Radiation
b) Convection
c) Conduction
d) Convection & Conduction
23 20% make up water is used In an Economic Boiler. The TDS of make up water and
blow down water are 200 ppm and 3000 ppm respectively. What is the blow down
rate?
a) 1.00 b) 1.25 c) 2.00d) 2.25
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NPC-AIP 2006
Paper 2

S-1 A 60 kg/hr of fuel oil (LDO) was fired in process boiler. The actual and theoretical
percentage of carbon-dioxide is 9 and 16% respectively. Assume Theoretical air
required for fuel oil is 14.The specific gravity of oil is 0.88.
Find out the Excess air and calculate the quantity of flue gas
Solution :
% of Excess air = 16 1 x 100 = 77.77%
9
Quantity of flue gas = 60 (14 x 1.78 +1) = 1555.2 kg/hr
S-2 List down ten energy conservation measures in steam system.
23 Usebackpressuresteamturbinestoproducelowersteampressures.
24 Usemoreefficientsteamdesuperheatingmethods.
25 Ensureprocesstemperaturesarecorrectlycontrolled.
26 Maintainlowestacceptableprocesssteampressures.
27 Reducehotwaterwastagetodrain.
28 Removeorblankoffallredundantsteampiping.
29 Ensurecondensateisreturnedorreusedintheprocess.
(6Craiseinfeedwatertemperaturebyeconomiser/condensaterecoverycorrespondstoa
1%savinginfuelconsumption,inboiler)
23 Preheatboilerfeedwater.
24 Recoverboilerblowdown.
25 Checkoperationofsteamtraps.
26 Removeairfromindirectsteamusingequipment
(0.25mmthickairfilmoffersthesameresistancetoheattransferasa330mmthickcopper
wall)
Inspectsteamtrapsregularlyandrepairmalfunctioningtrapspromptly.
S-3 Explain the features of packaged boilers and its features.
Packaged Boiler: The packaged boiler is so called because it comes as a complete

package. Once delivered to site, it requires only the steam, water pipe work, fuel
supply and electrical connections to be made for it to become operational. Package
boilers are generally of shell type with fire tube design so as to achieve high heat
transfer rates by both radiation and convection .
The features of package boilers are:
23 Small combustion space and high heat release rate resulting in faster evaporation.
24 Large number of small diameter tubes leading to good convective heat transfer.
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NPC-AIP 2006
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23 Forced or induced draft systems resulting in good combustion efficiency.

24 Number of passes resulting in better overall heat transfer.
These boilers are classified based on the number of passes the number of times
the hot combustion gases pass through the boiler. The combustion chamber is taken,
as the first pass after which there may be one, two or three sets of fire-tubes.
S-4 In agriculture based industry; wood with 30% moisture was burned in a boiler. The GCV of
wood was 2400 kcal/kg. Energy Manager has suggested to dry the wood in open Sun
drying to reduce the moisture content from 30% to 10% for wood saving. Flue gas
o o
temperature is 180 C. Ambient temperature is 30 C. How much wood can be saved
by this suggestion?
Solution:
CP
Loss due to moisture content in wood = M x [ 584 + [Tf- Ta]
------------------------------- x 100
GCV
Heat saving by solar drying = (0.3-0.1) [ 584+0.45 (180-30)]

-------------------------------------- x
100 2400
= 5.43%
S-5 Discuss Group trapping and Individual trapping.
The initial cost can be reduced by connecting several units to a common steam trap
as shown below. This is known as group trapping. However, it is rarely successful,
since it normally causes water-logging and loss of output. The steam consumption of
a number of units is never the same at a moment of time and therefore, the pressure
in the various steam spaces will also be different. It follows that the pressure at the
drain outlet of a heavily loaded unit will be less than in the case of one that is lightly or
properly loaded. Now, if all these units are connected to a common steam trap, the
condensate from the heavily loaded and therefore lower pressure steam space finds it
difficult to reach the trap as against the higher pressure condensate produced by
lightly or partly loaded unit. The only satisfactory arrangement, thus would be to drain
each steam space with own trap and then connect the outlets of the various traps to
the common condensate return main as
shown below.
S-6 Classify the various types of insulation as per temperature and give an example for each
type.
The Insulation can be classified into three groups according to the temperature
ranges for which they are used.
Low Temperature Insulations (up to 90 C)
This range covers insulating materials for refrigerators, cold and hot water
systems, storage tanks, etc. The commonly used materials are Cork, Wood, 85%
magnesia, Mineral Fibers, Polyurethane and expanded Polystyrene, etc.
Medium Temperature Insulations (90 325 C)
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NPC-AIP 2006
Paper 2
Insulators in this range are used in low temperature, heating and steam
raising equipment, steam lines, flue ducts etc. The types of materials used in
this temperatures range include 85%
Magnesia, Asbestos, Calcium Silicate and Mineral Fibers etc.
High Temperature Insulations (325 C above )
Typical uses of such materials are super heated steam system, oven dryer and
furnaces etc. The most extensively used materials in this range are Asbestos,
Calcium Silicate, Mineral Fibre, Mica and Vermiculite based insulation, Fireclay or
Silica based insulation and Ceramic Fibre.
S-7 Briefly explain mechanical type De-aeration.
Removal of oxygen, carbon dioxide and other non-condensable gases from boiler
feed water is vital to boiler equipment longevity as well as safety of operation.
Mechanical de-aeration
Mechanical de-aeration for the removal of these dissolved gases is typically utilized
prior to the addition of chemical oxygen scavengers. Mechanical de-aeration can be
the most economical. They operate at the boiling point of water at the pressure in
the deaerator.
They can be of vacuum or pressure type.

The vacuum type of de-aerator operates below atmospheric pressure, at about 82
C, can reduce the oxygen content in water to less than 0.02 mg/litre. Vacuum
pumps or steam ejectors are required to maintain the vacuum.
The pressure-type de-aerators operates by allowing steam into the feed water
through a pressure control valve to maintain the desired operating pressure, and
hence temperature at a minimum of 105 C. The steam raises the water temperature
causing the release of O2 and CO2 gases that are then vented from the system. This
type can reduce the oxygen content to 0.005 mg/litre.
S-8 Flash steam is generated at 2 bar from 7 bar condensate water.

Enthalpy of 7 bar condensate = 165.6 kcal/kg
Enthalpy of 2 bar condensate = 120 kcal/kg
Total heat content in flash and steam = 646 kcal/kg
Find out the % of flash steam generation.
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NPC-AIP 2006
Paper 2
Solution:
Flash Steam = S1-S2
--------
L2
= 165.6 120
---------------- x
100 646-120
= 8.7%
S-9 A batch type heat treatment furnace was operating 8 hrs. per day in a foundry
industry. Determine the Heat Loss due to furnace opening which is used for
charging and discharging from the given data
2
Area of door opening = 1.5 m
Factor of total radiation = 0.65

o
Furnace operating Temperature = 1200 C
o
Ambient temperature = 37 C
Solution:
4
Q = 4.88 [ 1200 + 273 ]
------------------------------ x 0.65 x 1.5 x 8
100
= 223993.5 kca;/hr
S-10What are the Benefits of WHR devices implementation in Industry? List down five
WHR sources in a typical industry.
Benefits:
Reduction in the utility consumption & costs, and process cost.

Reduction in pollution: A number of toxic combustible wastes such as
carbon monoxide gas, sour gas, carbon black off gases, oil sludge,
Reduction in equipment sizes: Waste heat recovery reduces the fuel
consumption, which leads to reduction in the flue gas produced. This results in
reduction in equipment sizes of all flue gas handling equipments such as fans,
stacks, ducts, burners, etc.
Reduction in auxiliary energy consumption: Reduction in equipment sizes
gives additional benefits in the form of reduction in auxiliary energy
consumption like electricity for fans, pumps etc..
WHR sources in a typical industry.

23 Heat in flue gases.
24 Heat in vapour streams..
25 Convective and radiant heat Low grade
26 Heat losses in cooling water.
-------- End of Section - II ---------

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NPC-AIP 2006
Paper 2
(i) Answer all Five questions (ii) Each question carries Ten marks
L-1 What is the predominant Hydrocarbon present in the LPG? Calculate the
Theoretical air required for complete combustion of 1 kg of propane with
0.04% Oxygen.
23 Propane and Butane are the predominant Hydroban in LPG
ii) Formula Propane = C3H8

C3H8 + 502 3CO2 + 4H2O
44 + 160 132 + 72
1 kg + 160
------ = 3.64 kg O2
44
Net Oxygen required for complete combustion = 3.64-0.04 =
3.60 kg of Oxygen
Theoretical air required = 3.60
------ = 15.65 kg of air
0.23
L-2 Determine the boiler efficiency by direct method and evaporation ratio from the
following data.
Boiler capacity Rating o
= 10 TPH, F & A 100 C
Fuel oil (LSHS) consumption = 600 lit/hr
Specific gravity of fuel oil = 0.90
Saturated steam generation pressure & 2 o
8 kg/cm (a) and 170 C
Temperature =
Qty. of steam generation = 8 TPH with 0.9 dryness 2fraction
Enthalpy of steam = 660.8 kcal/kg at 8 kg/cm (a)
o
Feed water temperature = 60 C
GCV of fuel oil = 10600 kcal/kg
Solution:
Qty. of steam generation = 8 T/hr
Dryness = 0.9
Pure steam + moisture = 7200 kg/hr + 800 kg/hr
Efficiency by = 7200 (660.8-60) + 800 X 170
--------------------------------------- X 100
Direct method (600 x 0.9) 10600
= 77.95%
Evaporation Ratio = 8000 8000
------------- = -------= 14.81

(600 x0.9) 540
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NPC-AIP 2006
Paper 2
L-3 Find out the pressure drop occurred in 500 meters length of steam pipelines. The bore of
the pipe is 250 mm in horizontal piping. Saturated steam velocity is 20 m/s and friction
factor is 0.005. How much pressure drop will be reduced if pipe dia has increased
from 250 mm to 350 mm.
Solution :
2
( i ) Pressure drop, hf = 4 f LV
-----------
23 gD
2
24 4x0.005x500x20
------------------------------
2 x 9.81 x 250
24 0.815 bar
23 ii ) gf pipe size is increased to 350 mm
2
234 x 0.005 x 500 m (20 m/s)
---------------------------------------
2 x 9.81 x 350 mm
24 0.582 bar
23 Pr. Drop Reduction = 0.815 0.582
23 .233 bar
L-4 Briefly explain the factors influencing cogeneration choice. For a particular site
specific industry.
The selection and operating scheme of a cogeneration system is site-specific and

depends on several factors, as described below:
Base electrical load matching

In this configuration, the cogeneration plant is sized to meet the minimum
electricity demand of the site based on the historical demand curve. The rest
of the needed power is purchased from the utility grid. The thermal energy
requirement of the site could be met by the cogeneration system alone or by
additional boilers. If the thermal energy generated with the base electrical
load exceeds the plants demand and if the situation permits, excess thermal
energy can be exported to neighbouring customers.
Base Thermal Load Matching
It is sized to supply the minimum thermal energy requirement of the site. Stand-by boilers or
burners are operated during periods when the demand for heat is higher.
If the electricity demand of the site exceeds that which can be provided by the prime mover,
then the remaining amount can be purchased from the grid.
Electrical Load Matching
In this option, the facility is totally independent of the power utility grid. All the power
requirements of the site are to be taken into account while sizing the system. This is also
referred to as a stand-alone system. If the thermal energy demand of the site is higher than
that generated by the cogeneration system, auxiliary boilers are used. On the other hand,
when the thermal energy demand is low, some thermal energy is wasted. If there is a
possibility, excess thermal energy can be exported to neighbouring facilities.
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NPC-AIP 2006
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Thermal Load Matching

The cogeneration system is designed to meet the thermal energy requirement of the site at
any time. The prime movers are operated following the thermal demand. During the period
when the electricity demand exceeds the generation capacity, the deficit can be compensated
by power purchased from the grid. Similarly, if the local legislation permits, electricity produced
in excess at any time may be sold to the utility.
L-5 What are the criteria for development of waste heat recovery system in an
industry. Explain the working principle and application of Heat pipes.
i)
The criteria for development of WHR are
Identify the following before selection of WHR devices

23 Sources and use of waste heat
24 Upset conditions if any (back pressure)
23 Availability of space
24 Acid due point problem if
any Review the process flow,
Layout Piping, Instrumentation &
Control Economic analyzer of WHR
Such as Investment, depreciation, pay back period, Commercial availability, etc.
ii)Heat Pipe
The Heat Pipe comprises of three elements - a sealed container, a capillary wick structure and
a working fluid. The capillary wick structure is integrally fabricated into the interior surface of
the container tube and sealed under vacuum. Thermal energy applied to the external surface
of the heat pipe is in equilibrium with its own vapour as the container tube is sealed under
vacuum. Thermal energy applied to the external surface of the heat pipe causes the working
fluid near the surface to evaporate instantaneously. Vapour thus formed absorbs the latent
heat of vapourisation and this part of the heat pipe becomes an evaporator region. The vapour
then travels to the other end the pipe where the thermal energy is removed causing the vapour
to condense into liquid again, thereby giving up the latent heat of the condensation. This part
of the heat pipe works as the condenser region. The condensed liquid then flows back to the
evaporated region. A figure of Heat pipe is shown below
23 Applications in industries are:

23 Preheating of boiler combustion air
24 Recovery of Waste heat from furnaces
25 Reheating of fresh air for hot air driers
26 Recovery of waste heat from catalytic deodorizing equipment
27 Reuse of Furnace waste heat as heat source for other oven
28 Cooling of closed rooms with outside air
29 Preheating of boiler feed water with waste heat recovery from flue gases
30 Drying, curing and baking ovens
End of Section - III ---------
_________________________ 12
NPC-AIP 2006
ModelQuestionPaper2006
NATIONALCERTIFICATIONEXAMINATION
FOR
ENERGYAUDITORSANDENERGYMANAGERS
Duration:3Hrs Max.Marks:150
GeneralInstructions:
Please check that this question paper contains 65 questions The

questionpapersisdividedintothreesections
Allquestionsinallthreesectionsarecompulsory
Allpartsofaquestionshouldbeansweredatoneplace
SectionI:ObjectiveTypeQuestions
0Answerallquestionofthissection.
1Eachquestioncarriesonemark.
2Puta()tickmarkontheappropriateboxintheanswerbook.
0 TheAgradecoalshavecalorificvalue
0 Greaterthen6200kcal/kg
1 Lessthen6200kcal/kg
2 Lessthen1300kcal/kg
3 Greaterthen1300kcal/kg
0 Thesmallestsizeofthecoal(75micron)isrequiredin
0 Fluidizedbedfiring
1 Pulverizedcoalfiring
2 Stokerfiring
3 Handfiring
0 Calorificvalueofliquidandgaseousfuelsisgenerallymeasuredintermsof
3 3
0 kcal/mandkcal/Nm
respectively
1 kcal/Nm3andkcal/m3respectively
2 kcal/kgandkcal/m3respectively
3 kcal/m3andkcal/kgrespectively
0Whichofthefollowingagroresidueshasthelowestgrosscalorificvalue
0 DeoiledBran
1 PaddyHusk
2 Sawdust
3 Coconutshell
0 Underoptimumcombustionconditionoffueloil,thepercentageofoxygeninfluegaswillrangebetween.
0 0to0.1%
1 2to3%
2 12to13%
3 22to23%
0 Heatgeneratedincombustiononperkgbasis,isthehighestfor
0 carbon
1 hydrogen
2 sulpher
3 oxygen
0 AshfusiontemperatureoftypicalIndiancoalis
0500C
1700C
2900C
31100C
0 StoichiometricVolumetricairtofuelratioforcompletecombustionofnaturalgasrangesbetween
23 9.5to10
24 14.5to15
25 18.5to19
26 22.5to23
0 Withincreaseinpercentageofexcessairforcombustionofagivenfuelpercentageofoxygeninflue
gas.
23 increases
24 decreases
25 remainssame
26 noneoftheabove
1 PermissiblelimitofTDSinboiler
a) increases for higher pressure boilers b)
decreases for higher pressing boilers c) is
independentofboilerpressure
d)noneoftheabove
2 Radiationlossesfromaboiler
a) increase with increase in % its loading b)
decrease with increase in % its loading c) are
independentof%itsloading
d)noneoftheabove.
3 Anevaporationratio(steamtofuelratio)ofanefficientoilfiredboilerisintherangeof___.a)56
b) 13 16
c)13
d)79
0 Namethepredominantlosscomponentforfurnaceoilfedboiler.
23 lossesduetoradiationandconvention
24 lossduetohydrogeninfuel
25 lossduetodryfluegas
26 lossduetomoistureinfuel
1 Ariseinconductivityofboilerfeedwaterindicates____.
23 dropinthecontaminationoffeedwater
24 greaterpurityoffeedwater
25 riseinthecontaminationoffeedwater
26 ithasgotnorelationwiththecontaminationoffeedwater
2 Deaerationofboilerfeedwaterisreferredtoas:
23 removalofdissolvedgases
24 removalofsilica
25 removalofscalesbyblowdown
26 phosphatetreatmentoffeedwater
3 F&A(FromandAt)ratingoftheboileristheamountofsteamgeneratedfrom
(a)Waterat0Ctosteamat100C
(b)Waterat27Ctosteamat100C
(c)Waterat77Ctosteamat100C
(d)Waterat100Ctosteamat100C
4 Demineralizationinwatertreatmentmeans
(a)removaloftotalsalts
(b)removalofonlyhardnesssalts
(c)removalofalkalisalts
(d)removalofnonhardnesssalts
5 Chemicaldearetionoffeedwaterwithsodiumsulphateasoxygenscavengerremovesoxygenbut
(a)decreasespHofthewater
(b)decreasesTDSlevelofthewater
(c)increasesTDSlevelofthewater
(d)Noneoftheabove
6 Forindustrialprocessheating,thebestqualityofsteamis:
23 drysaturatedsteam
24 superheatedsteam
25 wetsteam
26 highpressuresteam
7 Forflashsteamcalculation,flashsteamquantityavailabledependsupon___
23 condensatepressureandflashsteampressure
24 pressureofsteamgeneratedinboiler
25 Steamenthalpyatatmosphericpressure
26 Totalheatofflashsteam
0 Latentheatsteamatcriticalpointis
23 Infinite
24 540kcal
25 zero
26 noneofthethree
1 headlossduetoflowofsteaminapipelineisproportionalto
23 velocity4
24 velocity4
25 velocity2
26 velocity2
2 Failuremodeofbucketsteamtrapis
23 open
24 closed
25 noneofthetwo
3 Chancesofwaterhammeringwillbelargestin
23 downinclinedsteamline
24 upinclinedsteamline
25 horizontalsteamline
26 noneoftheabove
4 Thetemperaturemaintainedinforgingfurnacesrangesbetween
23 700850C
24 8501000C
25 10001150C
26 11501250C
5 RadiationRecuperatorsareusedforfluegastemperatureofmorethan
23 800C
24 600C
25 400C
26 200C
6 Thepressuredropastheexhaustgasespassthroughrecuperatorisoftheorderof
23 0.5to1.0mmofH2Ocolumn
24 1.0to5.0mmofH2Ocolumn
25 5.0to10mmofH2Ocolumn
26 10to50mmofH2Ocolumn
7 Toretaintheheatstoredinfurnacewallsitisadvisabletorunabatchfurnaceinbatchforagivenload.
23 48hrseverysixdays
24 8hrsperday
25 24hrseverythirdday
26 noneoftheabove
0 Inlargeglassindustries,theequipmentconnectedwithglassmeltingfurnaceforpreheatingtheairis___.
23 recuperators
24 regenerators
25 shell&tubeheatexchanger
26 heatwheels
1 Thetemperaturewhichseparatesovensfromfurnacesis
23 170C
24 270C
25 370C
26 470C
2 Theaxisoftheoilfiredburnerinafurnaceshouldbekept:
23 slightlyinclinedtowardstheroof
24 moreinclinedtowardsroof
25 slightlyinclinedtowardsthestock
26 paralleltostock
3 Higherexcessairinanoilfiredfurnacewouldresultin:
23 increasedfurnacetemperature
24 increasedheatingrate
25 reducedflametemperature
26 noneoftheabove
4 Whichofthefollowingisorganicinsulatingmaterial
23 ExpandedPolystyrene
24 Calciumsilicate
25 Mineralwool
c)Noneoftheabove
0 Themeltingtemperatureofthepurerefractorycompoundsinhighestfor
23 Alumina
24 Lime
25 Chromite
26 Meginisia
1 Theinsulationmaterialsuitableforlowtemperatureapplicationis
23 Mineralfibre
24 Fibreglass
25 Silica
26 Polyurethane
2 Theunitforthermalconductivityofinsulationandrefractoriesis____.
23 K.cal/mhrC
24 K.cal/mhrC
25 K.cal/mC
26 K.cal/mC
0 Theinsulationwhichcanbeusedforliningfurnacesoperatingupto1850Cis:
23 Alumina
24 Zirconia
25 Dolomite
26 Calciumsilicate
1 ThematerialusedtocontrolSOxintheFBCboileris
23 Limestone
24 Alumina
25 Silica
26 Alloftheabove
2 Thevelocityoffluidizingairinatmosphericfluidizedbedboilerisintherangeof:
23 Higherthan4.5m/sec
24 1.23.7m/sec
25 Lessthan1.2m/sec
26 46m/sec
3 InFBCboilerthecombustioniscarriedoutatatemperature
23 closertosteamtemperature
24 atadiabaticcombustiontemperature
25 atandaboveashfusiontemperature
26 belowashfusiontemperatureoffuelused
4 Residencetimeinfluidizedbedboiler
23 isequaltoconventionalgratefiringboiler
24 islessthenthatinconventionalgratefiringboiler
25 islittlemorethenthatinconventionalgratefiringboiler
26 manytimesmorethenthatinconventionalgratefiringboiler
5 ThecoalsizeusedinAFBCboilerranges.
23 1m10m
24 1mm10mm
25 10mm20mm
26 10m100mm
6 TheoverallconversionefficiencyofaPFBCboilerincogenerationmodeishigherby
23 2025%
24 1012%
25 58%
26 13%
7 Aneconomizerisusedtorecoverwasteheatfromfluegastoheat
23 stock
24 combustionair
25 feedwater
26 roomair
0 Inashellandtubeheatexchanger,thevapourstreamis
23 flowninthetubes
24 containedontheshellside
25 generallynotusedforheatexchange
26 noneoftheabove.
1 Majoradvantageofwasteheatrecoveryinindustryis:
23 reductioninpollution
24 increaseinefficiency
25 botha&b
26 noneoftheabove
2 Ceramicrecuperatorscanwithstandtemperaturesupto:
23 600C
24 1300C
25 1700C
26 950C
3 Inacombinedcyclepowerplantconsistingofgasturbineandwasteheatboiler,theexhaustgastemperatureis
____.
23 around150C
24 around500C
25 around300C
26 around400C
4 Theoverallefficiencyofcombinedcyclecogenerationisoftheorderof:
23 6983
24 9095
25 7090
26 5560
5 Heattopowerratioofcombinedcyclecogenerationisintherangeof
23 4.05.0
24 1.01.7
25 2.010
26 1.05.0
SectionII:ShortDescriptiveQuestions
0 AnswerallTENofthefollowingquestions.
1 EachquestioncarriesFIVEmarks
S1Explainthesignificanceoftheultimateanalysisofthefuelsfromthecombustionpointofview.
Ans. Ultimate analysis of the fuel besides its moisture and ash content gives percentage of various elemental
chemicalconstituentsofthefuelsuchascarbon,hydrogen,oxygen,sulpheretc.Ithelpsinestimatingthe
quantityofstoichiometricairrequiredfor
combustionandvolumeandcompositionofcombustiongases. Thisalsohelpsin
estimatingtheflametemperature,fluegasductdesignandcalorificvalueofthefuel.
S2 Explainwhystacktemperatureinboilerscannotbereducedbelow160170C
Ans. Forfuelscontainingsulpherlowtemperaturesofstackcanleadtosulpherdewpoint
corrosionofchimneyairpreheaterandeconomizer.
S3 Listoutthedatarequiredforcalculationofboilerefficiencyusingindirectmethod.
Ans. Thedatarequiredforcalculationofboilerefficiencyusingindirectmethodare:
Ultimateanalysisoffuel(H2,O2,S,C,moisturecontent,ashcontent)
PercentageofOxygenorCO2inthefluegas
FluegastemperatureinC(Tf)
AmbienttemperatureinC(Ta)&humidityofairinkg/kgofdryair.
GCVoffuelinkcal/kg
Percentagecombustibleinash(incaseofsolidfuels)
GCVofashinkcal/kg(incaseofsolidfuels)
S4 Listthecharacteristicofsteamwhichmakeitmostpopularforcarryingenergy
Ans. a) Highestspecificheatandlatentheat.
0 Highestheattransfercoefficientbothatgenerationandusepoint.
1 Easytocontrolanddistribute.
2 CheapandInert.
3 Source(water)iseasilyavailableinthequantitiesrequiredanywhereanytime.
S5 Explainwhyfurnacesshouldoperateatslightlypositivepressure?
Ans. Itisimportanttooperatefurnaceataslightlypositivepressure.Negativepressureleadtoair
exfiltrationaffectingairfuelratioandfurnacetemperaturethusincreasingfuelconsumption.
Excessivepositivepressureleadstoinfiltrationresultinginleakingoutofflames,overheating
offurnacerefractories,reducedbricklifeandotherassociatedproblems.
S6 Listadvantagesofceramicfibreinsulation?
Theadvantagesare
LowDowntime
Increasedproductivity
Lowmaintenancecost
Longerservicelife
Higherthermalefficiency
Fasterresponse
S7Calculaterateofheatlossfromafurnacewhoseexternalsurface(area20m 2)isattemperature70Cplacedinaroomat
35C
Ans. Rateofheatlossperunitarea=[10+(7035)/20][7035]=411.25kcal/m 2mRateofheatlossfrom

furnace=20x411.25=8225kcal/hr
S8 WhatistheprincipleofCFBC(circulatingfluidizedbedcombustion)boiler?
Ans. CFBC technology utilizes the fluidized bed principle in which crushed (6 12 mm size) fuel and
limestone are injected into the furnace or combustor. The particles are suspended in a stream of
upwardlyflowingair(6070%ofthetotalair),whichentersthebottomofthefurnacethroughair
distributionnozzles.Thebalanceofcombustionairisadmittedabovethebottomofthefurnaceas
secondary air. While combustion takes place at 840900oC, the fine particles (<450 microns) are
elutriatedoutofthefurnacewithfluegasvelocityof46m/s.Theparticlesarethencollectedbythe
solidsseparatorsandcirculatedbackintothefurnace.Thiscombustionprocessiscalledcirculating
fluidizedbed(CFB).
S9DiscusstheadvantageanddisadvantageofReciprocatingengine(Internalcombustionenergy)inthe
cogenerationmode.
Ans. Reciprocatingenginecogenerationsystems
Also known as internal combustion (I. C.) engines, these cogeneration systems have high power
generation efficiencies in comparison with other prime movers. There are two sources of heat for
recovery:exhaustgasathightemperatureandenginejacketcoolingwatersystematlowtemperature
(seeFigure).Asheatrecoverycanbequiteefficientforsmallersystems,thesesystemsaremorepopular
withsmallerenergyconsumingfacilities,particularlythosehavingagreaterneedforelectricitythan
thermalenergyandwherethequalityofheatrequiredisnothigh,e.g.lowpressuresteamorhotwater.
Thoughdieselhasbeenthemostcommonfuelinthepast,theprimemoverscanalsooperatewithheavy
fueloilornaturalgas.Thesemachinesareidealforintermittentoperationandtheirperformanceisnot
assensitivetothechangesinambienttemperaturesasthegasturbines.Thoughtheinitialinvestmenton
thesemachinesislow,theiroperatingandmaintenancecostsarehighduetohighwearandtear.
S10 Brieflyexplaintheprincipleofthermocompression.
Ans Inmanycases,verylowpressuresteamisreusedaswateraftercondensationforlackofanybetter
optionofreuse.Inmanycasesitbecomesfeasibletocompressthislowpressuresteambyveryhigh
pressuresteamandreuseitasamediumpressuresteam.Themajorenergyinsteamisinitslatentheat
valueandthusthermocompressingwouldgivealargeimprovementinwasteheatrecovery.
ThethermocompressorissimpleequipmentwithanozzlewhereHPsteamisacceleratedintoahighvelocity
fluid.ThisentrainstheLPsteambymomentumtransferandthenrecompressesinadivergentventuri.Itis
typicallyusedinevaporatorswheretheboilingsteamisrecompressedandusedasheatingsteam.
SectionII:LongDescriptiveQuestions
0 AnswerallFIVEofthefollowingquestions.
1 EachquestioncarriesTENmarks
L1 Listvariousenergyconservationopportunitiesinaboiler.
Ans. 1. Heatrecoveryfromfluegasthroughairpreheating.
0 Heatrecoveryfromfluegasthroughaneconomizerforfeedwaterheating.
1 ExcessAirControl.
2 Ensurancecompletecombustion
3 ReductioninRadiationandConnectionlossesfromboilershellsurface.
4 Reductioninscaleandsootlosses.
5 Reductioninboilersteampressure.
6 Variablespeedcontroloffans,blowersandpumps
7 AutomaticBlowdowncontrol.
8 ProperBoilerscheduling.
9 Replacementofinefficientboiler.
L2CalculatethetheoreticalairrequirementsforCH4onmassbasisandpercentagevolumeofCO2(ondrybasis)in
fluegas.IftheactualmeasuredvalueofpercentageofCO2influegasis10%,estimateexcessairratio
Ans.CH4+2(O2+3.76N2) =CO2+2H2O+2x3.76xN2
For16kgofCH4massofrequiredair=2x(32+3.76x2.8)=274.56kg
For1kgofCH4massof =17.16kg.
MolesofCO2influegas =1
MolesofN2influegas =2x3.76=7.52
0 molesofCO2influegas(drybasis)=(1/8.52)x100=11.7%
23%volumeofCO2influegas(asper
Avegadroslaw)
Excessair=[theoreticalCO2%/actualCO2%1]x100
=[11.7/101]x100=17%
L3DescribevariousconsiderationinvolvedinretrofittingofFBCsystemstoconventionalsystem.
Ans. Retrofittingfluidisedbedcoalfiredcombustionsystemstoconventionalboilershasbeencarriedout
successfullybothinIndiaandabroad.
Theimportantaspectstobeconsideredinretrofitprojectsare:
0 Water/steamcirculationdesign
1 Furnacebottomgrateclearance
2 Typeofparticulatecontroldevice
3 Fancapacity
4 Availabilityofspace.
Retrofittingofafluidisedbedcombustortoaconventionalstokerfiredwatertubeboilermayinvolve:
0 Thereplacementofgratebyadistributorplatewithshortstandpipesforadmittingairfromthewindbox
locatedunderneath.
1 Installationsofstandpipestoremoveashfromthebed.
2 Provisionofhorizontalhairpintubesinthebedwithapumpforforcedcirculationfromtheboilerdrum.
3 Modification of crusher to size the coal/limestone mixture for pneumatic underbed injection of the
mixture.
Itmaybeemphasisedthatconversionofaconventionalcoalfiredsystemtoafluidisedbedcombustion
systemcanbeaccomplishedwithouteffectingmajorchanges,aftermakingacostbenefitanalysis.Oilfired
boilerscanalsobeconvertedtocoalfiredfluidisedbedcombustionsystems.Howeverithastobeexamined
onacasetocasebasis.
L4Foranextractioncumcondensingturbinefromthegivendiagram,evaluate(i)heatloadoncoolingtower(ii)
powergenerationinMW.
Ans.
P=0.6MPa
T=250C
Q=5MT/h P=0.2MpakJ/cm2
h=2957.2kJ/kg T=150C
Q=50MT/h
P=4.5MPa h=2768.8kJ/kg
T=500C
Q=72MT/h
h=3439.6kJ/kg
P=10kPa
T=45.8C
Q=17MT/hr
hf=191.8kJ/kg
CONDENSOR
Inputheattoturbine :72,000x3439.6=2.477x108kJ/hr=68,792kW
Outputheatatdifferentstreams
1stextraction
:5000x2957.2=0.148x108kJ/hr=4,107kW
2ndextraction :50,000x2957.2=1.384x108kJ/hr=38,456kW
Condenserheatload :17,000x(2768.8191.8)=0.438x108kJ/hr=12169kW
0 Heatloadoncoolingtower:12169kW
1 Heatequivalenttopowergeneration:InputOutput
=68792(4,107+38,456+12,169)
Powergeneration =14,060kW
L5 Whatarewasteheatrecoveryboilers?Explaintheirneedandbenefits?
Ans Waste heat boilers are ordinarily water tube boilers in which the hot exhaust gases from gas
turbines,incinerators,etc.,passoveranumberofparalleltubescontainingwater.Thewateris
vaporizedinthetubesandcollectedinasteamdrumfromwhichitisdrawnoffforuseasheating
orprocessingsteam.Becausetheexhaustgasesareusuallyinthemediumtemperaturerangeandin
ordertoconservespace,amorecompactboilercanbeproducedifthewatertubesarefinnedin
ordertoincreasetheeffectiveheattransferareaonthegasside.Thepressureatwhichthesteamis
generatedandtherateofsteamproductiondependsonthetemperatureofwasteheat.Thepressure
ofapurevaporinthepresenceofitsliquidisafunctionofthetemperatureoftheliquidfrom
whichitisevaporated.Ifthewasteheatintheexhaustgasesisinsufficientforgeneratingthe
requiredamountofprocesssteam,auxiliaryburnerswhichburnfuelinthewasteheatboileroran
afterburnerintheexhaustgasesflueareadded.Wasteheatboilersarebuiltincapacitiesfrom25
m3almost30,000m3/min.ofexhaustgas.
Typicalapplicationsofwasteheatboilersaretorecoverenergyfromtheexhaustsofgasturbines,
reciprocatingengines,incinerators,andfurnaces.
ModelQuestionPaper2006
NATIONALCERTIFICATIONEXAMINATION
FOR
ENERGYAUDITORSANDENERGYMANAGERS
GeneralInstructions:
Please check that this question paper contains 65 questions The

questionpapersisdividedintothreesections
Allquestionsinallthreesectionsarecompulsory
Allpartsofaquestionshouldbeansweredatoneplace
SectionI:ObjectiveTypeQuestions
23 Answerallquestionofthissection.
24 Eachquestioncarriesonemark.
25 Puta()tickmarkontheappropriateboxintheanswerbook.
0 ThecalorificvalueofDgradecoalsvariesbetween
23 2000to3000kcal/kg
0 ThelargedifferencebetweenGCVandNCVofgaseousfuelsisduetotheir
23 largemoisturecontent
24 nomoisturecontent
25 lowhydrogencontent
26 largehydrogencontent
0 Whichofthefollowingagroresidueshasthehighestvolatilemattercontent
23 DeoiledBran
24 PaddyHusk
25 Sawdust
26 Coconutshell
0 Withincreaseinthepercentageofexcessesairforcombustionofagivenfuel,percentageofCO2influegas.
23 increases
24 decreases
25 remainssame
26 noneoftheabove
0 Themassairtofuelratioforcoalsrangesbetween
4 2025
5 1214
6 78
7 12
0 Clinkerhastendencytostickto
23 hotandroughsurfaces
24 hotandsmoothsurfaces
25 coldandroughsurfaces
26 coldandsmoothsurfaces
0 Excessairlevelingasburnersisoftheorderof
23 1%
24 5%
25 11%
26 15%
0 Reductioninexcessairby1%increasestheboilerefficiencyby
23 6%
24 0.6%
25 0.06%
26 0.006%
0 TherecommendedTDSlevelinboilerdrum,thatcanbesafelymaintainedforthewatertubeboileris:
23 30003500ppm
24 2000ppm
25 5000ppm
26 Itcanbeanything
1 Thepercentageexcessairrequiredforpulverisedcoalfiredboileris:
23 4050%
24 1520%
25 6080%
26 3040%
2 Controlledwettingofcoal(duringthecoalpreparation)wouldresultin
23 reductioninfluegasexittemperature
24 decreaseinthepercentageofunburntcarbon
25 impropercombustion
26 increaseinthefinesofcoal
3 Goodopportunityforenergysavingsfromcontinuousblowdownwaterofboilerisby___.
23 reusingthehotwatersoformedasmakeupwater
24 usingtheblowdownsteamtorunsteamturbine
25 utilisationofflashsteamindeaerator
26 noneoftheabove
0 Thepercentageraiseinboilerefficiencybya20degreecentigraderaiseincombustionairtemperatureis___.
23 0.1%
24 0.2%
25 10%
26 1%
1 Thetemperatureinpulverizedcoalfiredboilerfurnacesrangesbetween
(a)13001700C
(b)11001300C
(c)90001100C
(d)700900C
2 Softeninginwatertreatmentmeans
(a)removaloftotalsalts
(b)removalofonlyhardnesssalts
(c)removalofalkalisalts
(d)removalofnonhardnesssalts
3 Chemicaldearetionoffeedwaterwithhydrazineasoxygenscavengerremovesoxygen
(a)butincreasesTDSlevel
(b)withoutanyeffectonTDSlevel
(c)butdecreasesTDSlevel
(d)noneoftheabove
4 Thenormalvelocitiesencounteredinpipesforsuperheatedsteamis
23 5070m/sec
24 3040m/sec
25 2025m/sec
26 1520m/sec
5 Latentheatofsteam
23 decreaseswithpressure
24 increaseswithpressure
25 isindependentofpressure
26 isindependentoftemperature
6 Drainpocketsareprovidedinasteamlinefor
23 storageofsteam
24 storageofcondensate
25 checkingofsteamline
26 effectivelyremovalofcondensatefromtheline
7 Theheadlossinsteamlineforagivenvelocityofsteamisproportionalto
23 D1
24 D2
25 D2
26 D5
0 FailuremodeofFloattrapis
4 open
5 closed
6 noneofthetwo
1 1mliftofcondensatelinewillgeneratebackpressureonthedropequivalentto
4 0.7bar
5 0.5bar
6 0.3bar
7 0.1bar
2 Amodernrecuperatorusedforpreheatingofcombustionairbyheatrecoveryfromfluegascansaveenergyupto
4 50%
5 30%
6 10%
7 5%
3 ConvectiveRecuperatorsarenotusedforfluegastemperatureofmorethen
4 300C
5 500C
6 700C
7 900C
4 Relationtoestimatepercentageofflashsteamgeneratedisgivenby
4 (h1fh2f)/h2fg
5 (h1fh2f)/h1fg
6 h1f/h2fg
7 h2f/h1fg
5 Thehearthpressureintheheatingzoneoffurnaceshouldbe:
4 Slightlynegativepressure
5 Slightlypositivepressure
6 Highnegativepressure
7 Highpositivepressure
6 Incaseoffilmburners,theexcessairlevelmaintainedforoptimumcombustionisoftheorderof___.
4 2025%
5 5to10%
6 15to20%
7 noneoftheabove
7 Theemissivityofceramiccoatingsusedinfurnace:
4 decreaseswithincreaseintemperature
5 Increaseswithincreaseintemperature
6 remainsconstant
7 decreaseswithincreaseinfurnacepressure
0 Instrumentusedformeasuringbillettemperatureinareheatingfurnaceis___.
23 thermograph
24 infraredpyrometer
25 Pt/PtRhthermocouplewithindicator
26 chromealumnelthermocouplewithindicator
1 Thermalefficiencyofreheatingfurnaceisoftheorderof
23 70to80%
24 65to70%
25 40to50%
26 20to40%
2 Whichofthefollowingisinorganicinsulatingmaterial
23 ExpandedPolystyrene
24 PolyUrethane
25 Mineralwool
26 Noneoftheabove
3 Whichofthefollowingwhenaddedtoaluminasilicatehelpstoreducetheshrinkagelevellevelofceramic
fibre
23 ZrO2
24 SiO2
25 Al2O3
26 CaSo2
4 Ceramicfibreinsulationissuitableuptotemperatureof
23 540C
24 1050C
25 1430C
26 1850C
5 Thecoefficientofthermalexpansionofrefractorymaterialshouldbe___.
23 low
24 High
25 Medium
26 veryhigh
6 ThebedtemperatureforaFBCboilerrangesbetween
23 750800C
24 840950C
25 9501000C
26 10001200C
7 FBCboilerhasanadvantageof:
23 Burninghighqualitycoal
24 Burningvarietyliquidfuels
25 Burningwidevarietyofcoal
26 Noneoftheabove
2 The coal particle size used for
CFBCboilerisintherangeof:
2.0 56mm
2.1 612mm
2.2 1215mm
2.3 1525mm
3 Populartypeofboilerusedfor
combinedcyclepowergenerationapplicationis
3.0 CFBC
3.1 AFBC
3.2 PFBC
3.3 Alltheabove
4 In a CFBC boiler the capture
andreceivingofbedmaterialisaccomplishedin
4.0 Settelingchamber
4.1 Cyclone
4.2 Backfilter
4.3 Scrubber
5 The fluidizing velocity in is
AFBCBoilersrangebetween
5.0 7.1m/s9.2m/s
5.1 3.2m/s5.1m/s
5.2 1.2m/s3.7m/s
5.3 0.12m/s0.37m/s
6 In a shell and tube heat
exchanger,thehigherpressure
6.0 liquidflowsinsidethetubes
6.1 gasflowsinsidethetubes
6.2 liquidflowsontheshellside
6.3 gasflowsontheshellside
7 Parallelflowarrangementinsteadofcounterflow
arrangementoftwostreamsinametallicrecuperatorischosenbecause
7.0 combustionairalsoservesthepurposeofcoolingductcarryingthefluegases.
7.1 temperaturedifferencebetweenthetwosteamsisconstantalongtheflowdirection.
7.2 pressuredropsinthetwosteamarelessinthisarrangement
7.3 combustionaircaneasilyentertherecuperatorintheflowdirectionofthefluegases
8 Direct contact heat exchangers
areusedforheatexchange
8.0 exchangebetweentwosteamsofmiscibleliquids
8.1 betweentwosteamsofimmiscibleliquid
8.2 betweentwosteamsofvapours
8.3 betweenvapourandliquidstreams
9 Themajorlimitationofmetallic
recuperatoris
9.0 limitationofhandlingCOx,NOxetc.
9.1 limitationofreducedlifeforhandlingtemperaturemorethan1000C
9.2 manufacturingdifficultyoftherequireddesign
9.3 noneoftheabove
0 Typicalwastegasestemperaturefromglassmeltingfurnace
0.0 1000155C
0.1 800950C
0.2 650750C
0.3 760815C
1 Inalowtomediumtemperaturewasteheatrecoverysystemwhichofthedeviceismostsuitable
1.0 economizer
1.1 heatwheels
1.2 airpreheater
1.3 recuperator
2 Inaglassindustry,exhaustgasfromtheglassmeltingfurnaceisusedforpowergenerationbyinstallingsteam
boilerandturbine.Thenthetypeofcogenerationiscalledas:
2.0 gasturbine
2.1 dieselgenerator
2.2 toppingcycle
2.3 bottomcycle
3 Heattopowerratioinapaperindustryisintherangeof
3.0 1.14.5
3.1 1.52.5
3.2 0.83.0
3.3 1.52.5
4 Aircompressoraloneconsumesaboutoftheenergygeneratedinagasturbine
4.0 2030%
4.1 3040%
4.2 4050%
4.3 5060%
5 Whichoneofthefollowingcannotbeusedasfuelforthegasturbine:
5.0 naphtha
5.1 LPG
5.2 naturalgas
5.3 LSHS
SectionII:ShortDescriptiveQuestions
0 AnswerallTENofthefollowingquestions.
1 EachquestioncarriesFIVEmarks
S1Discussneedofprovidingexcessairforcombustion.Whatisthedisadvantageofprovidingtoomuchofexcessair.
Ans. OptimizingExcessAirforCombustion
Inpractice,mixingisneverperfect,acertainamountofexcessairisneededtocompletecombustionand
ensurethatreleaseoftheentireheatcontainedinfueloil.Iftoomuchairthanwhatisrequiredfor
completingcombustionwereallowedtoenter,additionalheatwouldbelostinheatingthesurplusairto
the chimney temperature. This would result in increased stack losses. Less air would lead to the
incompletecombustionandsmoke.Hence,thereisanoptimumexcessairlevelforeachtypeoffuel.
Forcompletecombustionofeveryonekgoffueloil14.1kgofairisneeded.
Calculatetheblowdownrateforaboilerwithanevaporationrateof5tons/hr,ifthemaximumpermissible
TDSinboilerwateris4000ppmandwith15%makeupwateraddition.ThefeedwaterTDSisaround300
ppm.
S2 Blowdown(%) Feed water TDS% Makeup
PermissibleTDS in Boiler FeedwaterTDS
Ans.
Percentageblowdown=300x15/(4000300)=1.22%
Forboilerevaporationrateis5000kg/hrthenrequiredblowdownrateis:
=5000x1.22/100=60.8kg/hr
S3WriterelationtodeterminepercentagelossduetoevaporationofwaterformedduetoH2inthefuel.
Ans. %ofheatloss=9xpercentageofhydrogeninfuel
[5840.45(Tf Ta)]
100
GCVoffuel (kcal/kg)
WhereTfisthefluegastemperatureinCandT aistheambientairtemperatureinC.
S4 Whysteamcondensaterecoveryisimportant?Explain.
Ans. Thecondensateisveryvaluablenotonlybecauseofitsheatcontentbutalsobecauseof
itspurity.Itisalreadytreatedandanyquantityofcondensaterecoveredwillalsomean
savingoftreatmentchemicalscorrespondingtothatmuchofcondensate.
S5 Explainwhygrouptrappingisnotrecommended
Ans. Thesteamconsumptionofanumberofunitsisneverthesameatamomentoftimeand
therefore,thepressureinthevarioussteamspaceswillalsobedifferent.Itfollowsthatthe
pressureatthedrainoutletofaheavilyloadedunitwillbelessthaninthecaseofonethat
islightlyorproperlyloaded.Now,ifalltheseunitsareconnectedtoacommonsteam
trap,thecondensatefromtheheavilyloadedandthereforelowerpressuresteamspace
findsitdifficulttoreachthetrapasagainstthehigherpressurecondensateproducedby
lightlyorpartlyloadedunit.Theonlysatisfactoryarrangement,thuswouldbetodrain
eachsteamspacewithowntrapandthenconnecttheoutletsofthevarioustrapstothe
commoncondensatereturnmainasshowninabove.
S6 Howdoesceramiccoatingshelpinreducingenergyconsumptioninafurnace?
Ans. Ceramiccoatingsinfurnacechamberpromoterapidandefficienttransferofheat,uniform
heatingandextendedlifeofrefractories.Theemissivityofceramiccoatedrefractories
increaseswithincreaseintemperature.Energysavingstoanorderof8to10%canbe
achievedforhightemperatureapplications.
S7 ListtypicalrefractoriesusedintheIndustry.
Ans. a) Firedayrefractory
b) HighAluminarefractory
c) SilicaBrick
d) Magnesite
e) Chromiterefractory
f) Zinconiarefractory
g) Oxide(alumina)refractory
h) Monolithics
S8 ListadvantagesofCFBCboilersoverAFBCboilers.
Ans. Higherprocessingtemperaturebecauseofhighgasvelocitythroughthesystem.
0Lowercombustiontemperatureofabout870oCcanbeachievedconstantly,whichresultsin
minimalNOxformation.
1Thecombustionairissuppliedat1.5to2psigratherthan3to5psigasrequiredbybubblingbed
combustors.
2Highercombustionefficiency.
3Betterturndownratio.
4Erosionofheattransfersurfaceinthecombustionchamberisreduced,sincethesurfaceis
paralleltotheflow.InAFBCsystem,thesurfaceisgenerallyperpendiculartotheflow.
S9 Explaintheconditionsunderwhichcogenerationcanbemostattractive.
Ans. Cogenerationislikelytobemostattractiveunderthefollowingcircumstances:
23 Thedemandforbothsteamandpowerisbalancedi.e.consistentwiththerangeof
steam:poweroutputratiosthatcanbeobtainedfromasuitablecogenerationplant.
24 A single plant or group of plants has sufficient demand for steam and power to permit
economiesofscaletobeachieved.
25 Peaksandtroughsindemandcanbemanagedor,inthecaseofelectricity,adequatebackupsupplies
canbeobtainedfromtheutilitycompany.
Theratioofheattopowerrequiredbyasitemayvaryduringdifferenttimesofthedayand
seasonsoftheyear.Importingpowerfromthegridcanmakeupashortfallinelectricaloutput
from the cogeneration unit and firing standby boilers can satisfy additional heat demand.
Manylargecogenerationunitsutilizesupplementaryorboostfiringoftheexhaustgasesin
ordertomodifytheheat:powerratioofthesystemtomatchsiteloads.
S10 WhatarethemajorpointstobeconsideredfordevelopmentsofWHRS?
Ans UnderstandingtheprocessisessentialfordevelopmentofWasteHeatRecoverysystem.Thiscanbe
accomplishedbyreviewingtheprocessflowsheets,layoutdiagrams,pipingisometrics,electricaland
instrumentationcableductingetc.Detailreviewofthefollowingdocumentswillhelpinidentifying:
0 Sourcesandusesofwasteheat
1 Upsetconditionsoccurringintheplantduetoheatrecovery
2 Availabilityofspace
3 Anyotherconstraint,suchasdewpointoccurringinanequipmentsetc.
Afteridentifyingsourceofwasteheatandthepossibleuseofit,thenextstepistoselectsuitableheat
recoverysystemandequipmentstorecoverandutilizethesame.
SectionIII:LongDescriptiveQuestions
0 AnswerallFIVEofthefollowingquestions.
1 EachquestioncarriesTENmarks
L1 Enumeratereasonsforincompletecombustionsofsolid,liquidandgaseousfuels.
Ans. IncompleteCombustion
Incompletecombustioncanarisefromashortageofairorsurplusoffuelorpoordistributionof
fuel.Itisusuallyobviousfromthecolourorsmoke,andmustbecorrectedimmediately.Inthecase
ofoilandgasfiredsystems,COorsmoke(foroilfiredsystemsonly)withnormalorhighexcess
airindicatesburnersystemproblems.Amorefrequentcauseofincompletecombustionisthepoor
mixingoffuelandairattheburner.Pooroilfirescanresultfromimproperviscosity,worntips,
carbonizationontipsanddeteriorationofdiffusersorspinnerplates.
Withcoalfiring,unburnedcarboncancompriseabigloss.Itoccursasgritcarryoverorcarboninash
andmayamounttomorethan2%oftheheatsuppliedtotheboiler.Nonuniformfuelsizecouldbeone
of the reasons for incomplete combustion. In chain grate stokers, large lumps will not burn out
completely,whilesmallpiecesandfinesmayblocktheairpassage,thuscausingpoorairdistribution.In
sprinklerstokers,stokergratecondition,fueldistributors,windboxairregulationandoverfiresystems
canaffectcarbonloss.Increaseinthefinesinpulverizedcoalalsoincreasescarbonloss.
L2 Explain why dry saturated steam is preferred over wet or super heated steam for process. Describe various
precaution/measuresonemusttaketosupplysaturatedsteam.
Ans. Thebeststeamforindustrialprocessheatingisthedrysaturatedsteam.Wetsteamreduces
totalheatinthesteam.Alsowaterformsawetfilmonheattransferandoverloadstrapsand
condensateequipment.Superheatedsteamisnotdesirableforprocessheatingbecauseitgives
upheatatarateslowerthanthecondensationheattransferofsaturatedsteam.
It must be remembered that a boiler without a superheater cannot deliver perfectly dry
saturatedsteam.Atbest,itcandeliveronly95%drysteam.Thedrynessfractionofsteam
dependsonvariousfactors,suchasthelevelofwatertobeapartofthesteam.Indeed,evenas
simpleathingasimproperboilerwatertreatmentcanbecomeacauseforwetsteam.
Assteamflowsthroughthepipelines,itundergoesprogressivecondensationduetothelossof
heattothecoldersurroundings,Theextentofthecondensationdependsontheeffectiveness
ofthelagging.Forexample,withpoorlagging,thesteamcanbecomeexcessivelywet.
Sincedrysaturatedsteamisrequiredforprocessequipment,dueattentionmustbepaidtotheboileroperation
andlaggingofthepipelines.
Wetsteamcanreduceplantproductivityandproductquality,andcancausedamagetomostitemsofplantand
equipment.Whilstcarefuldrainageandtrappingcanremovemost
ofthewater,itwillnotdealwiththewaterdropletssuspendedinthesteam.Toremovethesesuspendedwater
droplets,separatorsareinstalledinsteampipelines.
The steam produced in a boiler designed to generate saturated steam is inherently wet.
Althoughthedrynessfractionwillvaryaccordingtothetypeofboiler,mostshelltypesteam
boilerswillproducesteamwithadrynessfractionofbetween95and98%.Thewatercontent
ofthesteamproducedbytheboilerisfurtherincreasedifprimingandcarryoveroccur.
Asteamseparatormaybeinstalledonthesteammainaswellasonthebranchlinestoreduce
wetnessinsteamandimprovethequalityofthesteamgoingtotheunits.Bychangeofdirectionof
steam,steamseperatorscausestheentrainedwaterparticlestobeseparatedoutanddeliveredtoa
pointwheretheycanbedrainedawayascondensatethroughaconventionalsteamtrap.
L3 Inanindustryone40kWhoperatingload,electricalfurnacetobeconvertedintooilfired
furnace.Estimatethefurnaceoil(litre)requirement,consideringthefollowing:
CalorificvalueofFO :9800Kcal/kg
DensityofFO(kg/litreat15C) :0.95
Efficiencyofelectricalfurnace :72%
EfficiencyofFOfiredfurnace :50%
Ans. Operatingelectricalload :40kwh
Efficiencyofelectricalfurnace :72%
Usefulheat :40x860x0.72=24768kcal
FormeetingusefulheatrequiredFO :24768/9800=2.527kg
EfficiencyofFOfiredfurnace :50%
NetFOrequiredtomeetusefulheat :2.527/0.5=5.055kg
Estimatedfurnaceoilquantity :5.055/0.95=5.32lit/hrs
L4 Listmajoradvantageoffluidisedbedcombustion.
Ans. AdvantagesofFluidisedBedCombustionBoilers
01.HighEfficiency
02.ReductioninBoilerSize
03.FuelFlexibility
04.AbilitytoBurnLowGradeFuel
05.AbilitytoBurnFines
06.PollutionControl
07.LowCorrosionandErosion
08.EasierAshRemovalNoClinkerFormation
0 LessExcessAirHigherCO2inFlueGas
1 SimpleOperation,QuickStartUp
2 FastResponsetoLoadFluctuations
3 NoSlaggingintheFurnaceNoSootBlowing
4 ProvisionsofAutomaticCoalandAshHandlingSystem
5 ProvisionofAutomaticIgnitionSystem
6 HighReliability
7 ReducedMaintenance
QuickResponsestoChangingDemand
HighEfficiencyofPowerGeneration
L5 ExplaintheprinciplesofHeatpump.
Ans. Heatmustflowspontaneouslydownhill,thatisfromasystemathightemperaturetooneata
lowertemperature.Itispossibletoreversethedirectionofspontaneousenergyflowbytheuseofa
thermodynamicsystemknownasaheatpump.Thisdeviceconsistsoftwoheatexchangers,a
compressorandanexpansiondevice.Aliquidoramixtureofliquidandvaporofapurechemical
speciesflowsthroughanevaporator,whereitabsorbsheatatlowtemperatureand,indoingso,is
completelyvaporized.Thelowtemperaturevaporiscompressedbyacompressor,whichrequires
externalwork.Theworkdoneonthevaporraisesitspressureandtemperaturetoalevelwhereits
energy becomes available foruse.Thevaporflowsthroughacondenser where it givesupits
energyasitcondensestoaliquid.Theliquidisthenexpandedthroughanexpansionvalvebackto
theevaporatorwherethecyclerepeats.Theheatpumpwasdevelopedasaspaceheatingsystem
wherelowtemperatureenergyfromtheambientair,water,orearthisraisedtoheatingsystem
temperaturesbydoingcompressionworkwithanelectricmotordrivencompressor.
Theheatpumpshavetheabilitytoupgradeheattoavaluemorethantwicethatoftheenergyconsumed
bythedevice.Thepotentialforapplicationofheatpumpisgrowingandnumberofindustrieshavebeen
benefitedbyrecoveringlowgradewasteheatbyupgradingitandusingitinthemainprocessstream.
Heatpumpapplicationsaremostpromisingwhenboththeheatingandcoolingcapabilitiescan
beusedincombination.Onesuchexampleofthisisaplasticsfactorywherechilledwater
fromaheatisusedtocoolinjectionmouldingmachineswhilsttheheatoutputfromtheheat
pumpisusedtoprovidefactoryorofficeheating.Otherexamplesofheatpumpinstallation
includeproductdrying,maintainingdryatmosphereforstorageanddryingcompressedair.
Paper 2 Set A Solutions
Regn No: _________________

Name: ___________________
(To be written by the candidates)

FOR
Please check that this question paper contains 8 printed pages
Please check that this question paper contains 65 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

1. Which of the following is not measured in ultimate analysis?

a) carbon b) sulphur c) hydrogen d) ash
2. With increase in the percentage of excess air for combustion of coal, percentage of
CO2 in flue gas.
a) increases b) decreases c) remains same d) none of the above
3. Which of the following requires the least amount of oxygen /kg for complete
combustion
a) Carbon b) Sulphur c) Hydrogen d) Methane
4. Which of these fuels has the highest heating value?

a) Methane b) Hydrogen c) Diesel d) LPG
5. LPG is predominantly the mixture of Propane and ___

a) Methane b) Ethane c) Butane d) Isopropane
Natural gas consists of mainly the following
a) Ethane b) Methane c) Propane d) Butane

_________________________ 1
7. F & A (from and at) rating of the boiler is the amount of steam generated from
a) water at 0C to saturated steam at 100C
b) water at feed water temperature to saturated steam at 100C

c) water at ambient to saturated steam at 100C
d) water at 100C to saturated steam at 100C
8. The minimum capacity of any closed vessel which generates steam under pressure
as per Indian Boilers Regulation Act is
a) 2.275 litres b) 22.75 kilo litres c) 227.5 litres d) 22.75 litres
9. Automatic blowdown controls for boilers work by sensing

a) TDS b) conductivity c) pH d) conductivity and pH
10. The lowest excess air is required in a

a) coal burner b) low pressure oil burner
c) high pressure gas burner d) high pressure oil burner

11. A boiler generates 8 TPH of steam at an efficiency of 75 %. The enthalpy added to
steam in the boiler is 580 Kcal/kg. The fuel flow rate with a GCV of 3500 kcal/kg is
a) 1452 kg/hr b) 6032 kg/hr c) 4089 kg/hr d) 1768 kg/hr
12. Demineralization of water is the process to remove the dissolved

a) oxygen b) salts c) carbon dioxide d) chlorine

a) removal of dissolved gases b) removal of silica
c) removal of scales d) phosphate treatment of feed water

14. Latent heat of steam at the critical point is
a) infinite b) 540 kcal c) zero d) none of the above
15. Drain pockets are provided in a steam line for

a) effective removal of steam b) removal of dirt
c) checking of steam line d) effective removal of line condensate

16. The purpose of atomisation in an oil fired burner is to
a) increase excess air b) increase the surface area of oil
c) reduce power consumption d) reduce the flue gas temperature

17. The difference in temperature between steam and condensate is the principle of
operation in a
a) thermodynamic trap b) thermostatic trap
c) orifice type trap d) temperature trap

Which of the following benefits is not achieved by maximizing condensate recovery?
a) maximization of boiler output b) reduction in water treatment costs

c) reduction in energy input costs d) minimization of exit flue gas temperature
_________________________ 2
19. Which of the following will be ideal for heat transfer in a heat exchanger
a) super heated steam b) saturated dry steam
c) wet steam d) hot water

20. What is the primary mode of heat transfer in an oil fired melting furnaces
a) convection b) radiation c) conduction d) pulsation
21. Radiation recuperators are used when the furnace flue gas temperature is more than
a) 800C b) 600C c) 400C d) 200C
22. Operating the boiler at a pressure less than 80% of the rated pressure will result in
a) lower boiler exit flue gas temperature
b) reduced boiler feed water pump power

c) increased carryover of water
d) all of the above
23. Amount of oxygen required to burn one kg of hydrogen is
a) 9 b) 8 c) 0.5 d) 3
24. The emissivity of conventional refractory ____ with the increase in temperature
a) increases b) decreases
c) remains the same d) sometimes increases and sometimes decreases

25. Scale losses in reheating furnaces will
a) increase with excess air b) decrease with excess air
c) have no relation with excess air d) increase with CO in combustion gases

26. Steam trap is a device which discharges
a) steam only b) air and incondensable gases only
c) condensate only d) air, incondensable gases and condensate

27. Ceramic coating in furnaces influences
c) emissivity d) radiation factor

28. If the pressure of saturated steam is reduced through a pressure reducing valve
a) it will get superheated b) enthalpy will reduce
c) it will produce wet steam d) enthalpy of evaporation will reduce

29. Alumina is a ____ type of refractory
a) acid b) basic c) neutral d) none of the above
The effect of thermal conductivity on thermal resistance of an insulation
increases with increased thermal conductivity

decreases with decreased thermal conductivity
increases with decreased thermal conductivity
decreases with increased thermal conductivity
_________________________ 3
o
31. If the furnace temperature is T ( K) and the area of opening is A, quantity of radiation
loss in a reheating furnace is directly proportional to
a) T b) A
4
c) A
2
d) T
4
32. The insulating material made by blending and melting of alumina and silica at a
o
temperature of 1800-2000 C is known as
a) insulating brick b) high alumina brick
c) fire brick d) ceramic fibre
33. In a CFBC boiler ____ are required to capture recycled large amount of bed material
a) settling chambers b) mechanical cyclones
c) bag filters d) scrubbers

34. Electrical energy consumption for coal sizing will be maximum for
a) stoker fired boiler b) AFBC boiler
c) CFBC boiler d) pulverised coal boiler

35. For even distribution of fluidized air in AFBC boilers, which one of the following is
used?
a) perforated metal distributor plate b) secondary air from sides
c) compressed air through nozzles d) none of the above

36. Which material is used to control SO2 emissions in FBC boilers
b) lime stone c) silica d) sand
a) CaO
37. The low combustion temperature in FBC Boilers results in minimal formation of
d) CO
a) SOx b) NOx c) CO2
38. The efficiency of a typical FBC boiler is of the order of

a) 30 % b) 40% c) 70% d) 80%
39. The major advantage of the PFBC boilers are

a) low excess air b) low radiation loss
c) low hydrogen loss d) compactness in size

40. A paper plant needs steam at 3 bar and 10 bar in addition to electric power. The
most suitable cogeneration choice among the following will be
a) condensing turbine b) back pressure turbine
c) extraction cum back pressure turbine d) bottoming cycle

41. The cogeneration system which has high overall system efficiency is
a) back pressure steam turbine b) combined cycle
For standalone gas turbines without heat recovery system, the efficiency will be in the range
of
a) 35 to 40% b) 85 to 90% c) 75 to 80% d) 55 to 60%
_________________________ 4
43. In a gas turbine, air compressor alone consumes about _____of the energy
generated
a) 20-30% b) 30-40% c) 40-45% d) 50-60%
44. Which one is the preferred waste heat recovery system in a large gas turbine?
a) economizer b) air pre heater c) boiler d) heat wheel
45. Recuperator as a waste heat recovery system is used mainly in

a) boiler b) reheating furnace
c) compressor d) gas turbine

46. Which of the following works on a refrigeration cycle?
a) heat pipe b) heat wheel
c) heat pump d) thermo compressor

47. Heat transfer by gas radiation in a reheating furnace depends on
a) temperature
b) CO2 concentration
c) water vapor concentration d) all of the above
48. If pressure of saturated steam increases then
a) enthalpy of steam goes up b) enthalpy of steam goes down
c) enthalpy of evaporation goes up d) none of the above

49. Which of the following requires the least amount of oxygen /kg for combustion
a) carbon b) sulphur c) hydrogen d) methane
ThequestionisrepeatofQuestionNo.3.Awardmarkiftheanswerisright.
The amount of carbon dioxide produced by combustion of 1 kg of methane in comparison to

that produced by 1 kg of carbon is
a) more b) less c) same d) data insufficient
-------- End of Section - I ---------
_________________________ 5
Answer all Ten questions

Each question carries Five marks
S-1 What is meant by excess air in combustion systems and discuss the importance
of optimum excess air.
Excess air is the air provided in excess of stoichiometric air to ensure

complete combustion, since mixing between air and fuel is never perfect
in practice.
If too much excess air were allowed to enter, additional heat would be lost by
heating the surplus air to the chimney temperature. This would result in
increased stack (exhaust) losses.
Too much excess air will reduce flame temperature
Too less excess air would lead to the incomplete combustion and smoke.
High excess level increases the scale losses of the material to be heated in
the furnaces.
S-2 List any five energy conservation opportunities in a boiler system.
Reduce stack temperature

Feed water preheating using economizer
Combustion Air preheating
Control Incomplete combustion
Optimise excess air
Blow down heat recovery
Reduction of scaling and soot losses
Variable speed control of fans, blowers and pumps
Optimising efficiency of boiler by loading the boiler to 65-85% of full load
Replacement of old and inefficient boiler

Proper coal sizing to minimse unburnt losses
Proper insulation of boiler to minimize surface/radiation losses
_________________________ 6
S-3 What are the disadvantages of direct method of boiler efficiency evaluation over
the indirect method?
Disadvantage of Direct Method
Does not give clues to the operator as to why boiler efficiency of system is
lower or higher
Does not indicate individual losses accountable for various efficiency levels
If there is wetness in steam it may indicate higher efficiencies than actual

Does not indicate the improvement to be made in various loss areas
Fuel and steam flow measurements are difficult and may not be accurate
Any small error in measurement would lead to large variation in efficiency

levels
S-4 The efficiency of a boiler on GCV basis is 84%. The fuel contains 0.5 % moisture
and 11 % hydrogen. The GCV of fuel is 10,300 Kcal/kg. What is the boiler
efficiency on the basis of net calorific value?
%age of Hydrogen in fuel %age of moisture in fuel

NCV = GCV [9 x ------------------------------------ +--------------------------------] 584
100 100
11 0.5
NCV = 10300 [ 9 x ----- + -------- ] 584

100
10300 [ 9 x 0.11 + 0.005] 584
10300 - 581.08
9718.92
9719 Kcal / Kg
84
Boiler efficiency on NCV = ------ x 10300
9719
= 89.02 %
= 89%
S-5 List any five heat losses occurring in a furnace.

_________________________ 7
Sensible heat loss in flue gas

Loss due to evaporation of moisture present in fuel
Loss due to evaporation of water formed due to hydrogen in fuel
Heat loss due to openings
Heat loss through skin
Heat storage loss
Loss of furnace gases around charging door and opening
Heat loss by incomplete combustion
Loss of heat by conduction through hearth
Loss due to formation of scales
S-6 A boiler generates steam at the rate of 12 ton/hr consuming 2 ton/ hr of coal
having 4500 kcal/kg calorific value. Calculate the evaporation ratio and
efficiency of the boiler if the enthalpy of the generated steam is 722.5 kcal/kg
and feed water temperature is 55C.
1. Evaporation Ratio means Kilogram of steam generated per Kilogram of

fuel consumed
12
Evaporation Ratio = --- = 6
2
2. Efficiency of the boiler

12 ton x 1000 Kg / ton x (722.5 55)
----------------------------------------------------------- x 100
2 ton x 1000 Kg / ton x 4500 Kcal / Kg
89 %
S-7 200 kg/hr of hot condensate from a heat exchanger is coming out at 6 bar (g)
with a sensible heat of 166 kcal/kg. Using a flash vessel, the condensate is
flashed to 1 bar (g) with a sensible heat of 120 kcal/kg and latent heat of 526
kcal/kg. Find out the flash steam generation in kg/hr.
S1 - S2
Flash steam available % =
----------- x 100
L2
S1 = is the sensible heat of higher pressure steam
S = is the sensible heat of the steam at lower pressure

2
L2 = is the latent heat of flash steam (at lower pressure)

_________________________ 8
166- 120
Flash Steam generated = ( -------------- ) x 200 kg/hr

526
= 17.49Kg/hr.
S-8 What is the principle of CFBC (circulating fluidized bed combustion) boiler?
Evenly distributed air is passed upward through a finely divided bed of sand .
As air velocity is gradually increased fluidisation takes place.
At high fluidizing gas velocities a fast recycling bed of fine material is

superimposed on a bubbling bed of larger particles.
The combustion temperature is controlled by rate of recycling of fine material.
Hot fine material is separated from the flue gas by a cyclone and is partially
cooled in a separate low velocity fluidized bed heat exchanger, where the
heat is given up to the steam.
The cooler fine material is then recycled to the dense bed.

6 12 mm size fuel and limestone are injected in to the furnace.
While combustion takes place at 840 900 Deg. C., the fine particles (<450
microns) are elutriated out of the furnaces with flue gas velocity of 4-6
m/s.
S-9 What is heat-to-power ratio of cogeneration system and state its importance?
It is defined as the ratio of thermal energy to electricity required by the energy

consuming facility. It can be expressed in different units KWth / KWe,
Kcal/Kwh, Bth/Kwh, lb/hr/kw.
Heat-to-power ratio is one of the most important technical parameters

influencing the selection of the type of co-generation system.
The heat to power ratio of a facility should match the characteristic of the co-
generation system to be installed.
S-10 Describe in brief the principle of working of heat pipes.

_________________________ 9
The heat pipe comprises of three elements, a sealed container, capillary wick
structure and a working fluid.
Thermal energy applied to the external surface of the heat pipe causes the
working fluid near the surface to evaporate instantaneously.
Vapour thus formed absorbs the latent heat of vapourisation and this part of
the heat pipe becomes an evaporator region.
The vapour then travels to the other end of the pipe where the thermal energy
is removed causing the vapour to condense in to liquid again, thereby
giving up the latent heat of condensation.
The condensed liquid then flows back to the evaporated region.

Heat pipe can transfer upto 100 times more thermal energy than copper.
-------- End of Section - II ---------

_________________________ 10
Answer all Five questions

Each question carries Ten marks
L-1 A chemical plant has an AFBC boiler with the following specifications:
Boiler capacity : 70 TPH
2
Boiler pressure : 60 kg/cm
o
Steam temperature : 500 C
Fuel fired : coal with 35% ash content
GCV of coal : 4000 kcal/kg
Theoretical air for combustion : 5.6 kg/kg of coal
Hydrogen in fuel : 4%
o
Specific heat of flue gas : 0.24 kcal/kg C
Specific heat of superheated water vapor in the flue gas : 0.45 kcal/kg oC
Operating parameters are given below
Flue gas exhaust temperature o
: 160 C
Excess air : 30%
o
Feed water temperature : 105 C
Radiation and other losses : 8%
o
Ambient temperature : 30 C
Calculate the Boiler Efficiency using indirect method on GCV basis.
o 2
If the feed water temperature is 105 C and the steam is produced at 60 kg/ cm &
o
500 C, what is the hourly coal consumption? Total heat of steam at 60 kg/
2 o
cm & 500 C is 817 kcal/kg.
Theoretical air requirement = 5.6 Kg / Kg of coal

Excess Air = 30%
EA
Actual mass of Air supplied = [ 1 + ----- ] x Theoretical Air

100
30
= [ 1 + ---- ] x 5.6
100
= 7.28 Kg of Air / Kg of coal
a) Dry flue gas loss m x Cp x (Tf - Ta)
= ------------------------- x 100
GCV of fuel
Total mass of flue gas (m) = Mass of actual air supplied +
_________________________ 11
Mass of fuel supplied

= 7.28 + 1 = 8.28
8.28 x 0.24 x (160 30)
% Dry flue gas loss =-------------------------------- x 100

4000
6.4584
6.46 %
Heat loss due to evaporation of water formed due to H2 in fuel
9 x H2 x [584 + Cp (Tf Ta)]

= ----------------------------------------------------
GCV of fuel
Where H2 Percentage of H2 in fuel
9 x 4 x [ 584 + 0.45 (160 30) ]

= --------------------------------------------
4000
= 5.7825
= 5.78%
c) Radiation of other losses = 8%
Boiler efficiency = 100 (6.46 + 5.78 + 8)
79.76%
Hourly Coal Consumption
70 x 1000 x (817 105)

= ---------------------------------
0.7976 x 4000
15621.86 Kg / hr
15.621 Ton / hr.
L-2 (a) Briefly explain why the slight positive draft pressure should be maintained in
the furnaces.
(b) Explain the significance of achieving optimum capacity utilisation in furnaces.
_________________________ 12
By maintaining slight positive pressure, air infiltration in the furnace through

openings and cracks is avoided.
Air infiltration results in
higher heat loss due to high excess air

Lowering of the flame and furnace temperature
disturbance of the air fuel ratio control
cold metal and non-uniform metal temperature
increased power consumption of ID fan
increased scale losses
The significance of achieving optimum capacity utilisation in furnaces is to minimize

the proportionate fixed and variable energy losses. This will lead to reduced
specific energy consumption.
If the furnace is underloaded only a smaller fraction of the available heat in

the working chamber will be taken up by the load and leading to higher
variable losses and therefore efficiency will be low.
Fixed losses in the furnace is significant. Lower loading leads to increase in

fixed losses per unit of product.
So optimal loading will result in minimum losses and maximize the efficiency.
L-3 Discuss in detail four major energy conservation opportunities in steam systems.
1. Monitoring Steam Traps

Condensate Discharge
Inverted bucket and the thermodynamic disc traps should have

intermittent condensate discharge
Flout & thermostatic traps should have a continuous condensate

discharge
Thermostatic traps can have either continuous or intermittent

discharge depending upon the load
If inverted bucket traps are used for extremely small loads, it will have
continuous condensate discharge.
_________________________ 13
Flash Steam
If steam blows out continuously in a blue stream, it is leaking steam
If a steam floats out intermittently in a whitish cloud, it is flash steam
Continuous steam blow and no flow indicate, there is a problem in the trap
Wherever a trap fails to operate and the reasons are not readily
apparent, the discharge from the trap should be observed.
Avoiding Steam Leakage
Steam leakage is a visible indicator of waste and must be avoided.

Steam leaks on a high pressure mains are prohibited, costlier than an
low pressure mains. Any steam leakage must be quickly attended to.
Providing Dry Steam for Process
Wet steam reduces total heat in the steam. Also water forms a wet film
on heat transfer and overloads traps and condensate equipment.
Superheated steam is not desirable for process heating because it
gives up heat at a rate slower than the condensation heat transfer of
saturated steam.
Utilising Steam at the Lowest Acceptable pressure for the process

The latent heat in steam reduces as the steam pressure increases
But lower the steam pressure, the lower will be its temperature.
Therefore, there is a limit to the reduction of steam pressure.
Proper Utilisation of Directly Injected Steam
The injected steam should be condensed completely as the bubbles
rise through the liquid. This is possible only if the inlet steam pressure
are kept very low around 0.5 Kg/Sq.Cm. and certainly not exceeding
1 Kg/Sq.Cm. If pressure are high, the velocity of the steam bubbles
will also be high and they will not get sufficient time condense before
they reach the surface.
Miminising Heat Transfer Barrier

_________________________ 14
Heat is transferred from the steam to the material being heated

through an intermediate heating surface which acts as a barrier
between the steam and the material being heated
In case of indirect heating, temperature difference is required to
overcome the resistance of the barrier between the steam and the
material. It is not just the thermal conductivity of the barrier, along side
the heat transfer barrier in an air film as well as scaling on the steam
side and scaling as well as a stagnation product film on the product
side. The barrier which are formed that inspired the flow of heat from
steam to the material. It has been estimated that air is 1500 times
more resistance to heat transfer than steel and to be removed.
Proper Air Venting
Adequate air venting provision should be made at appropriate position

in the pipe lines, to purge out air as quickly as possible from the
equipment.
Condensate Recovery
For every 6 deg. C. rise in the feed water temperature, there will be
approximately 1% saving of fuel in the boiler.
Insulation of steam pipe lines and hot process equipments

Flash Steam Recovery
Flash steam is produced when condensate at a high pressure is

released to a lower pressure. Flash steam from the condensate can be
separated in a equipment called flash vessel.
Reducing the work to be done by steam
When the steam reaches the place where its heat is required, it must
be ensured that the steam has no more work to do than is absolutely
necessary.
Always use the most economical way to removing the bulk of water
from the wet material. Steam can then be used to complete the
process. For this reason, hydro extractors, spin dryers, squeeze or
_________________________ 15
calender rolls, presses etc. are initially used in many drying processes
to remove the mass of water.
L-4 For a backpressure steam turbine with the following operating data, evaluate
the heat to power ratio (kWTH/ kWE) if the turbine and generator efficiencies are
90% and 92% respectively.
Steam inlet conditions to the back Steam outlet conditions of the back
pressure turbine pressure turbine
P = 5.52 MPa P = 1.10 Mpa
T = 538C T = 288C
h = 3515.3 kJ/kg h = 3022.0 kJ/kg
Q = 72 MT/hr hf = 781.7 kJ/kg
3515.3 3022 0.90 x 0.92
Power output = 72 x 1000 x [ ---------- - ------- ] x ----------------

From the generator 4.187 4.187 860
0.90 x 0.92
= 72 x 1000 x [ 839.57 721.75] x ----------------

860
= 8167.39 KW
= 8167 KW
72 x 1000 3022 781.7
Heat Utilistion of Steam = x [ ------ - --------]

-------------------
860 4.187 4.187

72 x 1000
= x (721.75 - 186.69)
---------------------
860
= 44795.72 KW
= 44796 KW
44796
Heat to power ratio =

-----------
8167
= 5.48
_________________________ 16
L-5 The insulation of a steam pipeline is to be upgraded. With the following data
calculate the simple payback period for the insulation upgradation project.
Length of the steam pipeline 100 m

Bare pipe external diameter 100 mm
2
Heat loss from the pipe with existing 2000 kcal/m hr
25 mm insulation thickness
Thickness of insulation to be added 25 mm
2
Heat loss after insulation upgradation 400 Kcal/m /hr
Boiler efficiency 75%
GCV of coal 4000 kcal/kg
Annual operating hours 8000 hrs
Cost of coal Rs. 2000/Ton
Investment for insulation upgradation Rs. 4 lakhs
Ans
Existing heat loss (S1) = 2000 Kcal / Sq. M/hr.
Heat loss after insulation = 400 Kcal / Sq. M. / hr
Upgradation (S2)
Pipe dimension = 100 mm x 100 m length
Surface area existing (A1) = 2

3.14 x 0.15 x 100 = 47.1m
Surface are after insulation (A2) = 3.14 x 0.2 x 100 = 62.8 m2
With additional 25 mm insulation

Total heat loss in existing system(S1 x A1) = 2000 x 47.1
= 94,200 Kcal / hr
Total heat loss in modified system (S2 x A2)
= 400 x 62.8
= 25,120 Kcal / hr
Reduction in heat loss = 94,200 25,120
= 69,080 Kcal / hr
_________________________ 17

69080 x 8000
Annual coal saving = --------------------

0.75 x 4000
= 1,84,213 Kg
= 184 Tons
Annual monetary saving = 184 x 2000 = 3.68 Lakhs
Payback Period = 4 / 3.68
= 1.087 years
= 13 months
_________________________ 18
Paper 2 Set B Solutions
Regn No: _________________

Name: ___________________

FOR

1. Radiation recuperators are used when the furnace flue gas temperature is more than
a) 200C b) 800C c) 600C d) 400C
2. Operating the boiler at a pressure less than 80% of the rated pressure will result in
a) reduced boiler feed water pump power
b) increased carryover of water

c) lower boiler exit flue gas temperature
d) all of the above
3. Amount of oxygen required to burn one kg of hydrogen is
a) 3 b) 9 c) 8 d) 0.5
4. The emissivity of conventional refractory ____ with the increase in temperature

a) sometimes increases and sometimes decreases b) increases
c) decreases d) remains the same

Scale losses in reheating furnaces will
a) increase with CO in combustion gases b) increase with excess air

c) decrease with excess air d) have no relation with excess air
_________________________ 1
6. Steam trap is a device which discharges

a) air, incondensable gases and condensate b) steam only
c) air and incondensable gases only d) condensate only

7. Ceramic coating in furnaces influences
a) radiation factor b) conductivity
c) convective heat transfer coefficient d) emissivity

8. If the pressure of saturated steam is reduced through a pressure reducing valve
a) enthalpy of evaporation will reduce b) it will get superheated
c) enthalpy will reduce d) it will produce wet steam

9. Alumina is a ____ type of refractory
a) basic b) neutral c) acid d) none of the above
10. The effect of thermal conductivity on thermal resistance of an insulation

a) decreases with increased thermal conductivity
b) increases with increased thermal conductivity

c) decreases with decreased thermal conductivity
d) increases with decreased thermal conductivity
a) reciprocating engine b) back pressure steam turbine
c) combined cycle d) extraction condensing steam turbine

12. For standalone gas turbines without heat recovery system, the efficiency will be in
the range of
a) 55 to 60% b) 35 to 40% c) 85 to 90% d) 75 to 80%
generated
a) 50-60% b) 20-30% c) 30-40% d) 40-45%
14. Which one is the preferred waste heat recovery system in a large gas turbine?
a) heat wheel b) economizer c) air preheater d) boiler
15. Recuperator as a waste heat recovery system is used mainly in

a) gas turbine b) boiler
c) reheating furnace d) compressor

a) thermo compressor b) heat pipe
c) heat wheel d) heat pump

Heat transfer by gas radiation in a reheating furnace depends on
a) CO2 concentration b) water vapor concentration

c) temperature d) all of the above
_________________________ 2
18. If pressure of saturated steam increases then

a) enthalpy of steam goes down b) enthalpy of evaporation goes up
c) enthalpy of steam goes up d) none of the above

19. Which of the following requires the least amount of oxygen /kg for combustion
a) methane b) carbon c) sulphur d) hydrogen
20. The amount of carbon dioxide produced by combustion of 1 kg of methane in

comparison to that produced by 1 kg of carbon is
a) data insufficient b) more c) less d) same
21. The lowest excess air is required in a

a) high pressure oil burner b) coal burner
c) low pressure oil burner d) high pressure gas burner

22. Automatic blowdown controls for boilers work by sensing
a) conductivity and pH b) TDS c) conductivity d) pH
23. The minimum capacity of any closed vessel which generates steam under pressure
as per Indian Boilers Regulation Act is
a) 22.75 litres b) 2.275 litres c) 22.75 kilo litres d) 227.5 litres
24. F & A (from and at) rating of the boiler is the amount of steam generated from
a) water at 100C to saturated steam at 100C
b) water at 0C to saturated steam at 100C

c) water at feed water temperature to saturated steam at 100C
d) water at ambient to saturated steam at 100C
25. Natural gas consists of mainly the following
a) Butane b) Ethane c) Methane d) Propane
26. LPG is predominantly the mixture of Propane and ___

a) Isopropane b) Methane c) Ethane d) Butane

a) LPG b) Methane c) Hydrogen d) Diesel
28. Which of the following requires the least amount of oxygen /kg for complete
combustion
a) Methane b) Carbon c) Sulphur d) Hydrogen
29. With increase in the percentage of excess air for combustion of coal, percentage of
CO2 in flue gas.
a) decreases b) remains same c) increases d) none of the above
Which of the following is not measured in ultimate analysis?
a) ash b) carbon c) sulphur d) hydrogen
_________________________ 3
31. A paper plant needs steam at 3 bar and 10 bar in addition to electric power. The
most suitable cogeneration choice among the following will be
a) bottoming cycle b) condensing turbine
c) back pressure turbine d) extraction cum back pressure turbine

32. The major advantage of the PFBC boilers are
a) compactness in size b) low excess air
c) low radiation loss d) low hydrogen loss

33. The efficiency of a typical FBC boiler is of the order of
a) 80% b) 30% c) 40% d) 70%
34. The low combustion temperature in FBC Boilers results in minimal formation of
a) CO b) SOx c) NOx d) CO2
35. Which material is used to control SO2 emissions in FBC boilers

a) sand c) lime stone d) silica
b) CaO
36. For even distribution of fluidized air in AFBC boilers, which one of the following is
used?
a) secondary air from sides b) compressed air through nozzles
c) perforated metal distributor plate d) none of the above

37. Electrical energy consumption for coal sizing will be maximum for
a) pulverised coal boiler b) stoker fired boiler
c) AFBC boiler d) CFBC boiler

38. In a CFBC boiler ____ are required to capture recycled large amount of bed material
a) scrubbers b) settling chambers
c) mechanical cyclones d) bag filters

39. The insulating material made by blending and melting of alumina and silica at a
o
temperature of 1800-2000 C is known as
a) ceramic fibre b) insulating brick
c) high alumina brick d) fire brick

o
40. If the furnace temperature is T ( K) and the area of opening is A, quantity of radiation
loss in a reheating furnace is directly proportional to
a) T
4 b) T c) A
4
d) A
2
41. A boiler generates 8 TPH of steam at an efficiency of 75 %. The enthalpy added to

steam in the boiler is 580 Kcal/kg. The fuel flow rate with a GCV of 3500 kcal/kg is
a) 1768 kg/hr b) 1452 kg/hr c) 6032 kg/hr d) 4089 kg/hr
Demineralization of water is the process to remove the dissolved
a) chlorine b) oxygen c) salts d) carbon dioxide
_________________________ 4

a) phosphate treatment of feed water b) removal of dissolved gases
c) removal of silica d) removal of scales

a) 540 kcal b) zero c) infinite d) none of the above
45. Drain pockets are provided in a steam line for

a) effective removal of line condensate b) effective removal of steam
c) removal of dirt d) checking of steam line

46. The purpose of atomisation in an oil fired burner is to
a) reduce the flue gas temperature b) increase excess air
c) increase the surface area of oil d) reduce power consumption

operation in a
a) temperature trap b) thermodynamic trap
c) thermostatic trap d) orifice type trap

48. Which of the following benefits is not achieved by maximizing condensate recovery?
a) minimization of exit flue gas temperature b) maximization of boiler output
c) reduction in water treatment costs d) reduction in energy input costs

49. Which of the following will be ideal for heat transfer in a heat exchanger
a) hot water b) super heated steam
c) saturated dry steam d) wet steam

What is the primary mode of heat transfer in an oil fired melting furnaces
a) pulsation b) convection c) radiation d) conduction
-------- End of Section - I ---------
_________________________ 5
Answer all Ten questions

S-1 Describe in brief the principle of working of heat pipes.
The heat pipe comprises of three elements, a sealed container, capillary wick
structure and a working fluid.
Thermal energy applied to the external surface of the heat pipe causes the
working fluid near the surface to evaporate instantaneously.
Vapour thus formed absorbs the latent heat of vapourisation and this part of
the heat pipe becomes an evaporator region.
The vapour then travels to the other end of the pipe where the thermal energy
is removed causing the vapour to condense in to liquid again, thereby
giving up the latent heat of condensation.
The condensed liquid then flows back to the evaporated region.

Heat pipe can transfer upto 100 times more thermal energy than copper.
S-2 What is heat-to-power ratio of cogeneration system and state its importance?
It is defined as the ratio of thermal energy to electricity required by the energy

consuming facility. It can be expressed in different units KWth / KWe,
Kcal/Kwh, Bth/Kwh, lb/hr/kw.
Heat-to-power ratio is one of the most important technical parameters

influencing the selection of the type of co-generation system.
The heat to power ratio of a facility should match the characteristic of the co-
generation system to be installed.
S-3 What is the principle of CFBC (circulating fluidized bed combustion) boiler?
Evenly distributed air is passed upward through a finely divided bed of sand .
As air velocity is gradually increased fluidisation takes place.
At high fluidizing gas velocities a fast recycling bed of fine material is
superimposed on a bubbling bed of larger particles.
_________________________ 6
The combustion temperature is controlled by rate of recycling of fine material.
Hot fine material is separated from the flue gas by a cyclone and is partially
cooled in a separate low velocity fluidized bed heat exchanger, where the
heat is given up to the steam.
The cooler fine material is then recycled to the dense bed.

6 12 mm size fuel and limestone are injected in to the furnace.
While combustion takes place at 840 900 Deg. C., the fine particles (<450
microns) are elutriated out of the furnaces with flue gas velocity of 4-6
m/s.
S-4 230 kg/hr of hot condensate from a heat exchanger is coming out at 6 bar (g)
with a sensible heat of 166 kcal/kg. Using a flash vessel, the condensate is
flashed to 1 bar (g) with a sensible heat of 120 kcal/kg and latent heat of 526
kcal/kg. Find out the flash steam generation in kg/hr.
S1 - S2
Flash steam available % = -----------
L2
S2 = is the sensible heat of the steam at lower pressure

166 - 120
Flash Steam generated = ( --------------) 230
526
= 20.11 Kg/hr.
S-5 A boiler generates steam at the rate of 12 ton/hr consuming 2 ton/ hr of coal
having 4300 kcal/kg calorific value. Calculate the evaporation ratio and
efficiency of the boiler if the enthalpy of the generated steam is 722.5 kcal/kg
and feed water temperature is 55C.
Evaporation Ratio means Kilogram of steam generated for Kilogram of fuel

consumed
12
Evaporation Ratio = --- = 6
2
_________________________ 7
2. Efficiency of the boiler

12 ton x 1000 Kg / ton x (722.5 55)
= ----------------------------------------------------------- x 100
2 ton x 1000 Kg / ton x 4300 Kcal / Kg
= 93.13 % = 93%
S-6 List any five heat losses occurring in a furnace.

Loss due to evaporation of moisture present in fuel
Loss due to evaporation of water formed due to hydrogen in fuel
Heat loss due to openings
Heat loss through skin
Heat storage loss
Loss of furnace gases around charging door and opening
Heat loss by incomplete combustion
Loss of heat by conduction through hearth
Loss due to formation of scales
S-7 The efficiency of a boiler on GCV basis is 82%. The fuel contains 0.5 % moisture
and 11 % hydrogen. The GCV of fuel is 10,300 kcal/kg. What is the boiler
efficiency on the basis of net calorific value?
%age of Hydrogen in fuel %age of moisture in fuel

NCV = GCV [9 x ------------------------------------ +--------------------------------] 584
100 100
11 0.5
NCV = 10300 [ 9 x ----- + -------- ] 584

100
10300 [ 9 x 0.11 + 0.005] 584
10300 - 581.08
9718.92
9719 Kcal / Kg
_________________________ 8
82
Boiler efficiency on NCV = ------ x 10300
9719
= 86.90 %
S-8 What are the disadvantages of direct method of boiler efficiency evaluation over
the indirect method?
Disadvantage of Direct Method
Does not give clues to the operator as to why boiler efficiency of system is
lower or higher
Does not indicate individual losses accountable for various efficiency levels

Any small error in measurement would lead to large variation in efficiency

levels
S-9 List any five energy conservation opportunities in a boiler system.
Reduce stack temperature

Combustion Air preheating
Control Incomplete combustion
Optimise excess air
Blow down heat recovery
Variable speed control of fans, blowers and pumps
Optimising efficiency of boiler by loading the boiler to 65-85% of full load
Replacement of old and inefficient boiler

Proper coal sizing to minimse unburnt losses
Proper insulation of boiler to minimize surface/radiation losses
_________________________ 9
S-10 What is meant by excess air in combustion systems and discuss the importance
of optimum excess air.
Excess air is the air provided in excess of stoichiometric air to ensure

complete combustion, since mixing between air and fuel is never perfect
in practice.
If too much excess air were allowed to enter, additional heat would be lost by
heating the surplus air to the chimney temperature. This would result in
increased stack (exhaust) losses.
Too much excess air will reduce flame temperature
Too less excess air would lead to the incomplete combustion and smoke.
High excess level increases the scale losses of the material to be heated in
the furnaces.
-------- End of Section - II ---------
_________________________ 10
Answer all Five questions

L-1 The insulation of a steam pipeline is to be upgraded. With the following data
calculate the simple payback period for the insulation upgradation project.
Length of the steam pipeline 110 m

Bare pipe external diameter 100 mm
2
Heat loss from the pipe with existing 2000 kcal/m hr
25 mm insulation thickness
Thickness of insulation to be added 25 mm
Heat loss after insulation upgradation 400 Kcal/m /hr
2
Boiler efficiency 75%

GCV of coal 4000 kcal/kg
Annual operating hours 8000 hrs
Cost of coal Rs. 2000/Ton
Investment for insulation upgradation Rs. 4 lakhs
Existing heat loss (S1) = 2000 Kcal / Sq. M/hr.

Heat loss after insulation = 400 Kcal / Sq. M. / hr
Upgradation (S2)
Pipe dimension = 100 mm x 110 m length
Surface area existing (A1) = 3.14 x 0.15 x 110 = 51.81 Sq. M.
Surface are after insulation (A2)= 3.14 x 0.2 x 110 = 69.1 Sq. M.
Total heat loss is existing (S1 x A1) = 2000 x 51.81

= 103620 Kcal / hr
Total heat loss in modified system (S2 x A2)
= 400 x 69.1
_________________________ 11
= 27640 Kcal / hr
Reduction in heat loss = 103620 27640
= 75980 Kcal / hr
75980 x 8000
Annual coal saving = --------------------

0.75 x 4000
= 202613 Kg
= 202.6 Tons
Annual monetary saving = 202.6 x 2000 = 4.05 Lakhs
Payback Period = 4 / 4.05
= 0.987
= 1 year
L-2 For a backpressure steam turbine with the following operating data, evaluate the
heat to power ratio (kWTH/ kWE) if the turbine and generator efficiencies are
89% and 91% respectively.
Steam inlet conditions to the back Steam outlet conditions of the back
pressure turbine pressure turbine
P = 5.52 MPa P = 1.10 MPa
T = 538C T = 288C
h = 3515.3 kJ/kg h = 3022.0 kJ/kg
Q = 72 MT/hr hf = 781.7 kJ/kg
3515.3 3022 0.89 x 0.91

Power output = 72 x 1000 x [ ---------- - ------- ] x ----------------
from the generator 4.187 4.187 860
0.89 x 0.91
= 72 x 1000 x [ 839.57 721.75] x ----------------

860
= 7988.85 KW
= 7989 KW
_________________________ 12

72 x 1000 3022 781.7

Heat of Utilistion of Steam = ------------------- x [ ------ - --------]
860 4.187 4.187
72 x 1000
= --------------------- x (721.75 - 186.69)

860
= 44795.72 KW
= 44796 KW
44796
Heat to power ratio = -----------

7989
= 5.60
L-3 Discuss in detail four major energy conservation opportunities in steam
systems.
1. Monitoring Steam Traps

Condensate Discharge
Inverted bucket and the thermodynamic disc traps should have

intermittent condensate discharge
Flout & thermostatic traps should have a continuous condensate

discharge
Thermostatic traps can have either continuous or intermittent

discharge depending upon the load
If inverted bucket traps are used for extremely small loads, it will have
continuous condensate discharge.
Flash Steam
If steam blows out continuously in a blue stream, it is leaking steam
If a steam floats out intermittently in a whitish cloud, it is flash steam
_________________________ 13
Continuous steam blow and no flow indicate, there is a problem in the trap
Wherever a trap fails to operate and the reasons are not readily
apparent, the discharge from the trap should be observed.
Steam leakage is a visible indicator of waste and must be avoided.

Steam leaks on a high pressure mains are prohibited, costlier than an
low pressure mains. Any steam leakage must be quickly attended to.
Wet steam reduces total heat in the steam. Also water forms a wet film
on heat transfer and overloads traps and condensate equipment.
Superheated steam is not desirable for process heating because it
gives up heat at a rate slower than the condensation heat transfer of
saturated steam.
Utilising Steam at the Lowest Acceptable pressure for the process

The latent heat in steam reduces as the steam pressure increases
But lower the steam pressure, the lower will be its temperature.
Therefore, there is a limit to the reduction of steam pressure.
The injected steam should be condensed completely as the bubbles
rise through the liquid. This is possible only if the inlet steam pressure
are kept very low around 0.5 Kg/Sq.Cm. and certainly not exceeding
1 Kg/Sq.Cm. If pressure are high, the velocity of the steam bubbles
will also be high and they will not get sufficient time condense before
they reach the surface.
Heat is transferred from the steam to the material being heated

through an intermediate heating surface which acts as a barrier
between the steam and the material being heated
In case of indirect heating, temperature difference is required to
overcome the resistance of the barrier between the steam and the
_________________________ 14
material. It is not just the thermal conductivity of the barrier, along side
the heat transfer barrier in an air film as well as scaling on the steam
side and scaling as well as a stagnation product film on the product
side. The barrier which are formed that inspired the flow of heat from
steam to the material. It has been estimated that air is 1500 times
more resistance to heat transfer than steel and to be removed.
Proper Air Venting
Adequate air venting provision should be made at appropriate position

in the pipe lines, to purge out air as quickly as possible from the
equipment.
Condensate Recovery
For every 6 deg. C. rise in the feed water temperature, there will be
approximately 1% saving of fuel in the boiler.

Flash steam is produced when condensate at a high pressure is

released to a lower pressure. Flash steam from the condensate can be
separated in a equipment called flash vessel.
When the steam reaches the place where its heat is required, it must
be ensured that the steam has no more work to do than is absolutely
necessary.
Always use the most economical way to removing the bulk of water
from the wet material. Steam can then be used to complete the
process. For this reason, hydro extractors, spin dryers, squeeze or
calender rolls, presses etc. are initially used in many drying processes
to remove the mass of water.
L-4 (a) Briefly explain why the slight positive draft pressure should be maintained in
the furnaces.
(b) Explain the significance of achieving optimum capacity utilisation in furnaces.
_________________________ 15
By maintaining slight positive pressure, air infiltration in the furnace through

openings and cracks is avoided.
Air infiltration results in
higher heat loss due to high excess air

Lowering of the flame and furnace temperature
disturbance of the air fuel ratio control
cold metal and non-uniform metal temperature
increased power consumption of ID fan
increased scale losses
The significance of achieving optimum capacity utilisation in furnaces is to minimize

the proportionate fixed and variable energy losses. This will lead to reduced
specific energy consumption.
If the furnace is underloaded only a smaller fraction of the available heat in

the working chamber will be taken up by the load and leading to higher
variable losses and therefore efficiency will be low.
Fixed losses in the furnace is significant. Lower loading leads to increase in

fixed losses per unit of product.
So optimal loading will result in minimum losses and maximize the efficiency.
_________________________ 16
L-5 A chemical plant has an AFBC boiler with the following specifications:
Boiler capacity : 70 TPH
2
Boiler pressure : 60 kg/cm
o
Steam temperature : 500 C
Fuel fired : coal with 35% ash content
GCV of coal : 4100 kcal/kg
Theoretical air for combustion : 5.6 kg/kg of coal
Hydrogen in fuel : 4%
o
Specific heat of flue gas : 0.24 kcal/kg C
Specific heat of superheated water vapor in the flue gas : 0.45 kcal/kg oC
Operating parameters are given below
Flue gas exhaust temperature : 160oC
Excess air : 30%
o
Radiation and other losses : 8%
o
Calculate the Boiler Efficiency using indirect method on GCV basis.
o 2
If the feed water temperature is 110 C and the steam is produced at 60 kg/ cm &
o
500 C, what is the hourly coal consumption? Total heat of steam at 60 kg/
2 o
cm & 500 C is 817 kcal/kg.
Theoretical air requirement = 5.6 Kg / Kg of coal

Excess Air = 30%
EA
Actual mass of Air supplied = [ 1 + ----- ] x Theoretical Air
100
30
= [1+]x5.6
100
= 7.28 Kg of Air / Kg of coal
a) Dry flue gas loss m x Cp x (Tf - Ta)
= x 100
-------------------------
GCV of fuel
Total mass of flue gas (m) = Mass of actual air supplied +
Mass of fuel supplied

= 7.28 + 1 = 8.28
_________________________ 17
8.28 x 0.24 x (160 30)

% Dry flue gas loss = -------------------------------- x 100
4100
6.30 %
Heat loss due to evaporation of water formed due to H2 in fuel
9 x H2 x [584 + Cp (Tf Ta)]

= ----------------------------------------------------
GCV of fuel
Where H2 Percentage of H2 in fuel
9 x 4 x [ 584 + 0.45 (160 30) ]

= --------------------------------------------
4100
= 5.64 %
c) Radiation of other losses = 8%
Boiler efficiency = 100 (6.30 + 5.64 + 8)
80.06%
Hourly Coal Consumption
70 x 1000 x (817 105)

= ---------------------------------
0.8006 x 4100
15183.73 Kg / hr
15.183 Ton / hr.

_________________________ 18
Paper 2 Set A- SOLUTION
Regn No: _________________

Name: ___________________

FOR


Please hatch the appropriate oval in the OMR answer sheet with HB Pencil, as per
instructions
With increase in excess air for combustion which of the following will result in flue gas
% Oxygen decreases b) % CO2 decreases c) % Oxygen and CO2 decreases d) %

Oxygen and CO2 increases
2. Sulphur percentage in furnace oil

a) sets lower flue gas temperature limit b) improves viscosity c) does not add to heat
value d) forms soot
3. Stoichiometric air ratio for burning 1Kg of carbon is

a)3.76 b)10 c)11.6 d)None of the above
4. Carpet loss occurs in

a) Coal combustion b) atomization of oil c) furnaces d) coal storage
5. Excess air can be derived by measuring percentage of ____________ in flue gas

a) CO2 b) NO2c) CO d) CH4
6. For coal fired system the flame length is dictated by:

BEE-2007 Paper-2:Set-A-Key 1
a)moisture b) volatile matter. c)ash content. d)fixed carbon.
7. Deaeration in boiler removes

a) CO2 in flue gas b) O2 in feed water c) O2 in fuel d) O2 in fluel gas
8. In pure stoichiometric combustion of furnace oil which of the following will be absent in flue
gas ?
a) nitrogen b) carbon dioxide c) oxygend) sulphur dioxide
9. When pure hydrogen is burned, with theoretical air, the volume percentage of nitrogen in
flue gas on dry basis will be
a) 100% b) 79% c) 21% d) 0%
10. The factor that influences atomization of fuel oil the most is
a) density b) flash point c) pour point d) viscosity
11. In oil firing burners

a) primary air is used for creating turbulence and secondary air for completion of
combustion
b) primary air is used for cooling oil and secondary air for completion of the combustion c)
primary air is used for completion of the combustion and secondary air for creating
turbulence
d) Primary air is used for atomizations of oil and secondary air for completion of the
combustion.
12. Which of the following will require minimum excess air for combustion
a) fluidized bed boiler b) spreader stoker boiler c) pulverized coal fired boiler
d) manually fired boiler
13. Turndown ratio for burners is the ratio of

a) air to fuel b) maximum fuel input to actual fuel input c) maximum fuel input over
minimum fuel input d) maximum air input over minimum air input
14. Boiler Evaporation ratio is the amount of steam generated in kg

2
a) per unit time b) per kg of fuel burnt c) per m of boiler surface area d) per kg of
makeup water.
15. For equal capacity, the boiler size is the smallest for
a) AFBC b) CFBC c) PFBC d) Pulverized coil fired boiler
16. De-aeration of boiler feed water helps in combating

a) corrosion. b)TDS c) silica d) hardness
17. For industrial process indirect heating, the best quality of steam is
a) dry saturated steam b) superheated steam c) wet steam d) high pressure steam
18. Which one of the following cannot be used as fuel for the gas turbine
a) naphtha b) LPG c) natural gas d) LSHS
19. The content of solid left in the oven after volatile matter is distilled off (while analysing the
composition of coal in a laboratory) is ___.
a) only sulphur b)only moisture c)only ash d) mix of fixed carbon and ash
20. Wetting of coal with water in boiler helps in

a) increasing the calorific value of the coal b) keeping boiler grate cooled c) increasing the
furnace draft velocity d)stopping coal fines to fall through grate and being carried
away with furnace draft
21. The percentage radiation loss from a boiler will

a) increase with increased loading b) decreases with increased loading c) is
independent of loading d) none of the above

a)reducing dosage of chemicals b)steam venting c)blowdown d)deaeration
23. Which fuel uses the lowest amount of excess air during combustion process?
a) pulverised coal b) bagasse c)fuel oil d) natural gas.
24. Pre-heating of combustion air by 1000C will save about ------% of fuel.
a)0.5 b)5 c)7 d)None of the above
0
25. Increase in feed water temperature by 30 C for an oil fired boiler results in a savings of -----
-% of fuel.
a) 1 b) 5 c) 4 d) None of the above.
26. Which data is not required in calculation of thermal efficiency of boiler by indirect method
a)blow down quantity b)calorific value of fuel c)excess air level d)flue gas temperature.
27. Moisture in combustion air

a) contributes to latent heat loss but not sensible heat loss in flue gas b) does not
contribute to latent heat loss but contribute to sensible heat loss in flue gas c) does
not contribute to latent heat loss and sensible heat loss in flue gas d) contributes to both
the latent heat loss and sensible heat loss in flue gas.
28. Steam should always be generated and utilized at

a) same pressure b) lowest pressure and highest pressure respectively c) highest
pressure and lowest pressure respectively d) atmospheric pressure
29. Velocity of steam in a pipe depends on

a)number of bends b)length of pipe c)specific volume of steam d)none of the
above.
30. Which of the following is not true of steam ?

a) highest specific heat and latent heat b) low heat transfer coefficient c) easy to control
and distribute d) cheap and inert
31. At the critical point of steam

o
a) boiling point is 0 C b) sensible heat is zero c) enthalpy of evaporation is zero d) total
enthalpy is zero
32. What type of steam is generally used for power generation

a) high pressure steam with super heat b) dry saturated low pressure steam c) dry
saturated steam with high pressure d) wet steam with very high pressure
33. Air must be removed from steam line as

a) It reduces partial pressure of steam and decreases thermal resistance to heat transfer
b) It increase partial pressure of steam and decrease thermal resistance to heat transfer
c) It increases saturation temperature of steam and increases thermal resistance to heat
transfer
d) It reduce saturation temperature of steam and increase thermal resistance to heat
transfer
34. For flash steam calculation, flash steam quantity available depends upon ___
a) condensate pressure and flash steam pressure b) pressure of steam generated in
boiler c) steam enthalpy at atmospheric pressure d) total heat of flash steam
35. A bimetallic strip is used in which of the following traps

a) float trap b) thermodynamic c) inverted bucket d) thermostatic
36. Which of the energy saving measures will not be applicable for a heat treatment furnace
a) complete combustion with minimum excess air b) waste heat recovery from the flue
gases c) optimum capacity utilization d) heat recovery from furnace openings
37. Maximum heat transfer to the stock in a reheating furnace is by

a) radiation b) conduction c) convection d) none of these
38. High emissivity coatings are most effective on

a)outer surface of furnace b)inner surface of furnace
c)furnace charge d)none of the above

a)reducing surface heat loss b)preheating Combustion air.
c) maintaining high levels of excess air d)minimising unburnt losses
40. Major heat loss in an furnace is accounted by

a)radiation . b)openings. c)sensible heat in exit flue gas d)hydrogen in fuel
41. Ceramic fibre gives the maximum savings when used in

a) continuous furnace b) batch furnace c) arc furnace d) induction furnace
42. In determining the optimal economic insulation thickness for a steam pipeline, thickness
which of the following factors need not be considered
a) annual hours of operation b) calorific value c) pipe material d) cost of fuel
43. Magnesite, chrome-magnesite, dolomite are examples of --------- type of refractory

44. For same inlet conditions of the steam which of the following will generate the maximum
mechanical power
a) condensing turbine b) back pressure turbine c) extraction-cum-condensing turbine
b) extraction-cum-back pressure turbine
45. Co-generation is also known as

a)Re-generation system b)Brayton system
c)Combined heat and power system d)Reversible system
46. An axial compressor is used in conjunction with which of the following

a) Back pressure steam turbine b) Condensing turbine c) Gas turbine d) none of the
above
47. Which is not a property of Ceramic fibre insulation

a) low thermal conductivity b) light weight c) high heat storage d) thermal shock resistant
48. Chances of NOx formation are least in

a) Chain grate stoker boiler b) Spreader stoker boiler c) Pulverized coal fired boiler d)
FBC boilers
49. Quality of waste heat in flue gas refers to

a) dust concentration in flue gas b) temperature c) moisture in flue gas d)
corrosive gases in flue gas
50. The heat recovery device in which high conductivity bricks are used storing heat is
a) heat pipeb) heat pump c) thermo compressor d) regenerator
----------------------End of Section - I----------------------

Section II:SHORT TYPE QUESTIONS (Total 50 marks)

(10 questions x 5 marks each )
S.1 Discuss the role of three Ts in efficient combustion process
Ans
3 Ts of Combustion
The objective of good combustion is to release all of the heat in the fuel. This is accomplished
by controlling the "three T's" of combustion which are (1) Temperature high enough to ignite
and maintain ignition of the fuel, (2) Turbulence or intimate mixing of the fuel and oxygen, and
(3) Time sufficient for complete combustion.
For sustained combustion the temperature of fuel/air mixture must be at temperature above
ignition temperature. Air contains 21% O2 and 79% N2 only O2 takes part in combustion
process. For combustion each fuel molecule must be in contact with at least required number
of molecules (theoretical) of O2. This is only possible when fuel and O2 is mixed on molecule to
molecule basis. This complete mixing will require turbulence in fuel in gaseous from and air. To
ensure that each gaseous molecule meets the O 2 molecule, the fuel air mixture must stay for
sufficient longer period in region where temperature is more than the ignition temperature
(Furnace chamber).
S-2 In a natural gas fired boiler the air to fuel ratio is maintained at 10Nm3/Nm3 of gas. An air
preheater is installed to preheat combustion air at 30C. The flue gas temperature
decreases from 230C to 170C. Estimate the rise in temperature of the ambient air
assuming that the specific heat of flue gas and ambient air is equal.
Ans. Ratio of volume flow rate flue gas to that of combustion air = 11/10
Va.a.Cpa (Toa-Tia) = Vf.f. Cpf. (Tof-Tif)
Ratio of density of flue gas to that of combustion air = 27330 303
273230 503
Vf .f
Toa = Tia + . (Tof Tif) = 30 + 11/10 x 303/503 x (230-170)
Va.a
70C
(or)
If density correction is ignored
Va.Cpa (Toa-Tia) = Vf.Cpf. (Tof-Tif)
Vf .
Toa = Tia + . (Tof Tif) = 30 + 11/10 x 303/503 x (230-170)
Va.
30 + 11/10 x (230-170)
96C
S-3 Draw a schematic diagram of a combined cycle power plant

S-4 List five benefits of condensate recovery in a process plant
0
For every 6 C rise in the feed water temperature, there will be approximately 1%
saving of fuel in the boiler. So financial benefits.
Reduction in Water charges
Minimising effluent temperature and hence adhering to effluent restrictions
Maximises boiler output
Better boiler feedwater quality
S-5 A boiler generates saturated steam at 15 atmosphere absolute pressure (h g = 666 kcal/kg).
If the feedwater temperature is 60C (hf = 60 kcal/kg), for evaporation ratio of 6 for a particular
fuel (GCV of fuel = 4200 kcal/kg), estimate the boiler efficiency.
Ans.
= Q(hg hf ) x 100
GCV
6(66660)x 100
4200
86.6%
S-6 Explain the importance of draft in a reheating furnace
High negative pressures leads to air infiltration- affecting air-fuel ratio control, problems of
cold metal and non-uniform metal temperatures.
High positive Pressure leads to Ex-filtration -Problems of leaping out of flames, overheating
of refractories,burning out of ducts etc.
Hence the optimum condition is to maintain a slightly positive pressure
S.7 A boiler is generating steam at 5500 kgs/hr. The maximum permissible limit of TDS in the
boiler is 3500 ppm. If the make up water is 40% at a TDS level of 350 ppm, calculate the
blowdown percentage and blow down rate.
350 40
Ans. Blow down percentage = = 4%
3500
Blow down rate = 5500 x 0.04 = 220 kg/hr.
S.8 Howdoesathermocompressorwork?Explainbrieflywithasketch
In a thermocompressor low pressure steam is converted to medium pressure steam by

using high pressure steam. The thermocompressor is a simple equipment with a
nozzle where HP steam is accelerated into a high velocity fluid. This entrains the LP
steam by momentum transfer and then recompresses in a divergent venturi.
.
S-9 For a coal containing 5% hydrogen (GCV = 5500 kcal/kg), estimates the percentage of
sensible and latent heat loss due to evaporation of water formed due to hydrogen in the fuel, if
the flue gas temperature is 180C and combustion air temperature is 40C.
0
(latent heat of vapours = 584 Kcal/kg, specific heat of vapours = 0.45 kcal/kg/ C)
Ans. For 0.05 kg of hydrogen per kg of fuel, water generated is = 9 x 0.05 = 0.45 kg
0.45 0.45 (180 40)

Percentage Sensible Heat Loss = mCp (Tf-Ta)/GCV = = 0.52%
5500
mh fg 0.45x584
Percentage Latent Heat Loss = = = 4.78%
GCV 5500
S-10 Explain the working of a float trap with a sketch.
or
Float traps operate in a very similar way to a ball cock. A float contained within the trap body is raised or
lowered by the volume of condensate delivered to the trap. As increasing levels of condensate raise the
ball float, the mechanism lifts a valve allowing condensate to discharge thus lowering the level of
condensate within the trap. The trap eventually closes preventing the further passage of steam.
The trap will remain closed and partially flooded unless there is a sufficient level of condensate within
the trap. At start up any air ahead of the steam and condensate will not therefore be vented.
Consequently it is necessary to incorporate an air cock or a balanced pressure device (as described
above) to release air in the trap.
:80%
:Rs20,000/tonne.
0
:10300k.cal/kg :170 C
0
:50 C
0
:30 C
Long questions
L-1 A steam pipeline of 100mm diameter is not insulated for 100 metre length, supplying steam at 10
2
kg/cm .Find out the fuel savings if it is properly insulated with 50mm insulating material.Assume
8000 hours of operation per year.
Given:
Boiler efficiency
Cost of fuel oil
Gross Calorific value of fuel
Surface temperature without insulation
Surface temperature after insulation
Ambient temperature
Existing Heat Loss:

Surface heat loss S= 10+(Ts Ta)/20 x(Ts-Ta)
0
Where Ts =Hot surface temperature C
0
Ta =Ambient temperature C
2
S =Surface heat loss in k.Cal/hrm
Substituting values S= 10+(170 30)/20 x(170-30)
2
=2380 k.Cal/ hr-m
Modified System :
After insulating with 50mm insulating material the surface temperature has reduced to
0
50 C
2
=220 k.Cal/ hrm
Calculation of Fuel savings:
Pipe dimension =100 metre length and 100mm diameter

2
Surface area existing =3.14x 0.1x 100 =31.4 m
2
Surface area after insulation =3.14x0.2x100 =62.8 m
Total heat loss in existing system =2380x31.4 =74732 k.Cal/hr
Total heat loss in modified system=220x62.8 =13816 k.Cal/hr
Reduction in heat loss =74732-13816 =60916 k.Cal/hr

No of operating hours per annum =8000
Savings in heat per year =60916x8000 =487328000 k.Cal/year
Annual savings in fuel oil =487328000/(10300x0.8)x1000 = 59.142Tons

Monetary savings per annum =59.142x20000 =Rs11.83 lakhs
L-2 Compare the cost of power generation from a gas turbine installed with a 10 TPH
wast heat recovery boiler vis-a-vis grid supply.
The operational data are as under:

Capacity of gas turbine :5000kW
Auxiliary power consumption :1%
Operating hours per annum :8000
Plant load factor :90%
Heat rate : 3050k.Cal/kWh
3
Calorific value of natural gas : 9500k.Cal/sm
3
Cost of gas :Rs.6000/1000 sm
Cost of capital and operation W.H.R
charges per annum of gas turbine and boiler : Rs.600 lakhs
Cost of electric power from grid :Rs 4.5/kWh
(Demand and energy charges)
5
Power generation from Cogeneration 5000x(90/100)x8000 =360x10 kWh
plant
Auxiliary power consumption 1%

5
360x10 x 0.01
5
3.6 x 10
5 5
360x10 - 3.6 x 10
5
Net power generated 356.4 x 10
5
Natural gas required for above generation (360 x 10 )x3050/9500
5 3
115.57 x10 sm
5
Cost of fuel per annum 115.57 x10 x6000/1000
693.42 lakhs
Cost of capital and operation charges Rs 600 lakhs

Total cost of power from Cogeneration 693.42 + 600
plant
1293.42 lakhs
Cost of Cogenerated power Rs1293.42/356.4 =Rs3.63/kWh

Cost of grid power Rs 4.50/kWh
Cost of cogeneration power is cheaper by Rs 0.87/kWh
L-3
An oil fired boiler uses furnace oil with ultimate analysis of Sulpher 3%, Hydrogen 12%, Carbon
84% and oxygen 1% and gross calorific value of 10,268 kcal/kg. The boiler furnace is operated
with 15% excess air at 27C and humidity ratio 0.0175. If the flue gas temperature is 280C,
determine the dry flue gas losses and latent heat loss due to evaporation of water.
Ans. For 100 kg of oil
Combustion of carbon C + O2 = CO2

32
Theoretical O2 required = x 84 = 224 kg
12
44
CO2 produced = x 84 = 308 kg
12
Combustion of hydrogen 2H2 + O2 = 2H2O
Theoretical O2 required = 32 x 12 = 96 kg
4
H2O produced = 36 x 12 = 108 kg
4
Combustion of sulphur S + O2 = SO 2
Theoretical O2 required = 32 x 3 = 3 kg
32
SO2 produced = 64 x 3 = 6.0 kg
32
Theoretical O2 required = 224 + 96 + 3 = 323 kg

1% already available in fuel. So net oxygen required is 322 kgs.
Excess O2 required = 322 x 0.15 = 48.3 kg

Total O2 required = 322 + 48.45 = 370.3 kg
77
Accompanied N2 = 370.3 x = 1239.7 kg
23
Accompanied moisture = (1239.7 + 370.3) x 0.0175 = 28.18 kg
Dry flue gas loss = [(308 + 6 + 48.3 + 1239.7) x 0.23 x (280-27)
= 93320.3 kcal
Latent heat loss = 108 x 584 = 63,072 kcal
L4 Explain briefly the principal of operation of
a) Heat pipe
The Heat Pipe comprises of three elements a sealed container, a capillary wick
structure and a working fluid. The capillary wick structure is integrally fabricated into the
interior surface of the container tube and sealed under vacuum. Thermal energy
applied to the external surface of the heat pipe is in equilibrium with its own vapour as
the container tube is sealed under vacuum. Thermal energy applied to the external
surface of the heat pipe causes the working fluid near the surface to evaporate
instantaneously. Vapour thus formed absorbs the latent heat of vapourisation and this
part of the heat pipe becomes an evaporator region. The vapour then travels to the
other end the pipe where the thermal energy is removed causing the vapour to
condense into liquid again, thereby giving up the latent heat of the condensation. This
part of the heat pipe works as the condenser region. The condensed liquid then flows
back to the evaporated region.
b) Radiation Repuperator
A metallic radiation recuperator consists of two

concentric lengths of metal tubing. The inner tube
carries the hot exhaust gases while the external
annulus carries the combustion air from the
atmosphere to the air inlets of the furnace burners.
The hot gases are cooled by the incoming combustion
air which now carries additional energy into the
combustion chamber. Radiation recuperator gets its
name from the fact that a substantial portion of the
heat transfer from the hot gases to the surface of the
inner tube takes place by radiative heat transfer.
c) Plate heat exchanger
Ans.
A plate type heat exchanger consists of a series of separate parallel plates forming thin
flow pass. Each plate is separated from the next by gaskets and the hot stream passes
in parallel through alternative plates whilst the liquid to be heated passes in parallel
between the hot plates. To improve heat transfer the plates are corrugated.
Hot liquid passing through a bottom port in the head is permitted to pass upwards
between every second plate while cold liquid at the top of the head is permitted to pass
downwards between the odd plates. When the directions of hot & cold fluids are
opposite, the arrangement is described as counter current.
L5 List 10 energy saving measures in a steam system
Monitoring Steam Traps

Proper Air Venting
Condensate Recovery
Paper 2 Set B SOLUTION
Regn No: _________________
Name: ___________________

FOR
PAPER 2: ENERGY EFFICIENCY IN THERMAL UTILITIES
Date: 21.04.2007 Timings: 1400-1700 HRS Duration: 3 HRS Max.

Marks: 150


Please hatch the appropriate oval in the OMR answer sheet with HB Pencil, as per
instructions
1. Turndown ratio for burners is the ratio of

a) air to fuel b) maximum fuel input to actual fuel input c) maximum fuel input over
minimum fuel input d) maximum air input over minimum air input
2. A bimetallic strip is used in which of the following traps

a) float trap b) thermodynamic c) thermostatic d) inverted bucket
3. Air must be removed from steam line as

a) It reduces partial pressure of steam and decreases thermal resistance to heat transfer
b) It increase partial pressure of steam and decrease thermal resistance to heat transfer
c) It increases saturation temperature of steam and increases thermal resistance to heat
transfer
d) It reduce saturation temperature of steam and increase thermal resistance to heat
transfer
An axial compressor is used in conjunction with which of the following

Bureau of Energy Efficiency 1
a) Back pressure steam turbine b) Gas turbine

c) Condensing turbine d) none of the above
5. At the critical point of steam

o
a) boiling point is 0 C b) enthalpy of evaporation is zero
c) sensible heat is zero d) total enthalpy is zero
6. Boiler Evaporation ratio is the amount of steam generated in kg

a) per kg of fuel burnt b) per unit time
2
c) per m of boiler surface area d) per kg of makeup water.
7. Carpet loss occurs in

a) Coal combustion b) atomization of oil c) coal storage d) furnaces
8. Ceramic fibre gives the maximum savings when used in

a) continuous furnace b) induction furnace c) arc furnace d) batch furnace
9. Chances of NOx formation are least in

a) Chain grate stoker boiler b) FBC boilers
c) Pulverized coal fired boiler d) Spreader stoker boiler
10. Co-generation is also known as

a)Re-generation system b)Brayton system
c)Combined heat and power system d)Reversible system

a)reducing dosage of chemicals b) blowdown c) steam venting d)deaeration
12. Deaeration in boiler removes

a) CO2 in flue gas b) O2 in feed water c) O2 in fuel d) O2 in flue gas
13. De-aeration of boiler feed water helps in combating

a) corrosion. b)TDS c) silica d) hardness
14. Excess air can be derived by measuring percentage of ____________ in exit flue gas
a) CO b) NO2 c) CO2 d) CH4
15. For coal fired system the flame length is dictated by:
a) moisture b) volatile matter. c) ash content. d) fixed carbon.
16. For equal capacity, the boiler size is the smallest for
a) AFBC b) CFBC c) PFBC d) Pulverized coil fired boiler
17. For flash steam calculation, flash steam quantity available depends upon ___
a) condensate pressure and flash steam pressure b) pressure of steam generated in boiler
c) steam enthalpy at atmospheric pressure d) total heat of flash steam
18. For industrial process indirect heating, the best quality of steam is
a) dry saturated steam b) superheated steam c) wet steam d) high pressure steam
19. For same inlet conditions of the steam which of the following will generate the maximum
mechanical power
c) extraction-cum-condensing turbine b) extraction-cum-back pressure turbine
20. High emissivity coatings are most effective on

a)outer surface of furnace b)inner surface of furnace
c)furnace charge d)none of the above

21. In determining the optimal economic insulation thickness for a steam pipeline, thickness
which of the following factors need not be considered
a) annual hours of operation b) calorific value c) pipe material d) cost of fuel
22. In oil firing burners

a) primary air is used for creating turbulence and secondary air for completion of
combustion
b) primary air is used for cooling oil and secondary air for completion of the combustion
c) primary air is used for completion of the combustion and secondary air for creating
turbulence
d) Primary air is used for atomizations of oil and secondary air for completion of the
combustion.
23. In pure stochiometric combustion of furnace oil which of the following will be absent in flue
gas ?
a) nitrogen b) carbon dioxide c) oxygen d) sulphur dioxide
0
24. Increase in feed water temperature by 30 C for an oil fired boiler results in a savings of -----
-% of fuel.
a) 1 b) 4 c) 5 d) None of the above.
25. Magnesite, chrome-magnesite, dolomite are examples of --------- type of refractory

26. Major heat loss in an furnace is accounted by

a) radiation . b) openings. c) sensible heat in exit flue gas d) hydrogen in fuel
27. Maximum heat transfer to the stock in a reheating furnace is by

a) conduction b) radiation c) convection d) none of these
28. Moisture in combustion air

a) contributes to latent heat loss but not sensible heat loss in flue gas
b) does not contribute to latent heat loss but contribute to sensible heat loss in flue gas
c) does not contribute to latent heat loss and sensible heat loss in flue gas
d) contributes to both the latent heat loss and sensible heat loss in flue gas.
a)reducing surface heat loss b)preheating Combustion air.
c)maintaining high levels of excess air d)minimising unburnt losses

0
30. Pre-heating of combustion air by 100 C will save about ------% of fuel.
a)0.5 b)5 c)7 d)None of the above
31. Quality of waste heat in flue gas refers to

a) dust concentration in flue gas b) temperature
c) moisture in flue gas d) corrosive gases in flue gas
32. Steam for process heating should always be generated and utilized at
a) same pressure b) lowest pressure and highest pressure respectively
c) highest pressure and lowest pressure respectively d) atmospheric pressure
33. Stochiometric air ratio for burning 1Kg of carbon is

a)3.76 b)10 c)11.6 d)None of the above
34. Sulphur percentage in furnace oil

a) sets lower flue gas temperature limit b) improves viscosity
c) does not add to heat value d) forms soot
35. The content of solid left in the oven after volatile matter is distilled off (while analysing the
composition of coal in a laboratory) is ___.
a) only sulphur b) only moisture c) only ash d) mix of fixed carbon and ash
36. The factor that influences atomization of fuel oil most is

a) density b) flash point c) pour point d) viscosity
37. The heat recovery device in which high conductivity bricks are used storing heat is
a) heat pipe b) heat pump c) thermo compressor d) regenerator
38. The percentage radiation loss from a boiler will

a) increase with increased loading b) decreases with increased loading
c) be independent of loading d) none of the above
39. Velocity of steam in a pipe depends on

a) number of bends b) length of pipe c) specific volume of steam d) none of the above
40. Wetting of coal with water in boiler helps in

a) increasing the calorific value of the coal b) keeping boiler grate cooled
c) increasing the furnace draft velocity d)stopping coal fines to fall through grate and being
carried away with furnace draft
41. What type of steam is generally used for power generation

a) high pressure steam with super heat b) dry saturated low pressure steam
c) dry saturated steam with high pressure d) wet steam with very high pressure
42. When pure hydrogen is burned, with theoretical air, the volume percentage of nitrogen in
flue gas on dry basis will be
a) 79% b) 100% c) 21% d) 0%
43. Which data is not required in calculation of thermal efficiency of boiler by indirect method
a)blow down quantityb)calorific value of fuel c)excess air level d)flue gas temperature
44. Which fuel uses the lowest amount of excess air during combustion process?
a) pulverised coal b) bagasse c)fuel oil d) natural gas.
45. Which is not a property of Ceramic fibre insulation

a) low thermal conductivity b) light weight c) high heat storage d) thermal shock resistant
46. Which of the energy saving measures will not be applicable for a heat treatment furnace
a) complete combustion with minimum excess air b) waste heat recovery from the flue
gases c) optimum capacity utilization d) heat recovery from furnace openings
47. Which of the following is not true of steam ?

a) highest specific heat and latent heat b) low heat transfer coefficient
c) easy to control and distribute d) cheap and inert
48. Which of the following will require minimum excess air for combustion
a) fluidized bed boiler b) spreader stoker boiler
c) pulverized coal fired boiler d) manually fired boiler
49. Which one of the following cannot be used as fuel for the gas turbine
a) naphtha b) LPG c) LSHS d) natural gas
50. With increase in excess air for combustion which of the following will result in flue gas
a) % Oxygen decreases b) % CO2 decreases
c) % Oxygen and CO2 decreases d) % Oxygen and CO2 increases
----------------------End of Section - I----------------------

Section II: SHORT TYPE QUESTIONS (Total 50 marks)

(10 Questions x 5 Marks Each )
S-1 List five benefits of condensate recovery in a process plant
0
For every 6 C rise in the feed water temperature, there will be approximately 1%
saving of fuel in the boiler. So financial benefits.
Reduction in Water charges
Minimising effluent temperature and hence adhering to effluent restrictions
Maximises boiler output
Better boiler feedwater quality
3 3
S-2 In a natural gas fired boiler the air to fuel ratio is maintained at 10Nm /Nm of gas.
An air preheater is installed to recover the waste heat, which brings down the
o o
exit flue gas temperature from 220 C to 170 C. If inlet air temperature to air
preheater is 30C, find out the exit air temperature. Assume that the specific
heat of flue gas and ambient air is equal.

Ans.
Ratio of volume flow rate flue gas to that of combustion air = 11/10
Va.a.Cpa (Toa-Tia) = Vf.f. Cpf. (Tof-Tif)
Ratio of density of flue gas to that of combustion air = (273+30) / (273+220) = 0.6146
Vf .f
Toa = Tia + . (Tof Tif) = 30 + 11/10 x 0.6146 x (220-170)
Va.a
63.8C
S-3 Explain the importance of draft in a reheating furnace
High negative pressures leads to air infiltration- affecting air-fuel ratio control,
problems of cold metal and non-uniform metal temperatures.
High positive Pressure leads to Ex-filtration -Problems of leaping out of flames,

overheating of refractories,burning out of ducts etc.
Hence the optimum condition is to maintain a slightly positive pressure

S.4 Discuss the role of three Ts in efficient combustion process
Ans
3 Ts of Combustion
The objective of good combustion is to release all of the heat in the fuel. This is
accomplished by controlling the "three T's" of combustion which are (1) Temperature
high enough to ignite and maintain ignition of the fuel, (2) Turbulence or intimate mixing
of the fuel and oxygen, and (3) Time sufficient for complete combustion.
For sustained combustion the temperature of fuel/air mixture must be at temperature

above ignition temperature. Air contains 21% O 2 and 79% N2 only O2 takes part in
combustion process. For combustion each fuel molecule must be in contact with at
least required number of molecules (theoretical) of O 2. This is only possible when fuel
and O2 is mixed on molecule to molecule basis. This complete mixing will require
turbulence in fuel in gaseous from and air. To ensure that each gaseous molecule
meets the O2 molecule, the fuel air mixture must stay for sufficient longer period in
region where temperature is more than the ignition temperature (Furnace chamber).
S-5 A fluidized bed boiler generates saturated steam at 15 atmosphere absolute

pressure (hg = 666 kCal/kg). If the feedwater temperature is 60C (h f = 60
kCal/kg), for evaporation ratio of 5 for a particular fuel (GCV of fuel = 4200
kCal/kg), estimate the boiler efficiency.
Ans.
= Q(hg hf ) x 100 =
qGCV
5 * (666 60)
* 100
4200
=72.14%
S-6 Draw a schematic diagram of a combined cycle power plant
S-7 A boiler is generating steam at 5500 kg/hr. The maximum permissible limit of TDS
in the boiler is 3000 ppm. If the make up water is 40% at a TDS level of 200
ppm, calculate the blowdown percentage and blow down rate.
Ans. Blow down percentage = 200 * 40 = 2.67%

3000
Blow down rate = 5500 x .0267 = 146.85 kg/hr.
S-8 Explain the working of a float trap with a sketch.

or
Float traps operate in a very similar way to a ball cock. A float contained within the trap
body is raised or lowered by the volume of condensate delivered to the trap. As
increasing levels of condensate raise the ball float, the mechanism lifts a valve allowing
condensate to discharge thus lowering the level of condensate within the trap. The trap
eventually closes preventing the further passage of steam.
The trap will remain closed and partially flooded unless there is a sufficient level of
condensate within the trap. At start up any air ahead of the steam and condensate will
not therefore be vented. Consequently it is necessary to incorporate an air cock or a
balanced pressure device (as described above) to release air in the trap.
S-9 For a oil containing 9% hydrogen (GCV = 10,200 kCal/kg), estimate the
percentage of sensible and latent heat loss due to evaporation of water formed
due to hydrogen in the fuel, if the flue gas temperature is 180C and combustion
air temperature is 40C.
0
(latent heat of vapours = 584 kCal/kg, specific heat of vapours = 0.45 kCal/kg/ C)
Ans. For 0.09 kg of hydrogen per kg of fuel, water generated is = 9 x 0.09 = 0.81 kg
Percentage Sensible Heat Loss = mCp (Tf-Ta)/GCV =
0.81* 0.45 * (180-40)

= 0.5 %
10200
Percentage Latent Heat Loss =
0.81* 584
= 4.6 %
10200
S-10 How does a thermo compressor work? Explain briefly with a sketch.
In a thermocompressor low pressure steam is converted to medium pressure steam by

using high pressure steam. The thermocompressor is a simple equipment with a
nozzle where HP steam is accelerated into a high velocity fluid. This entrains the LP
steam by momentum transfer and then recompresses in a divergent venturi.
----------------------End of Section -II----------------------

: 75%
: Rs.2500/tonne.
: 4000
0
kCal/kg :
150 C
0
: 50 C
0
: 30 C
Section III: SHORT TYPE QUESTIONS (Total 50 marks)

(5 Questions x 10 Marks Each )
L-1 A steam pipeline of 100mm diameter is not insulated for 100 metre length, supplying steam at 8
2
kg/cm . Find out the fuel savings if it is properly insulated with 50mm insulating material.
Assume 8000 hours of operation per year.
Given:
Boiler efficiency
Cost of coal
Gross Calorific value of fuel
Surface temperature without insulation
Surface temperature after insulation
Ambient temperature
Existing Heat Loss:
Surface heat loss S= 10+(Ts Ta)/20 x(Ts-Ta)

0
0
2

2
=1920 k.Cal/ hr-m
Modified System :
After insulating with 50mm insulating material the surface temperature has reduced to
0
50 C
2
=220 k.Cal/ hrm
Calculation of Fuel savings:
Pipe dimension =100 metre length and 100mm diameter
2
Surface area existing =3.14x0.1x100 =31.4 m
Surface area after insulation =3.14x0.2x100 =62.8 m
2
Total heat loss in existing system =1920x31.4 = 60288 k.Cal/hr
Total heat loss in modified system =220 x 62.8 =13816 k.Cal/hr

Reduction in heat loss =60288 -13816 = 46472 k.Cal/hr

Savings in heat per year =46472 x 8000 = 371776000 k.Cal/year
Annual savings in fuel =371776000 /(4000x0.75)x1000 =123.93 Tons

Monetary savings per annum =123.93 x 2500 =Rs. 3.098 lakhs
L-2 Compare the cost of power generation from a gas turbine installed with a 10 TPH
waste heat recovery boiler vis-a-vis grid supply
The operational data are as under:
Capacity of gas turbine : 3000kW

Auxiliary power consumption : 1% of electricity generated
Operating hours per annum : 8000
Plant load factor : 90%
Heat rate : 3050kCal/kWh
3
Calorific value of natural gas : 9500kCal/sm
3
Cost of gas : Rs.6000/1000 sm
Cost of capital of gas turbine
and boiler and maintenance
of W.H.R charges per annum : Rs.400 lakhs
Cost of electric power from grid : Rs.4.5/kWh
(Demand and energy charges)
5
Power generation from Cogeneration 3000x(90/100)x8000 =216 x10 kWh
plant
5
Auxiliary consumption 0.01 * 216 x 10 = 216000 kWh
Net generated power 21600000 216000 = 21384000 kWh
5
Natural gas required for above generation (216*10 ) x 3050/9500
3
6934737 sm
Cost of fuel per annum 6934737 x 6000/1000

416.08 lakhs
Cost of capital and operation charges Rs 400 lakhs

Total cost of power from Cogeneration 416.08 + 400
plant
816.08 lakhs
Cost of Cogenerated power Rs 816.08 / 213.84 =Rs. 3.82/kWh

Cost of grid power Rs 4.50/kWh
Cost of cogeneration power is cheaper by Rs 0.68/ kWh
L-3 An oil fired boiler uses furnace oil with ultimate analysis of Sulphur 3%, Hydrogen
11%,Carbon 85% and oxygen 1% and gross calorific value of 10,268
kCal/kg. The boiler furnace is operated with 15% excess air at 27C and humidity
ratio 0.0175. If the flue gas temperature is 270C, determine the dry flue gas
losses and latent heat loss due to evaporation of water.
Ans. For 100 kg of oil

Combustion of carbon C + O2 = CO2
32
Theoretical O2 required = x 85 = 227 kg
12
44
CO2 produced = x 85 = 312 kg
12
Combustion of hydrogen 2H2 + O2 = 2H2O

32 x 11 = 88 kg
Theoretical O2 required =
4
36 x 11 = 99 kg
H2O produced =
4
2
Combustion of sulphur S + O2 = SO
32 x 3 = 3 kg
Theoretical O2 required =
32
64 x 3 = 6.0 kg
SO2 produced =
32
Theoretical O2 required = 227 + 88 + 3 = 318 kg

O2 in fuel = 1%
Actual O2 required = 318 1 = 317 kg
Excess O2 required = 317 x 0.15 = 47.55 kg

Total O2 required = 317 + 47.55 = 364.55 kg
77
Accompanied N2 = 364.55 x = 1220.45 kg
23
Accompanied moisture = (1220.45 + 364.55) x 0.0175 = 27.74 kg

Dry flue gas loss = [(312 + 6 + 47.55 + 1220.45) x 0.23 + (270-
27) = 88642 kcal
Latent heat loss = 99 x 584 = 57816 kcal
L-4 List 10 energy saving measures in a steam system


Proper Air Venting
Condensate Recovery
L-5 Explain briefly the principles of operation of

Heat pipe
Radiation Recuperator
Plate Heat Exchanger
Heat pipe
interior surface of the container tube and sealed under vacuum. Thermal energy
applied to the external surface of the heat pipe is in equilibrium with its own vapour as
the container tube is sealed under vacuum. Thermal energy applied to the external
surface of the heat pipe causes the working fluid near the surface to evaporate
instantaneously. Vapour thus formed absorbs the latent heat of vapourisation and this
part of the heat pipe becomes an evaporator region. The vapour then travels to the
other end the pipe where the thermal energy is removed causing the vapour to
condense into liquid again, thereby giving up the latent heat of the condensation. This
part of the heat pipe works as the condenser region. The condensed liquid then flows
back to the evaporated region.
A metallic radiation recuperator consists of two concentric lengths of metal tubing. The
inner tube carries the hot exhaust gases while the external annulus carries the
combustion air from the atmosphere to the air inlets of the furnace burners. The hot
gases are cooled by the incoming combustion air which now carries additional energy
into the combustion chamber. Radiation recuperator gets its name from the fact that a
substantial portion of the heat transfer from the hot gases to the surface of the inner
tube takes place by radiative heat transfer.
c) Plate Heat Exchanger

Ans.
A plate type heat exchanger consists of a series of separate parallel plates forming thin
flow pass. Each plate is separated from the next by gaskets and the hot stream passes
in parallel through alternative plates whilst the liquid to be heated passes in parallel
between the hot plates. To improve heat transfer the plates are corrugated.
between every second plate while cold liquid at the top of the head is permitted to pass
downwards between the odd plates. When the directions of hot & cold fluids are
opposite, the arrangement is described as counter current.
----------------------End of Section -III----------------------

Paper 2 Set A Answer Key
Regn. No: ____ _____________

Name: ___________________
th
5 NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUDITORS November, 2007
Date: 17-11-2007 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150

Please darken the appropriate oval in the OMR answer sheet with Black HB Pencil or
Black Colour Ball Pen, as per instructions
The amount of theoretical air required for complete combustion of one ton of coal as compared to
that required for one ton of natural gas is:
a) higher b)lower c) equal d) none of the above
2. Furnace oil contains 84% carbon by weight. How many kg of CO2 does complete
combustion of 1 kg of furnace oil generate?
a) 2.4 b) 3.1 c) 3.6 d) 4.0
3. The highest % of sulphur is present in

a) LDO b) FO c) LSHS d) Kerosene
LPG is predominantly a mixture of
a) methane & propane b) ethane & butane

c) propane & butane d) butane & isopropane
In flue gas, the theoretical CO 2 is 15.0% and the measured CO 2 is 12% by volume. The %
excess air is:
a) 50% b) 150% c) 25% d) 20%

6. The unit of specific heat is
o 3 d) kCal
a) kCal /kg b) kCal/kg C c) kCal /m
Pour point of LSHS is

o o o o
a) 72 C b) 25 C c) 50 C d) 100 C
_________________________ 1

For stoichiometric combustion of 1 kg of carbon, the required amount of air will be about
a) 31 kg b) 21 kg c) 11.6 kg d) 2.66 kg
9. For coal fired system, the flame length is dictated by
a) moisture b) volatile matter c) ash content d) fixed Carbon
10. One kg of wood contains 20% moisture and 5% hydrogen by weight. How much water is
evaporated during complete combustion of one kg of wood?
a) 0.2 kg b) 250 gram c) 0.65 kg d) none of the above
The largest heat loss in the heat balance of a coal fired boiler is due to:
a) dry flue gas loss b) loss due to hydrogen in the fuel

c) radiation losses d) moisture in the air
12. The maximum possible evaporation ratio of a boiler (From & At 100C basis)
fired with coal having calorific value of 5400 kCal/kg and operating at 90% efficiency will be
a) 5 b) 9 c) 15 d) 20
The presence of calcium and magnesium bicarbonates in boiler feed water would form:
a) acidic solution b) alkaline solution

c) neutral solution d) none of the above
Good opportunity for energy savings from continuous blow down water of boiler is by
reusing the hot water so formed as make-up water

using the blow down steam to run steam turbine
utilization of flash steam in deaerator
none of the above
Which data is not required to calculate the efficiency of boiler by indirect method
a) flue gas temperature b) ambient temperature

c) calorific value of fuel d) blow down rate
Water treatment for steam boilers is generally required to:
a) remove hydrogen b) prevent formation of scales

c) help improve combustion efficiency d) reduce stack temperature
Maximum Continuous Rating (MCR) of a boiler is the maximum evaporation rate that can be
sustained for
a) 24 hours b) 8 hours c) 16 hours d) none of the above

A rise in conductivity of boiler feed water indicates
a) drop in the contamination of feed water b) greater purity of feed water

c) rise in the TDS of feed water d) rise in oxygen level
The TDS level in boiler water for boiler blow down, is measured through
a) alkalinity of water b) thermal conductivity of water

c) electrical conductivity of water d) turbidity of water
Heat transfer rate for indirect heating application will be less if we heat with
a) saturated steam b) dry steam

c) superheated steam d) high pressure steam
_________________________ 2
For flash steam calculation, flash steam quantity available depends upon
a) condensate pressure and flash steam pressure b) steam pressure

o o
The heat which is required to change the phase from water at 100 C to saturated steam at 100
C at atmospheric pressure is
a) sensible heat b) latent heat c) super heat d) specific heat
For transporting the steam to the long distance, the best quality of steam is
a) dry saturated steam b) slightly superheated steam

c) mildly wet steam d) very high pressure steam
Velocity of steam in a steam pipe, is directly proportional to
a) number of bends in pipe b) specific volume of steam

c) length of pipe d) none of the above
a) 540 kCal/kg b) zero c) infinite d) none of the above
Mechanical steam traps work on the principle of
difference in density between steam and condensate

difference in thermodynamic properties between steam and condensate
difference in temperature between steam and condensate
none of the above
The inverted bucket trap operates on the principle of _______ difference between water and
steam
a) pressure b) density c) temperature d) velocity

The hearth pressure in the heating zone of furnace should be
a) slightly negative pressure b) slightly positive pressure

c) high negative pressure d) high positive pressure
For the same size and rating, efficiency of continuous furnaces will be more than batch type of
furnaces mainly because of
reduced opening losses in continuous furnace

reduced flue gas losses in continuous furnace
increased flue gas in batch furnace
loss of energy stored in walls of batch furnace
0
Which loss is the highest in a typical re-heating furnace operating at furnace temperature of 1250
C?
a) flue gas loss b) wall loss c) necessary opening loss d)cooling water loss
A re-heating furnace is operating at 10 TPH and consuming FO of 460 kg/hour for reheating the
O O o
material from 40 C to 1100 C. Considering specific heat of material as 0.13 kCal/kg C and
GCV of FO as 10500 kCal/kg, the efficiency of the re-heating furnace will be
a) 25% b) 29% c) 35% d) 40%

a) temperatures of external wall surfaces b) velocity of air around the furnace
c) thermal conductivity of wall brick d) material of stock to be heated.

_________________________ 3

The insulation material suitable for low temperature application to prevent heat gain is
a) mineral fiber b) fiber glass c) silica d) polyurethane

The coefficient of thermal expansion of refractory material should be
a) low b) high c) medium d) very high

Example for basic type of refractory is
a) chrome b) chrome magnesite c) alumina d) all the above

The unit for coefficient of heat transfer in SI system is
a) kCal /m-hr C b) kCal / m-hr C c) kCal /m C d) none of the above

The use of ceramic fiber results in fuel economy due to
a) chemical resistance b) thermal shock resistance

c) lower maintenance d) lower heat storage
The emissivity of ceramic coatings used in furnace:
decreases with increase in temperature

remains constant
increases with increase in temperature
decreases with increase in furnace pressure
The equipment having the highest efficiency in case of thermal power plant is
a) boiler b) turbine c) generator d) cooling tower

NOx formation in FBC boilers is eliminated because of
higher velocity of flue gas in combustion chamber

higher pressure of the air supplied
lower temperatures in the bed and combustion chamber
higher contact of solid particles in the flue gas
The difference between mean velocity of solid and gas in a FBC boiler is called
a) fluidization factor b) slip velocity c) settling velocity d) none of the above

The material used to control SOx in the FBC boiler is
a) limestone b) alumina c) silica d) lime

For efficient sulphur retention in the bed, temperature of a fluidized bed boiler should be
a) 700C b) 1100C c) 850C d) 1000C

44. In an industry, exhaust gas from the furnace is used for power generation by installing
waste heat recovery steam boiler and a steam turbine. This type of co-generation will be
called as
a) gas turbine b) diesel generator c) topping cycle d) bottoming cycle
Which type of steam turbines has high heat-to-power ratio?
a) back pressure turbine b) gas turbine

c) extraction condensing turbine d) reciprocating engine
_________________________ 4
A waste heat recovery system (Shell and Tube heat exchanger) receives hot fluid at 200C and
leaves at 70C, cold medium enters at 30C and leaves at 90C, the type of flow involved
in this is
a) cross-flow b) co- current flow c) counter-current flow d) none of the above

47. Among which of the following flue gas temperature options, heat recovery equipment will
be the least expensive (assuming same material of construction and heat recovered)
o o o o
a) 300 C b) 350 C c) 400 C d) 500 C
In a heat pump
work is added to improve quality of waste heat

heat is added to improve quality of waste heat
steam is added to improve quality of waste heat
air is added to improve quality of waste heat
A heat pipe can transfer up to ------times more thermal energy than copper
a) 10 b) 50 c) 70 d) 100
50. Wicks in the heat pipe are provided for
a) forward movement of vapours b) forward movement of hot liquid
c) return of hot vapours d) return of condensed liquid
-------- End of Section - I ---------
Answer all Eight questions

S-1 (a) State the stoichiometric combustion equation for Propane (C 3H8)
How many kg of Carbon Dioxide will be generated by complete combustion of 1

kg of Propane
Ans i) C3H8 +5O2 =3CO2 +4H2O
+ 160 = 132 + 72
44 kg of propane on combustion produces 132 kg of CO2. Hence 1Kg

of propane will generate 3 Kg of Carbon dioxide
2
S-2 In a plant, a boiler is generating saturated steam of 2 TPH at a pressure of 7 kg/cm g.
The feed water temperature is 60C and furnace oil consumption is 150 kg/hr.
What is the efficiency of the boiler by using direct method of efficiency evaluation?
(Calorific value of FO is 10,000 kCal/kg, enthalpy of steam is 660
_________________________ 5
2
kCal/kg at 7 kg/cm g)
Ans
= 2000 x (660-60) x 100 = 80%
150 x 10000
Note : Deduct 3 marks if 60 is not subtracted from 660

S-3
O
A reheating furnace output is 10 TPH. The billets are heated from 50 C to
O
1200 C. The oil consumption rate is 700 liters /hr. Specific gravity of FO is 0.95;
Net Calorific value of FO is 9650 kCal/kg, and the specific heat of the billet is 0.12
O
kCal/kg C. Find out the thermal efficiency of the furnace on NCV basis.
6
Ans Heat input into the furnace : 700x0.95x9650 = 6.42x10 kCal/hr
Heat output of the furnace : 10,000x0.12x(1200-50) =1.38x106 K.Cal/hr.
Thermal efficiency of the furnace = (1.38/6.42) x 100
= 21.5 %
S-4 Name any five parameters required to evaluate economic thickness of insulation
Ans
For determination of economic thickness following parameters are required:
Cost of fuel
Annual hours of operation
Heat content of fuel
Operating surface temperature
Pipe diameter / thickness of surface
Estimated cost of insulation
Average ambient air temperature
S-5 What are the advantages of fluidized bed combustion over fixed grate boiler?
Ans The major advantages are as under:

Burn low-grade fuels.
Reduces NOx and SOx
No clinker formation.Faster response to changing
demand. Suited for fluctuating fuel quality
Higher combustion efficiency
Any other relevant point
S-6 For a 5 TPH capacity boiler, estimate the rise in temperature of feed water in an
economizer, when the flue gas temperature decreases from 310C to 180C. Air to
fuel ratio and evaporation ratio of the boiler are 22 and 10 respectively. Assume
condensate recovery and boiler blow down is nil. Specific heat of flue gas: 0.23
o
kCal/kg C
_________________________ 6
Ans For 1 kg of fuel steam generated is = 10 kg

For 1 kg of fuel makeup water is = 10 kg
For 1 kg of fuel required combustion air is = 22 kg
For 1 kg of fuel flue gas generated is = 22 +1= 23 kg
In economizer heat given by flue gas = heat received by makeup water

23 x 0.23 x (310-180) = 10 x 1 x T
T = 68.77 C
S-7 Sketch the schematic of Back Pressure Turbine and Extraction Condensing
Turbine Cogeneration systems
Ans
_________________________ 7
S-8 Explain briefly with a neat sketch the operation of a Regenerator for waste heat
recovery.
The heat from flue gases is stored in the refractory bricks alternately between
time intervals
Air for combustion gets preheated by moving over one set of hot refractory
bricks After some time the air moves over another set of bricks
Thus preheated air is supplied for combustion
-------- End of Section II ---------
_________________________ 8
Answer all Six questions

L-1 A boiler utilizes bio-mass as fuel and the ultimate analysis (by weight %) of the fuel is
given below:
COMPONENT ANALYSIS %
Carbon 45
Hydrogen 6
Nitrogen 0.5
Oxygen 46.5
Sulfur 0.5
Ash 1.5
The component analysis is provided on dry basis and the CO 2 content of the flue gas
measured is 13%. Using the basic combustion equations estimate the following on
dry fuel basis for 100 kg of dry fuel fired:
Theoretical amount of air required for combustion
Theoretical CO2 content in flue gas.
Excess air supplied
Ans Basic equations:
C+O2 = CO2
2H2+O2 = 2H2O
S+O2 = SO2
a) Theoretical amount of air for combustion
12 kg carbon requires 32 kg of oxygen forming 44 kg of

CO2. 1 kg carbon requires 32/12=2.67 kg O2.
(45)C+(2.67x45)O2= (165.15) CO2
4 kg of Hydrogen requires 32 kg of oxygen.1 kg of Hydrogen requires 8 kg

of oxygen.
(6) H2+(6x8)O2 =(54)H2O
32 kg Sulfur requires 32 kg oxygen to form 64 kg of SO2. 1 kg Sulfur requires

1 kg Oxygen.
( 0.5)S+(0.5)O2 = (1)SO2
_________________________ 9
Total oxygen required = (120+48+0.5) = 168.5 kg
Oxygen present in fuel = 46.5 kg

Oxygen to be supplied = 168.5-46.5 = 122 kg
Amount of air to be supplied=122 x100/23= 530 kg
b) Theoretical CO2 content in flue gas

Nitrogen in flue gas : (530-122)+0.5 =408.5 kg
Moles of CO2 in flue gas= 165.15/44= 3.75

Moles of N2 in flue gas = 408.5/28 = 14.6
Moles of SO2 in flue gas= 1/64 = 0.016
Total moles =18.37
Theoretical CO2 by Volume = (Moles of CO2X100)/ Total moles( Dry)
=(3.75x100)/18.37
= 20.41%
c) Calculation of excess air
Excess air= (Theoretical CO2/Actual CO2)-1 X100
= (20.41/13)-1 X100
= 57 %
L-2 List any 10 energy conservation opportunities in a steam distribution and utilization
system
Ans 1) Fix steam leaks and condensate leaks
2) Ensure process temperatures are correctly controlled.
3) Maintain lowest acceptable process steam pressures
4) Remove or blank off all redundant steam piping
5) Ensure condensate is returned or re-used in the process.
6) Recover boiler blowdown.
7) Check operation of steam traps.
8) Remove air from indirect steam using equipment
9) Reduce the work done by steam
10) Insulate pipelines
_________________________ 10
L-3 A plant proposes to install an air pre-heater to pre-heat combustion air from 30 C to
160 C in the existing boiler. The other performance parameters are as given below.
Fuel used : Bio-mass

Bio-mass firing rate : 28TPH
Sulfur in fuel : 0.1%
GCV of fuel : 2300 kCal/kg
Boiler efficiency : 70%
Flue gas temperature : 300 C
Air requirement : 4.5 kg/kg of fuel
o
Specific heat of combustion air : 0.24 kCal/kg C
o
Specific heat of flue gas : 0.23 kCal/kg C
Estimate the following:

Quantity of flue gas assuming negligible ash content in the fuel.
Heat transferred to the combustion air.
Exit flue gas temperature and whether it is acceptable.
Annual fuel savings using GCV for an operating period of 8600 hours/ year
Ans a. Quantity of flue gas

Quantity of fuel fired: 28000 kg/hour.
Combustion air supplied = 28000 x 4.5 = 1,26,000 kg / hour. Total

quantity of flue gas = 28000 + 1,26,000= 1,54,000 kg / hour
b. Heat transferred to combustion air

Heat transferred = 1,26,000 x 0.24 x (160-30) = 39,31,200 kCal / hour
c. Exit flue gas temperature

Heat drop for the flue gas = 39,31,200 / (1,54,000 x 0.23) = 111C.
Therefore the exit gas temperature = 300 111 = 189 C.
The fuel contains very little sulfur and hence the sulfur dew point is
very low. Hence the temperature of 189 C. is acceptable.
d. Annual fuel saving

Quantity of heat saved / hour = 39,31,200 kCal/hour.
Equivalent bio-mass savings = 39,31,200 / (2300 x 0.7) = 2442 kg / hour
Annual bio-mass savings = 2442 x 8600 / 1000 = 21001 MT / year.
_________________________ 11
L-4 (a) Explain why dry saturated steam is preferred over wet or superheated steam for
Complete the enthalpy equation hg =. +., for wet steam and name the
variables
Why should one use dry saturated steam at the lowest possible pressure for
indirect steam heating?
Ans i) Dry saturated steam is the preferred choice because:

Wet steam has a lower heat content than dry steam.
Superheated steam gives up heat at a slower rate than
saturated steam.
Dry steam alone condenses quickly, thereby providing a higher
heat transfer rate.
hg =hf +X*hfg
Where hf = Enthalpy of saturated water at a given
pressure. hfg =Enthalpy of evaporation
hg =Enthalpy of saturated steam.
X=Dryness fraction of steam.
The latent heat of steam increases with reduction of steam pressure and it
is only the latent heat that is transferred during indirect heating
applications.
L-5 In an industry, an electrical furnace consuming 50 kWh/batch is to be converted

into furnace oil fired furnace. Estimate the annual savings with furnace oil
replacement considering the following:
i) Efficiency of electrical furnace : 75%
ii) Efficiency of FO fired furnace (NCV Basis) : 52 %
iii) Number of batches : 5000 batches/ year
iv) Cost of Electricity : Rs. 4 per kWh
v) Cost of FO : Rs. 20 per kg
vi) Net Calorific Value of FO : 9650 kCal /kg
Ans
Energy consumption per batch by furnace : 50 kWh
Efficiency of electrical furnace : 75%
Useful heat generated : 50 x 5000 x 860 x 0.75
= 161250000 kCal/year
Conversion of Electrical Furnace into Oil Fired Furnace
For meeting useful heat, requirement of FO : 161250000 /9650
= 16710 kg/year
Efficiency of FO fired furnace : 52 %

_________________________ 12
Net FO required to meet useful heat : 16710 /0.52 = 32134 kg/year

Cost required to run the electrical furnace = 50 x 5000 x 4 = Rs. 1000000
Cost required to run the furnace by (FO) = 32134 x 20= Rs. 642680
Cost savings = Rs. 357320
L-6 (a) Calculate the blow down rate for a boiler with an evaporation rate of 5 tons/hr,
if the maximum permissible TDS in boiler water is 3500 ppm and with 17 %
make up water addition. The feed water TDS is around 350 ppm.
2
(b) Steam at a pressure of 15 kg/cm g is flashed to a lower pressure of 2
2
kg/cm g. If the steam flow rate is 1000 kg/hr. Calculate the % of flash steam
and flow rate of flash steam?
Given are the data from steam tables :
2
Sensible heat of steam at 15 kg/cm g : 200 kCal/kg
2
Latent heat of steam at 2 kg/cm2g : 666 kCal/kg
Answer FeedwaterTDSx%Makeup
a) Blow down (%) =
PermissibleTDSinBoiler
Percentage blow down = 350 x 17/3500 = 1.7 %
If boiler evaporation rate is 5000 kg/hr then required blow down rate
is: = 5000 x 1.7/100 = 85 kg /hr
The flash steam quantity can be calculated from the following formula:
Flash steam =S1 S2

---------------
L2
Where S1 is the sensible heat of high pressure condensate.
S2 is the sensible heat of steam at lower pressure
L2 is the latent heat of flash steam at the lower pressure.

Substituting values= (200-120)/666 =80/666 =12%
Flow rate of high-pressure steam: 1000 kg/hr.

Flash steam quantity: 1000*(12/100) = 120 kg/hr.

_________________________ 13
Paper 2 Set B Answer Key
Regn. No: ____ _____________

Name: ___________________
th
FOR
ENERGY MANAGERS & ENERGY AUDITORS November, 2007
Date: 17-11-2007 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150

Please darken the appropriate oval in the OMR answer sheet with Black HB Pencil or
Black Colour Ball Pen, as per instructions
A re-heating furnace is operating at 10 TPH and consuming FO of 460 kg/hour for reheating the
o o o
material from 40 C to 1100 C. Considering specific heat of material as 0.13 kCal/kg C and
GCV of FO as 10500 kCal/kg, the efficiency of the re-heating furnace will be
a) 25% b) 35% c) 29% d) 40%
The inverted bucket trap operates on the principle of __________ difference between water
and steam
3. The maximum possible evaporation ratio of a boiler (From & At 100C basis)
fired with coal having calorific value of 5400 kCal/kg and operating at 90% efficiency will be
a) 20 b) 15 c) 9 d) 5
Maximum Continuous Rating (MCR) of a boiler is the maximum evaporation rate that can be
sustained for
a) 16 hours b) 8 hours c) 24 hours d) none of the above

5. Which type of steam turbines has high heat-to-power ratio?
a) gas turbine b) back pressure turbine

The emissivity of ceramic coatings used in furnace:
a) increases with increase in temperature b) remains constant

c) decreases with increase in temperature
d) decreases with increase in furnace pressure
_________________________ 1
For flash steam calculation, flash steam quantity available depends upon
steam enthalpy at atmospheric pressure

condensate pressure and flash steam pressure
steam pressure
total heat of flash steam
A heat pipe can transfer up to ------times more thermal energy than copper
a) 10 b) 100 c) 70 d) 50
a) FO b) LDO c) LSHS d) Kerosene
10. The amount of theoretical air required for complete combustion of one ton of coal as
compared to that required for one ton of natural gas is:
a) higher b) equal c) lower d) none of the above
The coefficient of thermal expansion of refractory material should be
a) very high b) high c) medium d) low

The difference between mean velocity of solid and gas in a FBC boiler is called
a) slip velocity b) fluidization factor c) settling velocity d) none of the above

Pour point of LSHS is
o o o o
a) 100 C b) 25 C c) 50 C d) 72 C
Among which of the following flue gas temperature options, heat recovery equipment will be the
least expensive (assuming same material of construction and heat recovered).
o o o o
a) 500 C b) 350 C c) 400 C d) 300 C
Latent heat at the critical point of a steam phase diagram is
a) zero b) 540 kCal/kg c) infinite d) none of the above

The unit of specific heat is
3 o
a) kCal /kg b) kCal /m c) kCal/kg C d) kCal
In flue gas, the theoretical CO 2 is 15.0% and the measured CO 2 is 12% by volume. The % excess
air is:
a) 25% b) 150% c) 50% d) 20%

Furnace wall heat loss does not depend on

c) material of stock to be heated d) brick thermal conductivity of wall
Water treatment for steam boilers is generally required to:
a) remove hydrogen b) reduce stack temperature

c) help improve combustion efficiency d) prevent formation of scales
For coal fired system the flame length is dictated by
a) moisture b) ash content c) volatile matter d) fixed Carbon
Furnace oil contains 84% carbon by weight. How many kg of CO 2 does complete combustion of 1
kg of furnace oil generate?
a) 2.4 b) 4.0 c) 3.6 d) 3.1
_________________________ 2

For efficient sulphur retention in the bed, temperature of a fluidized bed boiler should be
a) 850C b) 1100C c) 700C d) 1000C
A waste heat recovery system (Shell and Tube heat exchanger) receives hot fluid at 200C and
leaves at 70C, cold medium enters at 30C and leaves at 90C, the type of flow involved
in this is
a) counter-current flow b) co-current flow c) cross-flow d) none of the above
The presence of calcium and magnesium bicarbonates in boiler feed water would form:

Which data is not required to calculate the efficiency of boiler by indirect method
a) blow down rate b) ambient temperature

c) calorific value of fuel d) flue gas temperature
26. For stoichiometric combustion of 1 kg of carbon, the required amount of air will be about
a) 11.6 kg b) 21 kg c) 31 kg d) 2.66 kg
27. Heat transfer rate for indirect heating application will be less if we heat with
c) high pressure steam d) superheated steam

The material used to control SOx in the FBC boiler is
a) lime b) alumina c) silica d) limestone

For transporting the steam to the long distance, the best quality of steam is
a) slightly superheated steam b) dry saturated steam

A rise in conductivity of boiler feed water indicates

c) rise in oxygen level d) rise in the TDS of feed water
One kg of wood contains 20% moisture and 5% hydrogen by weight. How much water is
32. LPG is predominantly a mixture of
a) propane & butane b) ethane & butane
c) methane & propane d) butane & isopropane

33. Mechanical steam traps work on the principle of
a) difference in density between steam and condensate
b) difference in temperature between steam and condensate

c) difference in thermodynamic properties between steam and condensate
In a heat pump
air is added to improve quality of waste heat

heat is added to improve quality of waste heat
steam is added to improve quality of waste heat
work is added to improve quality of waste heat
_________________________ 3
Wicks in the heat pipe are provided for
a) forward movement of vapours b) forward movement of hot liquid

c) return of condensed liquid d) return of hot vapours
The TDS level in boiler water for boiler blow down, is measured through
a) alkalinity of water b) electrical conductivity of water

c) thermal conductivity of water d) turbidity of water
The largest heat loss in the heat balance of a coal fired boiler is due to:
a) radiation losses b) loss due to hydrogen in the fuel

c) dry flue gas loss d) moisture in the air
o o
The heat which is required to change the phase from water at 100 C to saturated steam at 100
C at atmospheric pressure is
a) sensible heat b) specific heat c) super heat d) latent heat

Example for basic type of refractory is
a) chrome magnesite b) chrome c) alumina d) all the above
For the same size and rating, the efficiency of continuous furnaces will be more than batch type of
furnaces mainly because of
loss of energy stored in walls of batch furnace

reduced flue gas losses in continuous furnace
increased flue gas in batch furnace
reduced opening losses in continuous furnace
In an industry, exhaust gas from the furnace is used for power generation by installing waste heat
recovery steam boiler and a steam turbine. This type of co-generation will be called as
a) gas turbine b) bottoming cycle c) topping cycle d) diesel generator

The equipment having the highest efficiency in case of thermal power plant is
a) boiler b) generator c) turbine d) cooling tower

The insulation material suitable for low temperature application to prevent heat gain is
a) mineral fiber b) polyurethane c) silica d) fiber

glass
The unit for coefficient of heat transfer in SI system is
a) kCal /m-hr C b) kCal /m C c) kCal / m-hr C d) none of the above

The hearth pressure in the heating zone of furnace should be
a) slightly positive pressure b) slightly negative pressure

c) high negative pressure d) high positive pressure
0
Which loss is the highest in a typical re-heating furnace operating at furnace temperature of 1250
C?
a) cooling water loss b) wall loss c) necessary opening loss d) flue gas loss
NOx formation in FBC boilers is eliminated because of
higher velocity of flue gas in combustion chamber

higher pressure of the air supplied
higher contact of solid particles in the flue gas
_________________________ 4
d) lower temperatures in the bed and combustion chamber

48. Velocity of steam in a steam pipe, is directly proportional to
a) number of bends in pipe b) length of pipe
c) specific volume of steam d) none of the above
49. Good opportunity for energy savings from continuous blow down water of boiler is by
a) utilization of flash steam in deaerator
b) using the blow down steam to run steam turbine

c) reusing the hot water so formed as make-up water
The use of ceramic fiber results in fuel economy due to
a) lower heat storage b) thermal shock resistance

c) lower maintenance d) chemical resistance
-------- End of Section - I ---------

S-1 Name any five parameters required to evaluate economic thickness of insulation
Ans For determination of economic thickness following parameters are required:
i) Cost of fuel
ii)Annual hours of operation
iii) Heat content of fuel
iv) Operating surface temperature
v)Pipe diameter / thickness of surface
vi) Estimated cost of insulation
vii) Average ambient air temperature
S-2 For a 5 TPH capacity boiler, estimate the rise in temperature of feed water in an
economizer, when the flue gas temperature decreases from 320C to 212C. Air to
fuel ratio and evaporation ratio of the boiler are 20 and 11 respectively. Assume
condensate recovery and boiler blow down is nil. Specific heat of flue gas: 0.23
o
kCal/kg C
Ans For 1 kg of fuel steam generated is = 11 kg

_________________________ 5
21 x 0.23 x (320-212) = 11 x 1 x T
T = 47.42 C
S-3 Explain briefly with a neat sketch the operation of a Regenerator for waste heat
recovery.
The heat from flue gases is stored in the refractory bricks alternately
between time intervals
Air for combustion gets preheated by moving over one set of hot
refractory bricks
After some time the air moves over another set of
bricks Thus preheated air is supplied for combustion
S-4 (a) State the stoichiometric combustion equation for Propane (C 3H8)
How many kg of Carbon Dioxide will be generated by complete combustion of 2 kg

of Propane
Ans i) C3H8 +5O2 =3CO2 +4H2O
+ 160 = 132 + 72
44 kg of propane on combustion produces 132 kg of CO2. Hence 2Kg

of propane will generate 6 Kg of Carbon dioxide
S-5 O
A reheating furnace output is 20 TPH. The billets are heated from 55 C to 1200 C.
O
The oil consumption rate is 1300 liters /hr. Specific gravity of FO is 0.95; Net
Calorific value of FO is 9650 kCal/kg, and the specific heat of the billet is 0.12
O
kCal/kg C. Find out the thermal efficiency of the furnace on NCV basis
Ans Heat input into the furnace 6
: 1300 x 0.95x 9650 = 11.9 x10 kCal/hr
Heat output of the furnace : 20,000 x 0.12x(1200-55) =2.75x 106 K.Cal/hr.

Thermal efficiency of the furnace = (2.75 / 11.9) x 100
_________________________ 6

= 23 %
S-6
In a plant, a boiler is generating saturated steam of 2.5 TPH at a pressure of 7
2
kg/cm g. The feed water temperature is 70C and furnace oil consumption is 175
kg/hr. What is the efficiency of the boiler by using direct method of efficiency
evaluation? (Calorific value of FO is 10,000 kCal/kg, enthalpy of steam is 660
2
Ans kCal/kg at 7 kg/cm g)
= 2500 x (660-70) x 100/ 175 x 10000 = 84.3%
Note : Deduct 3 marks if 70 is not subtracted from 660

S-7
What are the advantages of fluidized bed combustion over fixed grate boiler?
Ans
The major advantages are as under:
Burn low-grade fuels.
Reduces NOx and SOx
No clinker formation.Faster response to changing
demand. Suited for fluctuating fuel quality
Higher combustion efficiency
S-8
Sketch the schematic of Back Pressure Turbine and Extraction Condensing
Ans Turbine Cogeneration systems
-------- End of Section II ---------
_________________________ 7

L-1 In an industry, an electrical furnace consuming 60 kWh/batch is to be converted into

furnace oil fired furnace. Estimate the annual savings with furnace oil replacement
considering the following:
i) Efficiency of electrical furnace : 70%
ii) Efficiency of FO fired furnace (NCV Basis) : 52 %
iii) Number of batches : 4500 batches/ year
iv) Cost of Electricity : Rs. 4 per kWh
v) Cost of FO : Rs. 20 per kg
vi) Net Calorific Value of FO : 9650 kCal /kg
Energy consumption per batch by furnace : 60 kWh

Useful heat generated : 60 x 4500 x 860 x 0.70
= 162540000 kCal/ year
Conversion of Electrical Furnace into Oil Fired Furnace
For meeting useful heat, requirement of FO : 162540000 /9650

= 16843.5 kg/ year
Efficiency of FO fired furnace : 52 %
Net FO required to meet useful heat : 16843.5 /0.52 = 32391 kg/ year
Cost required to run the electrical furnace = 60 x 4500 x 4 = Rs. 1080000

Cost required to run the furnace by (FO) = 32391 x 20 = Rs. 647820
Cost savings = Rs. 432180
L-2 (a) Explain why dry saturated steam is preferred over wet or superheated steam for
Complete the enthalpy equation hg =. +., for wet steam and name the variables
Why should one use dry saturated steam at the lowest possible pressure for indirect
steam heating?
_________________________ 8
Ans i) Dry saturated steam is the preferred choice because:

Wet steam has a lower heat content than dry steam.
Superheated steam gives up heat at a slower rate than saturated steam.
Dry steam alone condenses quickly, thereby providing a higher heat
transfer rate.
hg =hf +X*hfg
The latent heat of steam increases with reduction of steam pressure and it is only
the latent heat that is transferred during indirect heating applications.
given below:
COMPONENT ANALYSIS %
Carbon 40
Hydrogen 7
Nitrogen 0.5
Oxygen 50.5
Sulfur 0.5
Ash 1.5
The component analysis is provided on dry basis and the CO 2 content of the flue gas
measured is 12%. Using the basic combustion equations estimate the following on dry
fuel basis for 100 kg of dry fuel fired:
Excess air supplied
1.0. Basic equations:
C+O2 = CO2
2H2+O2 = 2H2O
S+O2 = SO2
2.0. Theoretical amount of air for combustion
12 kg carbon requires 32 kg of oxygen forming 44 kg of

CO2. 1 kg carbon requires 32/12=2.67 kg O2.
(40)C+(2.67x40)O2= (146.67) CO2
4 kg of Hydrogen requires 32 kg of oxygen.1 kg of Hydrogen requires 8 kg
of oxygen.
_________________________ 9
(7) H2+(7x8)O2 =(63)H2O

32 kg Sulfur requires 32 kg oxygen to form 64 kg of SO2. 1 kg Sulfur requires 1
kg Oxygen.
( 0.5)S+(0.5)O2 = (1)SO2
Total oxygen required = (106.67+56+0.5) = 163.17 kg

Oxygen to be supplied = 163.17-50.5= 112.6 kg
Amount of air to be supplied=112.6 x100/23= 490 kg
2. Theoretical CO2 content in flue gas

Nitrogen in flue gas : (490-112.6)+0.5 = 377.9 kg
Moles of CO2 in flue gas= 146.67/44= 3.33

Moles of N2 in flue gas = 377.9/28 = 13.49
Moles of SO2 in flue gas= 1/64 = 0.016
Total moles =16.9
Theoretical CO2 by Volume = (Moles of CO2X100)/ Total moles( Dry)
=(3.33 x100)/16.9
= 19.7 %
3. Calculation of excess air

Excess air= (Theoretical CO2/Actual CO2)-1 X100
(19.7/12)-1 X100
64.16%
L-4 (a) Calculate the blow down rate for a boiler with an evaporation rate of 10 tons/hr, if the
maximum permissible TDS in boiler water is 3500 ppm and with 20 % make up
water addition. The feed water TDS is around 350 ppm.
2 2
Steam at a pressure of 15 kg/cm g is flashed to a lower pressure of 2 kg/cm g. If the
steam flow rate is 1500 kg/hr. Calculate the % of flash steam and flow rate of flash
steam?
2
2
2
Latent heat of steam at 2 kg/cm g : 666 kCal/kg
Ans FeedwaterTDSx%Makeup
a) Blow down (%) =
PermissibleTDSinBoiler
Percentage blow down = 350 x 20/3500 = 2%
_________________________ 10

If boiler evaporation rate is 10000 kg/hr then required blow down rate is:
= 10000 x 2/100 = 200 kg /hr
The flash steam quantity can be calculated from the following formula:
Flash steam =S1 S2

---------------
L2

Substituting values= (200-120)/666 =80/666 =12%

Flash steam quantity: 1500*(12/100) = 180 kg/hr.
L -5 A plant proposes to install an air pre-heater to pre-heat combustion air from 30 C to

150 C in the existing boiler. The other performance parameters are as given below.
Fuel used : Bio-mass

Bio-mass firing rate : 28TPH
Sulfur in fuel : 0.1%
GCV of fuel : 2100 kCal/kg
o
Flue gas temperature : 300 C.
Air requirement : 4.5 kg/kg of fuel
o
Specific heat of combustion air : 0.24 kCal/kg C
o
Specific heat of flue gas : 0.23 kCal/kg C
Estimate the following:
Quantity of flue gas assuming negligible ash content in the fuel.
Heat transferred to the combustion air.
Exit flue gas temperature and whether it is acceptable.
Annual fuel savings using GCV for an operating period of 8600 hours/ year
a. Quantity of flue gas

Quantity of fuel fired: 28000 kg/hour.
Combustion air supplied = 28000 x 4.5 = 1,26,000 kg / hour.
Total quantity of flue gas = 28000 + 1,26,000= 1,54,000 kg / hour
b. Heat transferred to combustion air

Heat transferred = 1,26,000 x 0.24 x (150-30) = 36,28,800 kCal / hour
c. Exit flue gas temperature
Temperature drop for the flue gas = 36,28,800 / (1,54,000 x 0.23) = 102.5C.
_________________________ 11
Therefore the exit gas temperature = 300 102.5 = 197.5 C.

The fuel contains very little sulfur and hence the sulfur dew point is very low.
Hence the temperature of 197.5 C. is acceptable.
d. Annual fuel saving
Quantity of heat saved / hour = 36,28,800 kCal/hour.
Equivalent bio-mass savings = 36,28,800 / (2100 x 0.65) = 2658.5 kg / hour
Annual bio-mass savings = 2658.5 x 8600 / 1000 = 22863 MT / year.
L- 6 List any 10 energy conservation opportunities in a steam distribution and utilization

system
Ans 1) Fix steam leaks and condensate leaks

Ensure process temperatures are correctly controlled.
Maintain lowest acceptable process steam pressures
Remove or blank off all redundant steam piping
Ensure condensate is returned or re-used in the process.
Recover boiler blowdown.
Check operation of steam traps.
Remove air from indirect steam using equipment
Reduce the work done by steam
Insulate pipelines

_________________________ 12
Paper 2 Set A Solution
Regn No: ____ _____________

Name: ___________________
th
6 NATIONAL CERTIFICATION EXAMINATION May, 2008
FOR


Please hatch the appropriate oval in the OMR answer sheet with Black Pen, as per
instructions
1 0
The heat required for phase change from water at 0 C to ice is called
a) Specific Heat b) Superheat c) Latent heat d) Sensible heat
2 The thermostatic trap operates on the principle of:

a) Differential density b) Differential temperature
c) Differential thermodynamic properties d) differential pressure

3 To drain condensate from steam mains, the trap normally used is :
a) Bucket trap b) Thermostatic trap
c) Thermodynamic trap d) Float trap
0
4 Pre-heating of combustion air by 100 C will save about ------% of fuel.
a) 0.5 b) 5 c) 2.5 d) None of the above
Fluidized bed combustion takes place in the temperature range of :
0 0 0 0
a) above 1000 C b) below 500 C c) 600-700 C d) 800-900 C
_______________________ 1
6 Excess air can be derived by measuring the % of ------- in flue gases.

a) CO b) N2 c) O2 d) SO2
7 The lower limit to exit flue gas temperature of furnace oil fired system is dependant
on ------- in fuel.
a) Ash b) Magnesium c) Sulphur. d) Carbon
8 The viscosity of furnace oil will be maximum at which of the following temperatures
o o o o
a) 40 C b) 60 C c) 90 C d) 110 C
9 Which of the following releases the maximum energy per kg on complete

combustion.
a) Carbon b) Hydrogen c) Sulphur. d) Magnesium
10 The % sulphur content of LSHS is about

a) 2 b) 4 c) 0 d) 0.5
11 The type of draft used in an oil fired package boiler is

a) Balanced draft b) Natural draft.
c) Forced draft d) Induced draft
12 In flue gas the theoretical CO2 is 15% and the measured CO2 is 12% by volume.
The % excess air is:
a) 50% b) 150% c) 25% d)20%
13 Which data is not required to calculate the efficiency of boiler by indirect method
a) Flue gas temperature b) Ambient temperature
c) Calorific value of fuel d) Blow down rate
14 For coal fired system the flame length is dictated by:

a) Moisture b) Volatile matter c) Ash content d) Fixed Carbon
15 De-aeration of boiler feed water is referred to as

a) Removal of silica b) Removal of dissolved gases.
c) Removal of TDS d) Phosphate conditioning

16 Velocity of steam in a pipe depends on
a) Number of bends b) Length of pipe
c) Specific volume of steam d) None of the above
17 Concentration of solids in boiler drum is controlled by :
a) Reducing dosage of chemicals b) Steam venting
c) Blowdown d) condensate recovery
18 The heat loss dependant on chemical characteristics of liquid fuel is:
a) Unburnt losses b) blowdown loss
c) Radiation loss d) Hydrogen loss
_______________________ 2
19 High emissivity coatings are most effective on :

a) Outer surface of furnace b) Inner surface of furnace
c) Furnace charge d) burner nozzles
20 Pick the wrong statement. The thermal efficiency of a furnace increases by :

a) Reducing surface heat loss. b) Preheating Combustion air.
c) Increasing excess air d) Minimising unburnt losses
21 The use of ceramic fibre in a batch type furnace results in fuel economy is due to:
a) Chemical resistance b) Thermal shock resistance
c) Lower maintenance d) Lower heat storage
22 Which of the following when added to aluminosilicate helps in reducing shrinkage

level of ceramic fibre:
a) MgO b) ZrO2 c) MgSO4 d) CaSO4
23 Which is the common coal firing system used in Indian thermal power plants?
a) pulverized coal firing b) stoker firing c) AFBC d) PFBC
24 Which of the following fuel requires maximum air for stochiometric combustion?
a) Furnace oil b) Bagasse c) Hydrogen d) Coal

26 Evaporation ratio of an efficient oil fired boiler is in the range of

a) 5 - 6 b) 13 14 c) 1 - 3 d) 7 9

b) more steam generation

c) greater purity of feed water
28 Which property is the most important for an insulating brick:

a) Mechanical strength b) Chemical resistance
c) Compact strength d) Porosity
29 What type of steam is used for electric power generation in thermal power plants
a) Dry saturated b) High pressure with superheat.
c) Wet steam d) None of the above
Air compressor alone consumes about _____ of the energy generated in a gas turbine
a) 5-10% b) 10-20% c) 20-30% d) 50-60%

_______________________ 3
31 In a glass industry waste heat is used for power generation. This type of
cogeneration is called
c) gas turbine cycle d) reheat cycle
32 In circulating fluidized bed combustion boilers most of the heat transfer takes place

33 Water hammer in a steam system is caused by
a) collected condensate hitting obstructions
b) leaking pipe joints

c) slow moving steam
d) continuous slope in direction of flow
34 When pure hydrogen is burn with stochiometric air, percentage nitrogen on volume
basis in flue gas on dry basis will be
a) 79% b) 21% c) < 21% d) 100%
35 Latent heat of any vapour at its critical point will be

a) highest b) above zero c) zero d) less then zero
36 Steam separators are used in steam lines to remove

a) water droplets from the wet steam b) dirt from the steam
c) air from the steam d) silica from the steam

37 High percentage of carbon monoxide presence in the flue gas of boiler is an indicator
of
a) high excess air b) complete combustion
c) good control of pollutants d) low excess air
38 Flash steam can be recovered from

a) leaking steam b) condensate at vacuum
c) condensate at high pressure d) condensate at atmospheric pressure

39 The type of combustion used for coal fired combined cycle power generation
application is
a) CFBC b) AFBC c) PFBC d) All the above
40 Reverse osmosis for water treatment involves

a) removal of total salts b) removal of only hardness causing salts
c) removal of alkali salts d) removal of non-hardness salts
When 100 kg of fuel with 60% carbon is burnt with theoretical air, the mass of CO 2 released
will be
a) 319 kg b) 4400 kg c) 4500kg d) 220 kg

_______________________ 4
42 When a vapour-liquid combination of 1 kg water at 120C is supplied with 50 kCal of

heat at constant pressure conditions, its temperature will be
a) 220C b) 190C c) 170C d) 120C
43 Strainers are used in steam line to ensure that

a) no steam reaches the trap b) no dirt reaches the trap
c) no condensate reaches the trap d) no air reaches the trap

44 Radiation losses from a boiler practically
a) increase with increase in its % loading
b) decrease with increase in its % loading

c) are independent of its % loading
d) none of the above.
45 The large difference between GCV and NCV of gaseous fuels is due to their
a) large moisture content b) no moisture content
c) low hydrogen content d) large hydrogen content

46 Parallel flow arrangement instead of counter flow arrangement of two streams in a
metallic recuperator is chosen because
a) combustion air also serves the purpose of cooling duct carrying the flue
gases.
b) temperature difference between the two steams is constant along the flow
direction.
c) pressure drops in the two steam are less in this arrangement
d) combustion air can easily enter the recuperator in the flow direction of the flue
gases.
47 Which of the following heat recovery equipment works on a refrigeration cycle ?
a) thermocompressor b) heat wheel c) heat pump d) heat pipe
48 In which of the following equipment stored heat is used for preheating combustion air
a) Convective recuperator b) radiation recuperator
c) regenerator d) heat pump
49 Reduction of steam pressure in a process heating application will
a) reduce the steam temperature b) reduce the sensible heat
c) increase the enthalpy of evaporation d) all of the above
50 At the same temperature which of the following fuels will have maximum viscosity ?
a) LDO b) HSD c) Furnace oil d) LSHS
.. End of Section I ...
_______________________ 5

S-1 For stochiometric combustion of C3H8 , estimate air to fuel ratio.
Ans. C3H8 + 5O2 + 5 x 3.76 N2 = 3CO2 + 4H2O + 5 x 3.76 N2

Air to fuel ratio = massofairrequired = 5x4.78x29 = 15.7 kg/kg
massoffuel 44
5 Marks
S-2 An oil-fired boiler is generating 10 TPH of saturated steam at absolute

2 o
pressure of 10 kg/cm . boiler feed water temperature is 60 C. Estimate
o
its F & A capacity if the latent heat of steam at 100 C is 540 kCal/kg (At
2
10 kg/cm the enthalpy of steam is 662 kcal/kg)
2
Rate at which Heat is supplied for converting 10 TPH 60C water to 10 kg/cm
Saturated steam = 10 x 1000 x (662-60) kcal

3 Marks
Steam generated at F & A 100C = 10x 1000 x (662-60)/ 540 = 11.15 TPH
2 Marks
S-3 Two identical biomass fired boilers of capacity 10 TPH are operated in a
chemical industry. They have a full load efficiency of 80%. The part load
efficiencies at 70% and 40% load are 75% and 68% respectively. For
meeting 14 TPH requirement of steam, would you prefer to run both the
boilers at 7 TPH capacity or one at full load capacity and other at 40%
capacity. Estimate the % savings in the preferred case.
Fuel energy required when both the boilers are run at 7 TPH load
2 x7 x h
= = 18.67 h
0.75
2 Marks
Fuel energy required when one boilers is running at full load and other at part
load of 40%
10 h 4x h
= + = 18.38 h
0.8 0.68
2 Marks
The first care is preferred
18.67 18.38
% savings = x 100 = 1.55%
18.67
1 Mark
_______________________ 6
S-4 List the properties which are measured in proximate analysis and ultimate
analysis of solid fuels
proximate analysis
moisture
volatile matter
ash
fixed carbon
3 Marks for any three
Ultimate Analysis
Moisture
% of different elements (hydrogen, carbon, sulfur, nitrogen, oxygen)
Ash (or mineral water )
2 Marks for any two
2
S-5 The average surface temperature of a bare furnace walls (area = 80 m ) with
surrounding ambient air temperature of 40C, is recorded to be 130C.
After insulation of the wall, the surface temperature reduces to 50C. If
the fuel oil (calorific value = 11,000 kcal/kg) cost is Rs. 22,000 per tonne,
and efficiency of the furnace is 35%, estimate annual savings from the
insulation of the wall for 300 working days per year.
13040
Rate of heat loss from the wall = 80 [10+ 3
] (130-40) = 104.4 x10
20
kcal/hr
2 Marks
Rate of heat loss from the insulation wall = 80 [ 10 + 5040 ] (50-40) = 8.4 x
20
3
10 kcal/hr
2 Marks
3 8
Annual energy savings = (104.4-8.4) x 10 x 300 x 24 = 6.9 x 10 kcal/hr
6.9x108
5
Annual fuel savings = = 1.8 x 10 kg
0.35x11000
1.8x105x22000
Annual Rs savings = 1000
= 3.96 x 106
1 Mark
S-6 What do you understand by the term quality of waste heat
Name two devices, which are used for improving the energy quality of
streams and explain the functioning of any one in brief.
_______________________ 7
The quality of waste heat refers to the temperature at which it is available
1 Mark
Two devices are

1, Heat pump
2.Thermocompressors
2 Marks
(1) Heat Pump
The majority of heat pumps work on the principle of the vapour compression
cycle. In this cycle, the circulating substance is physically separated from the
source (waste heat, with a temperature of T in) and user (heat to be used in the
process, Tout) streams, and is re-used in a cyclical fashion, therefore called
'closed cycle'. In the heat pump, the following processes take place:
In the evaporator the heat is extracted from the heat source to boil the
circulating substance;
The circulating substance is compressed by the compressor, raising its

pressure and temperature; The low temperature vapor is compressed
by a compressor, which requires external work. The work done on the
vapor raises its pressure and temperature to a level where its energy
becomes available for use
The heat is delivered to the condenser;
The pressure of the circulating substance (working fluid) is reduced back

to the evaporator condition in the throttling valve, where the cycle
repeats.
The heat pump was developed as a space heating system where low
temperature energy from the ambient air, water or earth is raised to heating
system temperatures by doing compression work with an electric motor driven
compressor
2 Marks
(OR)
(2) Thermocompressor :
In many cases, very low pressure steam are reused as water after
condensation for lack of any better option of reuse. In many cases it
becomes feasible to compress this low pressure steam by very high
pressure steam and reuse it as a medium pressure steam. The major
energy in steam, is in its latent heat value and thus thermocompressing would
give a large improvement in waste heat recovery.
The thermocompressor is a simple equipment with a nozzle where HP
steam is accelerated into a high velocity fluid. This entrains the LP
_______________________ 8
steam by momentum transfer and then recompresses in a divergent

venturi. A figure of thermocompressor is shown in Figure.
It is typically used in evaporators where the boiling steam is recompressed
and used as heating steam.
Thermocompressor
2 Marks
S-7 A reheating furnace output is 8 tons/hour. Thermal efficiency is 15% on NCV

o
basis. Specific heat of billet is 0.12 kcal/kg C. Billets enter the furnace at
o o
50 C and leave at 1200 C. Calculate the hourly oil consumption in liters
per hour.(NCV of oil is 9650 kCal/kg & Specific gravity of oil is 0.95.)

heat in the fuel Flow rate (kgs/hr) x9650
4 Marks
Flow rate of oil =762.7 kg/hr or 762.7/0.95=802.8 lit/hr

1 Mark
2
S-8 A coal-fired boiler is generating steam at 8 kg/cm . The evaporation ratio of
the boiler is 5. The NCV of the fuel is 3800 kCal/kg. The Hydrogen and
moisture content in the coal are 3% and 6% respectively. Find out the
efficiency of the boiler on GCV basis if the enthalpy of the steam is 661
o
kCal/kg and the feed water temperature is 48 C
Answer
GCV = NCV + (9H + M) x 584
= 3800 + (9 x .03 + .06) x 584 = 3992.72 kCal/kg
2 Marks
Efficiency = Evaporation ratio x (Enthalpy of steam- enthalpy of water)x 100/

GCV
5 x (661-48) x 100 / 3992.72
76.76%
3 Marks
_______________________ 9
.. End of Section II ...

L-1 What are the functions of a steam trap ?
Explain with a neat sketch the working principle of thermodynamic trap.

Functions of Steam Traps
Thethreeimportantfunctionsofsteamtrapsare:
Todischargecondensateassoonasitisformed
Nottoallowsteamtoescape
Tobecapableofdischargingairandotherincondensiblegases
3 Marks
Working principle of thermodynamic trap

Thethermodynamic trapoperates bymeansofthedynamiceffect offlashsteam asit passes
throughthetrap.Theonlymovingpartisthediscabovetheflatfaceinsidethecontrolchamberor
cap.
Onstartup,incomingpressureraisesthedisc,andcoolcondensateplusairisimmediately
dischargedfromtheinnerring,underthedisc,andoutthroughthreeperipheraloutlets.
Hotcondensateflowingthroughtheinletpassageintothechamberunderthediscdropsin
pressureandreleasesflashsteammovingathighvelocity.Thishighvelocitycreatesa
lowpressureareaunderthedisc,drawingittowardsitsseat.Atthesametime,theflash
steampressurebuildsupinsidethechamberabovethedisc,forcingitdownagainstthe
incomingcondensateuntilitseatsontheinnerandouterrings.Atthispoint,theflash
steamistrappedintheupperchamber,andthepressureabovethediscequalsthepressure
beingappliedtotheundersideofthediscfromtheinnerring.However,thetopofthedisc
issubjecttoagreaterforcethantheunderside,asithasagreatersurfacearea.
Thediscisraisedbythenowhighercondensatepressureandthecyclerepeats
_______________________ 10
4 Marks for explanation and 3 marks for sketch
L-2 Explain the following
Dryness fraction of steam

Net calorific value
Emissivity coatings
Turndown ratio

Dryness fraction is defined as mass of dry steam in one kg of mixture of dry
steam and water vapour.
(or)
The total heat of dry saturated steam or enthalpy of saturated steam is given by
sum of the two enthalpies hf +hfg. When the steam contains moisture the total
heat of steam will be hg = hf + hfg where is the dryness fraction. Here is
fraction.
2 .5 Marks
Net calorific value

The calorific value is the measurement of heat or energy produced. Net calorific
value (NCV) assumes the water leaves with the combustion products without
fully being condensed.
2 .5 Marks
Emissivity coatings
high emissivity coatings allows the surface emissivity of materials to be
increased, with resultant benefits in heat transfer efficiency and in the service life
of heat transfer components. High emissivity coatings are applied in the interior
surface of furnaces. High emissivity coating shows a constant value of emisivity
_______________________ 11
over varying process temperatures.
The application of high-emissivity coatings in furnace chambers promotes rapid

and efficient transfer of heat, uniform heating, and extended life of Refractories
and metallic components such as radiant tubes and heating elements. For
intermittent furnaces or where rapid heating is required, use of such coatings was
found to reduce fuel or power to tune of 25-45%. Other benefits are temperature
uniformity and increased refractory life
2 .5 Marks
Turndown ratio
Turndown ratio is an important aspect to be considered in selection of burner.
Turndown ratio is the relationship between the maximum and minimum fuel input
without affecting the excess air level.
2 .5 Marks
L-3 Steam pipeline 100mm diameter is insulated with 25 mm mineral wool material. The
pipe line carries steam at 5 ata and has a length of 100m.Due to increased cost
of fuel, the Energy Auditor had recommended an increase of additional 25 mm of
thickness. Find out the economics if the additional cost of insulation is 0.5
lakhs. Assume 8000 hours of operation per year.
Given: Boiler efficiency on NCV basis : 80%
Cost of fuel oil : Rs. 22,000/tonne.
Net Calorific value of fuel : 9650 kCal/kg
0
Existing surface temperature of insulation : 80 C
0
Expected surface temperature after additional insulation : 40 C
0
Heat Loss: (Existing System)

Surface heat loss S= 10+(Ts Ta)/20
0
x(Ts-Ta)
0
2
2
=625 k.Cal/ hrm
3 Marks.
Heat Loss (Modified System) :

After insulating with additional 25mm mineral wool the surface temperature
0
has reduced to 40 C
Substituting values S= 10+(40 30)/20 x(40-
2
30) =105 k.Cal/ hrm
3 Marks
Calculation of Fuel Savings:

Pipe Details-Existing:100 m length and 100mm dia with 25mm thick insulation.
2
2
Surface area after additional insulation=3.14x0.2x100 =62.8 m
Total heat loss in existing system =625x47.1 =29,438 k.Cal/hr
_______________________ 12
Total heat loss in modified system =105x62.8 =6594 k.Cal/hr

Reduction in heat loss =29,438-6594 =22,844 k.Cal/hr
Savings in heat per year =22,844x8000 =182752000 k.Cal/yr
Annual savings in fuel oil =182752000/(9650x0.8)x1000 =23.673Tons
Monetary savings per annum =23.673x22000 =Rs5.21lakhs.
Simple Pay Back Period(Months) : (0.5/5.21)*12=1.07.
4 Marks
L-4 Draw simple schematic sketch to describe the following (No explanations
required)
Cogeneration with extraction condensing turbine

Combined cycle power plant
Diesel engine cogeneration
Bottoming cycle cogeneration
Cogeneration with double extraction backpressure turbine
a) Cogeneration with extraction condensing turbine
2 Marks
b) Combined cycle power plant
2 Marks
_______________________ 13
c) Diesel engine cogeneration
2 Marks
d) Bottoming cycle cogeneration
2 Marks
e) Cogeneration with double extraction backpressure turbine
2 Marks
L-5 a) List five benefits of condensate recovery
2
b) Condensate at a pressure of 10 kg/cm g is flashed to a lower pressure of 2
2
kg/cm g. If the Condensate flow rate is 1000 kg/hr. Calculate the % of flash steam

2
_______________________ 14
2
2
a) benefits of condensate recovery
Water charges are reduced.

Effluent charges and possible cooling costs are reduced.
Fuel costs are reduced.
More steam can be produced from the boiler.
Boiler blowdown is reduced - less energy is lost from the boiler.
Chemical treatment of raw make-up water is reduced.
5 Marks (1 for each point)
b)
% Flash Steam available : (185-133)/650 = 8 %

Flow rate of flash steam : 1000 x 8 %
: 80 kgs/hr
5 Marks
L-6 List 10 energy saving measures in boilers and steam systems
Energy saving measures in boiler
The stack temperature should be as low as possible.
Feed Water Preheating using Economiser
Combustion Air Preheat
Avoid Incomplete Combustion
Excess Air Control
Radiation and Convection Heat Loss
Automatic Blowdown Control
Reduction of Scaling and Soot Losses
Reduction of Boiler Steam Pressure
Variable Speed Control for Fans, Blowers and Pumps

_______________________ 15
Effect of Boiler Loading on Efficiency
Proper Boiler Scheduling
Energy saving measures in steam systems

Avoiding Steam Leakages
Utilising Steam at the Lowest Acceptable Pressure for the Process
Proper Utilization of Directly Injected Steam
Minimising Heat Transfer Barriers
Proper Air Venting
Condensate Recovery
Insulation of Steam Pipelines and Hot Process Equipments
10 Marks (One mark for any of the 10 points in boiler and steam)
.. End of Section III ...
_______________________ 16
Paper 2 Set B Solution
Regn No: ____ _____________

Name: ___________________
th
6 NATIONAL CERTIFICATION EXAMINATION May, 2008
FOR


Please hatch the appropriate oval in the OMR answer sheet with Black Pen, as per
instructions
1 What type of steam is used for electric power generation in thermal power plants
a) Dry saturated b) High pressure with superheat.
c) Wet steam d) None of the above
2 The heat loss dependant on chemical characteristics of liquid fuel is:

a) Unburnt losses b) blowdown loss
c) Radiation loss d) Hydrogen loss

3 When pure hydrogen is burn with stochiometric air, percentage nitrogen on volume
basis in flue gas on dry basis will be
a) 79% b) 21% c) < 21% d) 100%


The type of draft used in an oil fired package boiler is
a) Balanced draft b) Natural draft.

c) Forced draft d) Induced draft
_______________________ 1

6 Which of the following when added to aluminosilicate helps in reducing shrinkage

level of ceramic fibre:
a) MgO b) ZrO2 c) MgSO4 d) CaSO4
7 The type of combustion used for coal fired combined cycle power generation
application is
a) CFBC b) AFBC c) PFBC d) All the above
8 Strainers are used in steam line to ensure that

a) no steam reaches the trap b) no dirt reaches the trap
c) no condensate reaches the trap d) no air reaches the trap

9 In flue gas the theoretical CO2 is 15% and the measured CO2 is 12% by volume.
The % excess air is:
a) 50% b) 150% c) 25% d)20%

11 Excess air can be derived by measuring the % of ------- in flue gases.

a) CO b) N2 c) O2 d) SO2
12 Water hammer in a steam system is caused by

a) collected condensate hitting obstructions
b) leaking pipe joints

c) slow moving steam
d) continuous slope in direction of flow
13 De-aeration of boiler feed water is referred to as
a) Removal of silica b) Removal of dissolved gases.
c) Removal of TDS d) Phosphate conditioning

b) more steam generation

c) greater purity of feed water
15 High emissivity coatings are most effective on :

a) Outer surface of furnace b) Inner surface of furnace
c) Furnace charge d) burner nozzles
Air compressor alone consumes about _____ of the energy generated in a gas turbine
a) 5-10% b) 10-20% c) 20-30% d) 50-60%

_______________________ 2
17 High percentage of carbon monoxide presence in the flue gas of boiler is an indicator
of
18 Which of the following fuel requires maximum air for stochiometric combustion?
a) Furnace oil b) Bagasse c) Hydrogen d) Coal

20 At the same temperature which of the following fuels will have maximum viscosity ?
a) LDO b) HSD c) Furnace oil d) LSHS
21 In circulating fluidized bed combustion boilers most of the heat transfer takes place

22 The lower limit to exit flue gas temperature of furnace oil fired system is dependant
on ------- in fuel.
a) Ash b) Magnesium c) Sulphur. d) Carbon
23 Evaporation ratio of an efficient oil fired boiler is in the range of

a) 5 - 6 b) 13 14 c) 1 - 3 d) 7 9
o o o o
a) 40 C b) 60 C c) 90 C d) 110 C
0
25 The heat required for phase change from water at 0 C to ice is called
a) Specific Heat b) Superheat c) Latent heat d) Sensible heat
26 Fluidized bed combustion takes place in the temperature range of :

0 0 0 0
0
27 Pre-heating of combustion air by 100 C will save about ------% of fuel.
a) 0.5 b) 5 c) 2.5 d) None of the above
28 The thermostatic trap operates on the principle of:

a) Differential density b) Differential temperature
c) Differential thermodynamic properties d) differential pressure
29 In which of the following equipment stored heat is used for preheating combustion air
a) Convective recuperator b) radiation recuperator

_______________________ 3
30 To drain condensate from steam mains, the trap normally used is :

a) Bucket trap b) Thermostatic trap
c) Thermodynamic trap d) Float trap
31 The use of ceramic fibre in a batch type furnace results in fuel economy is due to:
a) Chemical resistance b) Thermal shock resistance
c) Lower maintenance d) Lower heat storage
32 When a vapour-liquid combination of 1 kg water at 120C is supplied with 50 kCal of

heat at constant pressure conditions, its temperature will be
a) 220C b) 190C c) 170C d) 120C
33 Which data is not required to calculate the efficiency of boiler by indirect method
a) Flue gas temperature b) Ambient temperature
c) Calorific value of fuel d) Blow down rate
34 Reduction of steam pressure in a process heating application will

a) reduce the steam temperature b) reduce the sensible heat
c) increase the enthalpy of evaporation d) all of the above
35 Pick the wrong statement. The thermal efficiency of a furnace increases by :

a) Reducing surface heat loss. b) Preheating Combustion air.
c) Increasing excess air d) Minimising unburnt losses
36 Concentration of solids in boiler drum is controlled by :
a) Reducing dosage of chemicals b) Steam venting
c) Blowdown d) condensate recovery
37 Which is the common coal firing system used in Indian thermal power plants?
a) pulverized coal firing b) stoker firing c) AFBC d) PFBC
38 Parallel flow arrangement instead of counter flow arrangement of two streams in a

metallic recuperator is chosen because
a) combustion air also serves the purpose of cooling duct carrying the flue
gases.
b) temperature difference between the two steams is constant along the flow
direction.
c) pressure drops in the two steam are less in this arrangement
d) combustion air can easily enter the recuperator in the flow direction of the flue
gases.
39 The % sulphur content of LSHS is about
a) 2 b) 4 c) 0 d) 0.5
40 The large difference between GCV and NCV of gaseous fuels is due to their
a) large moisture content b) no moisture content
c) low hydrogen content d) large hydrogen content
_______________________ 4

42 In a glass industry waste heat is used for power generation. This type of
43 Velocity of steam in a pipe depends on

a) Number of bends b) Length of pipe
c) Specific volume of steam d) None of the above
44 Which of the following releases the maximum energy per kg on complete
combustion.
a) Carbon b) Hydrogen c) Sulphur. d) Magnesium
45 Steam separators are used in steam lines to remove

a) water droplets from the wet steam b) dirt from the steam
c) air from the steam d) silica from the steam

46 Which property is the most important for an insulating brick:
a) Mechanical strength b) Chemical resistance
c) Compact strength d) Porosity
47 For coal fired system the flame length is dictated by:

a) Moisture b) Volatile matter c) Ash content d) Fixed Carbon

49 When 100 kg of fuel with 60% carbon is burnt with theoretical air, the mass of CO 2
released will be
a) 319 kg b) 4400 kg c) 4500kg d) 220 kg
Radiation losses from a boiler practically
increase with increase in its % loading

decrease with increase in its % loading
are independent of its % loading
none of the above.
.. End of Section I ...

_______________________ 5

S-1 For stochiometric combustion of C3H8 , estimate air to fuel ratio.
Ans. C3H8 + 5O2 + 5 x 3.76 N2 = 3CO2 + 4H2O + 5 x 3.76 N2

Air to fuel ratio = massofairrequired = 5x4.78x29 = 15.7 kg/kg
massoffuel 44
5 Marks
S-2 An oil-fired boiler is generating 10 TPH of saturated steam at absolute pressure of

2 o
10 kg/cm . boiler feed water temperature is 60 C. Estimate its F & A capacity if
o 2
the latent heat of steam at 100 C is 540 kCal/kg (At 10 kg/cm the enthalpy of
steam is 662 kcal/kg)
2
Rate at which Heat is supplied for converting 10 TPH 60C water to 10 kg/cm
Saturated steam = 10 x 1000 x (662-60) kcal

3 Marks
Steam generated at F & A 100C = 10x 1000 x (662-60)/ 540 = 11.15 TPH
2 Marks
S-3 Two identical biomass fired boilers of capacity 10 TPH are operated in a chemical
industry. They have a full load efficiency of 80%. The part load efficiencies at
70% and 40% load are 75% and 68% respectively. For meeting 14 TPH
requirement of steam, would you prefer to run both the boilers at 7 TPH
capacity or one at full load capacity and other at 40% capacity. Estimate the %
savings in the preferred case.
Fuel energy required when both the boilers are run at 7 TPH load
2 x7 x h
= = 18.67 h
0.75
2 Marks
Fuel energy required when one boilers is running at full load and other at part
load of 40%
10 h 4x h
= + = 18.38 h
0.8 0.68
2 Marks
The first care is preferred
18.67 18.38
% savings = x 100 = 1.55%
18.67
1 Mark
_______________________ 6
S-4 List the properties which are measured in proximate analysis and ultimate
analysis of solid fuels
(i) proximate analysis

moisture
volatile matter
ash
fixed carbon
3 Marks for any three

Ultimate Analysis
Moisture
% of different elements (hydrogen, carbon, sulfur, nitrogen, oxygen)
Ash (or mineral water )
2 Marks for any two
2
S-5 The average surface temperature of a bare furnace walls (area = 80 m ) with
surrounding ambient air temperature of 40C, is recorded to be 130C. After
insulation of the wall, the surface temperature reduces to 50C. If the fuel oil
(calorific value = 11,000 kcal/kg) cost is Rs. 22,000 per tonne, and efficiency
of the furnace is 35%, estimate annual savings from the insulation of the wall
for 300 working days per year.
11040
Rate of heat loss from the wall = 80 [10+ ] (130-40) = 118.8 x 10
3
20
kcal/hr
2 Marks
50 40
Rate of heat loss from the insulation wall = 80 [ 10 + ] (50-40) = 8.4 x
20
3
10 kcal/hr
2 Marks
3 8
Annual energy savings = (118.8-8.4) x 10 x 300 x 24 = 7.95 x 10 kcal/hr
7.95x108
5
Annual fuel savings = = 2.06 x 10 kg
0.35x11000
2.06x105x22000
Annual Rs savings = 1000
= 4.54 x 106
1 Mark
S-6 What do you understand by the term quality of waste heat
Name two devices, which are used for improving the energy quality of streams
and explain the functioning of any one in brief.
_______________________ 7
The quality of waste heat refers to the temperature at which it is available

1 Mark
Two devices are

Heat pump
Thermocompressors
2 Marks
(1) Heat Pump
The majority of heat pumps work on the principle of the vapour compression
cycle. In this cycle, the circulating substance is physically separated from the
source (waste heat, with a temperature of T in) and user (heat to be used in the
process, Tout) streams, and is re-used in a cyclical fashion, therefore called
'closed cycle'. In the heat pump, the following processes take place:
In the evaporator the heat is extracted from the heat source to boil the
circulating substance;
The circulating substance is compressed by the compressor, raising its

pressure and temperature; The low temperature vapor is compressed
by a compressor, which requires external work. The work done on the
vapor raises its pressure and temperature to a level where its energy
becomes available for use
The heat is delivered to the condenser;
The pressure of the circulating substance (working fluid) is reduced back

to the evaporator condition in the throttling valve, where the cycle
repeats.
The heat pump was developed as a space heating system where low
temperature energy from the ambient air, water or earth is raised to heating
system temperatures by doing compression work with an electric motor driven
compressor
2 Marks
(OR)
(2) Thermocompressor :
In many cases, very low pressure steam are reused as water after
condensation for lack of any better option of reuse. In many cases it
becomes feasible to compress this low pressure steam by very high
pressure steam and reuse it as a medium pressure steam. The major
energy in steam, is in its latent heat value and thus thermocompressing
would give a large improvement in waste heat recovery.
The thermocompressor is a simple equipment with a nozzle where HP
steam is accelerated into a high velocity fluid. This entrains the LP
steam by momentum transfer and then recompresses in a divergent
venturi. A figure of thermocompressor is shown in Figure.
It is typically used in evaporators where the boiling steam is
_______________________ 8
recompressed and used as heating steam.
Thermocompressor
2 Marks
S-7 A reheating furnace output is 10 tons/hour. Thermal efficiency is 15% on NCV

o o
basis. Specific heat of billet is 0.12 kcal/kg C. Billets enter the furnace at 50 C
o
and leave at 1200 C. Calculate the hourly oil consumption in liters per hour.
(NCV of oil is 9650 kCal/kg & Specific gravity of oil is 0.95.)

heat in the fuel Flowrate(kgs/hr) x9650
4 Marks
Flow rate of oil = 953.36 kg/hr
or
762.7/0.95=1003.54lit/hr
1 Mark
2
S-8 A coal-fired boiler is generating steam at 8 kg/cm . The evaporation ratio of the
boiler is 5. The NCV of the fuel is 3800 kCal/kg. The Hydrogen and moisture
content in the coal are 4% and 9% respectively. Find out the efficiency of the
boiler on GCV basis if the enthalpy of the steam is 661 kCal/kg and the feed
o
water temperature is 48 C
Answer
GCV = NCV + (9H + M) x 584
= 3800 + (9 x .04 + .09) x 584 = 4062.8 kCal/kg
2 Marks
Efficiency = Evaporation ratio x (Enthalpy of steam- enthalpy of water)x 100/

GCV
5 x (661-48) x 100 / 4062.8
75.4%
3 Marks
_______________________ 9
.. End of Section II ...

L-1 What are the functions of a steam trap ?
Explain with a neat sketch the working principle of thermodynamic trap.

Functions of Steam Traps
Thethreeimportantfunctionsofsteamtrapsare:
Todischargecondensateassoonasitisformed
Nottoallowsteamtoescape
Tobecapableofdischargingairandotherincondensiblegases
3 Marks
working principle of thermodynamic trap

Thethermodynamic trapoperates bymeansofthedynamiceffect offlashsteam asit passes
throughthetrap.Theonlymovingpartisthediscabovetheflatfaceinsidethecontrolchamberor
cap.
Onstartup,incomingpressureraisesthedisc,andcoolcondensateplusairisimmediately
dischargedfromtheinnerring,underthedisc,andoutthroughthreeperipheraloutlets.
Hotcondensateflowingthroughtheinletpassageintothechamberunderthediscdropsin
pressureandreleasesflashsteammovingathighvelocity.Thishighvelocitycreatesa
lowpressureareaunderthedisc,drawingittowardsitsseat.Atthesametime,theflash
steampressurebuildsupinsidethechamberabovethedisc,forcingitdownagainstthe
incomingcondensateuntilitseatsontheinnerandouterrings.Atthispoint,theflash
steamistrappedintheupperchamber,andthepressureabovethediscequalsthepressure
beingappliedtotheundersideofthediscfromtheinnerring.However,thetopofthedisc
issubjecttoagreaterforcethantheunderside,asithasagreatersurfacearea.
Thediscisraisedbythenowhighercondensatepressureandthecyclerepeats
_______________________ 10
4 Marks for explanation and 3 marks for sketch
L-2 Explain the following

Net calorific value
Emissivity coatings
Turndown ratio

Dryness fraction is defined as mass of dry steam in one kg of mixture of dry
steam and water vapour.
(or)
The total heat of dry saturated steam or enthalpy of saturated steam is given by
sum of the two enthalpies hf +hfg. When the steam contains moisture the total
heat of steam will be hg = hf + hfg where is the dryness fraction. Here is
fraction.
2 .5 Marks
Net calorific value

The calorific value is the measurement of heat or energy produced. Net calorific
value (NCV) assumes the water leaves with the combustion products without
fully being condensed.
2 .5 Marks
Emissivity coatings
high emissivity coatings allows the surface emissivity of materials to be
increased, with resultant benefits in heat transfer efficiency and in the service life
of heat transfer components. High emissivity coatings are applied in the interior
surface of furnaces. High emissivity coating shows a constant value of emisivity
_______________________ 11
over varying process temperatures.
The application of high-emissivity coatings in furnace chambers promotes rapid

and efficient transfer of heat, uniform heating, and extended life of Refractories
and metallic components such as radiant tubes and heating elements. For
intermittent furnaces or where rapid heating is required, use of such coatings was
found to reduce fuel or power to tune of 25-45%. Other benefits are temperature
uniformity and increased refractory life
2 .5 Marks
Turndown ratio
Turndown ratio is an important aspect to be considered in selection of burner.
Turndown ratio is the relationship between the maximum and minimum fuel input
without affecting the excess air level.
2 .5 Marks
L-3 Steam pipeline 100mm diameter is insulated with 25 mm mineral wool material. The
pipe line carries steam at 5 ata and has a length of 100m.Due to increased cost
of fuel, the Energy Auditor had recommended an increase of additional 25 mm of
thickness. Find out the economics if the additional cost of insulation is 0.5
lakhs. Assume 8000 hours of operation per year.
Given: Boiler efficiency on NCV basis : 80%
Cost of fuel oil : Rs. 22,000/tonne.
Net Calorific value of fuel : 9650 kCal/kg
0
Existing surface temperature of insulation : 70 C
0
Expected surface temperature after additional insulation : 40 C
0
Heat Loss: (Existing System)

Surface heat loss S= 10+(Ts Ta)/20
0
x(Ts-Ta)
0
2
2
=480 k.Cal/ hrm
3 Marks
Heat Loss (Modified System) :
After insulating with additional 25mm mineral wool the surface temperature
0
has reduced to 40 C
Substituting values S= 10+(40 30)/20 x(40-
2
30) =105 k.Cal/ hrm
3 Marks
Calculation of Fuel Savings:

Pipe Details-Existing:100 m length and 100mm dia with 25mm thick insulation.
2
2
Surface area after additional insulation=3.14x0.2x100 =62.8 m
Total heat loss in existing system = 480x47.1 =22608 k.Cal/hr
_______________________ 12
Total heat loss in modified system =105x62.8 =6594 k.Cal/hr
Reduction in heat loss =22608-6594 =16014 k.Cal/hr

Savings in heat per year =16014x8000 =182752000 k.Cal/yr
Annual savings in fuel oil =128112000/(9650x0.8)x1000 =16.6Tons
Monetary savings per annum =16.6x22000 =Rs3.652lakhs.
Simple Pay Back Period(Months) : (0.5/3.652)*12=1.64 months
4 Marks
L-4 Draw simple schematic sketch to describe the following (No explanations
required)
Cogeneration with extraction condensing turbine

Combined cycle power plant
Diesel engine cogeneration
Bottoming cycle cogeneration
Cogeneration with double extraction backpressure turbine
a) Cogeneration with extraction condensing turbine
2 Marks
b) Combined cycle power plant
2 Marks
_______________________ 13
c) Diesel engine cogeneration
2 Marks
d) Bottoming cycle cogeneration
2 Marks
e) Cogeneration with double extraction backpressure turbine
2 Marks
_______________________ 14
L-5 a) List five benefits of condensate recovery
2
b) Condensate at a pressure of 10 kg/cm g is flashed to a lower pressure of 2
2
kg/cm g. If the Condensate flow rate is 2000 kg/hr. Calculate the % of flash steam

2
2
2
benefits of condensate recovery
Water charges are reduced.

Effluent charges and possible cooling costs are reduced.
Fuel costs are reduced.
More steam can be produced from the boiler.
Boiler blowdown is reduced - less energy is lost from the boiler.
Chemical treatment of raw make-up water is reduced.
5 Marks (1 for each point)
b)
% Flash Steam available : (185-133)/650
:8 %
Flow rate of flash steam : 2000 x 8 %
: 160 kg/hr
5 Marks
L-6 List 10 energy saving measures in boilers and steam systems

Energy saving measures in boiler
The stack temperature should be as low as possible.
Combustion Air Preheat
Avoid Incomplete Combustion
Excess Air Control

_______________________ 15
Reduction of Scaling and Soot Losses
Effect of Boiler Loading on Efficiency
Proper Boiler Scheduling
Energy saving measures in steam systems

Proper Air Venting
Condensate Recovery
10 Marks (One mark for any of the 10 points in boiler and steam)
_______________________ 16
Paper 3 Set A Key
Regn No: ____ _____________

Name: ___________________
7th NATIONAL CERTIFICATION EXAMINATION Nov. 2008

FOR
PAPER 3: Energy Efficiency in Electrical Utilities
_______________________ 1
Paper 3 Set A Key
_______________________ 2
Paper 3 Set A Key
_______________________ 3
Paper 3 Set A Key
_______________________ 4
Paper 3 Set A Key
_______________________ 5
Paper 3 Set A Key
_______________________ 6
Paper 3 Set A Key
_______________________ 7
Paper 3 Set A Key

S-1 List any five problems that can arise due to harmonics in a system.
Answer:
The problems that arise due to harmonics in a system are:
Blinking of Incandescent Lights - Transformer Saturation
Capacitor Failure - Harmonic Resonance
Circuit Breakers Tripping - Inductive Heating and Overload
Conductor Failure - Inductive Heating
Electronic Equipment Shutting down - Voltage Distortion
S-2 Why does the power factor of a induction motor decreases with the decrease in the
applied load on the motor?
kW
The power factor of the motor is given as: Power Factor Cos kVA
As the load on the motor decreases, the magnitude of the active current or active
power decreases. However, there is no corresponding decrease in the
magnetizing current or reactive power, which is proportional to the supply
voltage. With the result, the apparent current or apparent power does not
decrease in the same proportion to that of the active current or active power.
Therefore, the motor power factor decrease, with decrease in the applied load.
S-3 A water pump is delivering 300 m3/hr flow at 40 meter head at ambient conditions.
The pump shaft power is 52kW. The impeller diameter is trimmed by 8%. Find
out the new water flow, head and pump shaft power at the changed condition.
Q1 = 300 m3 / hr.
D2 = 0.92 D1
Q2 = ?
Q D Q1 = D1
Q2 D2
_______________________ 8
Paper 3 Set A Key
300 = D1 D1
Q2 0.92
Q2 = 0.92 x 300
Q2 = 276 m3 /hr.
Head= ( D1/0.92 D1)2 = (1.0869)2 =1.1815

40/H2 = 1.1815
H2 = 40/1.1815=33.85 m
Power= ( D1/0.92 D1)3= (1.0869)3=1.284 52/P2
=1.284
P2= 52/1.284
= 38.94 kW
S-4 If inlet and outlet water temperatures of a cooling tower are 42 oC and 36oC
respectively and atmospheric DBT and WBT are 39 oC and 32 oC respectively,
find out the range, approach and the effectiveness of cooling tower.
Range: 42-36=6 deg C
Approach: = 36-32= 4 deg C
Cooling Tower Effectiveness = Range / (Range + Approach).

6/ (6+4)
0.60
S-5 Draw a sketch of a typical centrifugal fan characteristic curve along with system
resistance. (Note: No explanation is required)
Y axis can be total pressure or static pressure
_______________________ 9
Paper 3 Set A Key
S-6 The COP of a vapour compression refrigeration system is 3.0. If the compressor
motor draws power of 15 kW at 90% motor efficiency, find out the tonnage of the
refrigeration system.
Answer:
Power input to compressor = 0.90 x 15
= 13.5kw
Cooling effect = 13.5 x 3.0
= 40.5 kw
40.5 kW x 860 kcal/kwh = 34830 kcals/hr
Refrigeration tonnage = 34830/3024
= 11.52 Tonnes
S-7 List any 5 energy conservation opportunity in an air compression system
Answer
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 4 0C rise in
air inlet temperature will increase power consumption by 1 percent.
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.
_______________________ 10
Paper 3 Set A Key
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.
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.
_______________________ 11
Paper 3 Set A Key
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 equipments 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.
S-8 A Reciprocating Compressor with 220 CFM capacity is connected with a 75 HP

motor. The energy manager of the plant noticed frequent unloading and loading
of compressor .In your opinion, what reasons he may conclude for this situation
and accordingly propose the remedial actions.
Answer:
There could be three reason(s)

Requirement of compressed air for plant is very less.
Compressor selected is higher capacity.
Malfunctioning of unloader valves.
To replace existing Motor with smaller capacity motor after measuring actual
requirement of compressed air, this could be done by measuring loading and
unloading time of compressor.
_______________________ 12
Paper 3 Set A Key
OR
To increase driven side Pulley size. It will reduce capacity of compressor as well
power consumption
OR
To go for VFD
-------- End of Section II ---------

L-1 A 7.5 kW, 415 V, 14.5 Amp,4 pole, 50 Hz rated, 3 phase squirrel cage induction
motor has a half load efficiency of 84% and power factor of 0.7. Find the
following if the motor operates at 50% of its rated output.
Current drawn by the motor

Ratio of the current drawn to its rated current. Is this exactly 50% at half loading?
If not, briefly explain the reasons for the same.
RPM at a half load slip of 2%
ANS:
a) Pin (Input power) = 7.5x0.5/ 0.84 = 4.46428 kW I(Input
current) = 4.46428/ (3 x 0.415 x 0.70) = 8.87 A
b) Ratio of the current drawn to its rated current = 9/14.5=61.2%

NO, this ratio is not exactly half.
The current drawn by the motor is the resultant sum of the active and
reactive current of the induction motor. The reactive current drawn is
independent of load as it is supply voltage dependent, and hence remains
constant as long as the supplied voltage remains constant. On the other
hand, active current drawn is directly proportional to load and changes in
direct proportion to the load. Therefore, the resultant of active current and
reactive current, which is the current drawn by the motor, does not change
in direct proportion to the change in load as one of the current component
is load independent. Therefore, current drawn by the induction motor at
any part load may not be a true reflection of the load.
_______________________ 13
Paper 3 Set A Key
Ns = 120 x f / p = 120 x 50 / 4 = 1500 RPM N

= Ns ( 1- S )
1500 ( 1- 0.02)
1470 RPM
L-2 Give very short answers for the following
Which loss is assumed in the efficiency determination of an induction motor?

Which parameter needs to be measured to assess the percentage loading of a
motor by slip method neglecting voltage correction?
What is meant by the term specific power requirement with respect to air
compressors? State the units.
Which three variables need to be measured to calculate the efficiency of a
pump?
Which expression to state the energy efficiency of a chiller does not follow the
trend a higher number means a more efficient system?
ANS:
Stray losses
Motor speed
The ratio of power consumption (in kW) to the volume delivered at ambient
conditions. Unit is kW per cubic meter per hour or kW/(m3/hr)
The variables to be measured (i) volumetric flow (ii) pressure difference
across the pump and (iii) electrical power input to the motor driving the
pump.
The expression power per ton (in kW/ton) does not follow the trend. The
higher the number the more inefficient the chiller.
L-3 The suction head of a pump is 3 m below the pump centerline. The pump discharge
pressure is 2.9 kg/cm2. The flow rate of water is 90 m3 /hr. Find out the pump
efficiency if the actual power input by the motor is 15kW. Assume motor
efficiency at the operating load as 88%.
Discharge Head : 2.9 kg/cm2 equals 29 metre head.
Suction Head : - 3 metre.
Total Head : 29 (-3) = 32 metre.
Hydraulic Power : (90/3600) x 1000 x 9.81 x 32/1000 = 7.848 kW
Pump Efficiency : 100 x 7.848/(15x0.88) = 59.45%
L-4 A V-belt driven centrifugal fan is supplying air in a process plant. The
performance test conducted by an energy auditor on the fan generated the
following data:
_______________________ 14
Paper 3 Set A Key
Ambient temperature 30oC

Density of air at 0oC 1.293 kg/m3
Diameter of the discharge air duct 0.8 m
Velocity pressure measured by Pitot tube in 45 mmWC
discharge duct
Pitot tube coefficient 0.9
Static pressure at fan inlet - 20 mmWC
Static pressure at fan outlet 185 mmWC
Power drawn by the motor coupled with the fan 70 kW
Belt transmission efficiency 96%
Motor efficiency at the operating load 90 %
The energy auditor concludes after analyzing the above data that the efficiency
of the fan is about 33.3%. Do you agree with his above observation? If not, can
you find the mistake made by the auditor?
Ans:
Ambient temperature 30oC

Diameter of the discharge air duct 0.8 m
Velocity pressure measured by Pitot tube 45 mmWC
Static pressure at fan inlet - 20 mmWC
Static pressure at fan outlet 185 mmWC
Power drawn by the motor 70 kW
Transmission efficiency 96%
Motor efficiency 90 %
Area of the discharge duct 3.14 x 0.8 x 0.8 x 1/4
0.502672 m2
Pitot tube coefficient 0.9
Corrected gas density (273 x 1.293) / (273 + 30) = 1.165
Air velocity
Cp x 2 x 9.81 x U p x

0.9 x Sq rt.(2 x 9.81 x 45 x 1.165)

1.165
24.776 m/s
Volume 24.776 x 0.502672

12.4543 m3/s
Power input to the shaft 70 x 0.96 x 0.9
60.48 kW
_______________________ 15
Paper 3 Set A Key
Static Fan Efficiency % Volume in m3 / Sec x total static pressure in mmwc

102 x Power input to the shaft in (kW)
Fan static Efficiency 12.4543 x (185 (-20)

102 x 60.48
41%
No, the fan static efficiency is 41%. The auditor, while working out the total static
pressure has committed a mistake. He has taken suction pressure as positive.
Fan static Efficiency = 12.4543 x (185

(20) 102 x 60.48
= 33.3%
L-5 The parameters measured for of a centrifugal chiller are as follows:
_______________________ 16
Paper 3 Set A Key
Cooling effect (kW)
Evaluate the CoP of centrifugal chiller

Find the ratio of evaporator refrigeration load(TR) to condenser heat rejection
load(TR)
Ans. i. Refrigeration load (TR) : (m x cp x t)/3024

: 8o x 3600 x 1 x (13-
8)/3024 : 476 TR
Coefficient of performance COP = Power input to compressor (kW)

= (476TRx3024/860) / 300= 5.579
ii. Evaporator cooling load (TR) : 476 TR
Condenser heat rejection load (TR) : 185 x 3600 x (28 25.2)/3024

: 616 TR
Ratio : Evaporator 0.77
476
Condenser 616
L-6: a) Two FD fans, one fan on each side of the Boiler, are supplying the total
combustion air requirement for a boiler. These fans are connected to a common
header through discharge dampers. Each fan is having 260 kW rating and
provided with VSDs. Each fan is designed to cater 60% of Boiler capacity
(MCR).
It was observed by an energy auditor that when one FD fan was in service
(when the boiler requirement is below 60% MCR), power drawn by that fan is
105 kW at 570 rpm where as the total power drawn by keeping both the fans in
service for the same steam generation (below 60% MCR) is around 70 kW only
(each fan is drawing 35 kW at 430 rpm).
In your opinion what could be the reasons for low power consumption with both
fans in service than a single fan for generation of same quantity of steam? (Note:
No calculation or working is required. Only brief explanation is sufficient)
Answer:
When one fan was in service as it was common discharge header system the possibility
of recirculation of part of air from the running fan cannot be ruled out due to passing of
discharge dampers and inlet vane of the fan that is not in service. This increases the air
requirement for maintaining the same excess oxygen conditions, hence increase in load
on the running fan.
_______________________ 17
Paper 3 Set A Key
Second reason can be that when only one fan is in service as airflow is from one side
only, increases the system resistance than when same air is distributed from both the
sides. This forces the single fan to develop more head for the same total airflow, hence
operation at higher RPM. With both fans in service the system resistance will be low
distributed flow.
Because of the above reasons there is a net saving of energy when both fans are in
service than single fan.
b) On the advice of an energy auditor, a chemical plant replaced the existing

standard induction motor powering a centrifugal pump with a new energy efficient
induction motor of same kW ratings and number of poles. The plant energy
manager observed that the temperature rise of the stator windings of energy
efficient induction motor was comparatively higher than that of the standard
induction motor. Briefly explain any reason for this situation
Answer
Due to lower slip level in energy efficient motor (EEM), operate at slightly higher speeds,
and result in operation at a higher point in the load curve of the pump. This increase in
load is proportional to approximately the cube of the increase in speed. This means
motor must produce more horsepower (i.e, EEM may be operating above its rated
power).
Because the temperature rise in a motor increases slightly less than the square of
the horse power output, the net effect is that the temperature rise of the rotor
is roughly proportional to the fifth power of the increase in rotor speed.
. End of Section III .
_______________________ 18
Paper 2 Set B Key
Regn No: _________________

Name: ___________________
th
7 NATIONAL CERTIFICATION EXAMINATION Nov. 2008
FOR

1
_________________________
Paper 2 Set B Key
2
_________________________
Paper 2 Set B Key
3
_________________________
Paper 2 Set B Key
4
_________________________
Paper 2 Set B Key
5
_________________________
Paper 2 Set B Key
(i) Answer all Eight questions

(ii) Each question carries Five marks
S-1 What are the advantages & disadvantages of calculating Boiler efficiency by
direct method? Calculate the boiler efficiency if the evaporation ratio is 6 for a
coal fired boiler? Steam enthalpy 650 kcal/kg & GCV of coal 5000 kcal/kg,
feed water temperature 40oC
Answer:
Advantages of Direct Method - Simple & Easy to calculate

Disadvantages - It does not indicate which loss is predominant
Evaporation Ratio = 6
Boiler Efficiency = Evap. Ratio ( Steam Enthalpy F.Water enthalpy) x 100
------------------------------------------------------------------
GCV of fuel
= 6 (( 650 40)/(5000)) * 100
= 73.2%
S-2 Match the following:
Cogeneration system Typical range of heat to power ratio

a) Back pressure steam turbine 1) 2.0 10.0
b) Extraction-condensing steam turbine 2) 1.3 2.0

c) Gas turbine 3) 1.1 2.5
d) Combined cycle 4) 1.0 1.7
e) Reciprocating engine 5) 4.0-14.3
Answer:
a 5, b 1, c 2, d 4, e - 3
S-3 In a re -rolling mill furnace the outlet flue gas temperature is 550oC. The industry has
installed a recuperator to preheat combustion air upto 300 oC and reduces fuel
consumption by 15%. List down other three more advantages other than
reduction in fuel consumption which would accrue to the industry.
Answer:
Reduction in scale losses
Yield Improvement
Higher throughput from the furnace
Any other relevant point !!!!
6
_________________________
Paper 2 Set B Key
S-4 List five disadvantages if the steam pipe line is not insulated:
Answer:
Heat Loss from bare surfaces

Steam condensation in pipes
Water Hammering
Poor quality of steam to process
Leakage through the flanges and valves due to vibration caused by
water hammering effect
Any other relevant point !!!!
S-5 The data of gas turbine of gas based power plant is given below. Calculate the
efficiency of gas turbine.
Capacity of gas turbine = 0.220 GW
Plant operating hours per Annum = 8000 hrs
Plant load factor = 90 %
Gas Consumption per Annum = 526 MMSCM
Calorific value of gas = 8400 Kcal/SCM
Answer:
Efficiency of Gas Turbine =
Power Generation in KWh X 860 Kcal/KWh x 100

Avg. Gas Consumption/month in SCM x NCV in Kcal/SCM
Annual power generation = 0.220 x 10^6 x 8000 x 0.9

= 1584 x 10^6 KWh
Efficiency = (1584 x 10^6 x 860) x 100 = 30.83%

(526 x 10^6 x 8400)
S-6 List three methods by which steam trap performance is assessed
Answer:
Visual testing
Sound Testing
Temperature Testing
S-7 Calculate the savings in heat loss due to reduction in blow down by using auto blow-
down controller, from 2.5% to 1% for 10T/hr boiler, which operates 8000 hrs/year.
The temperature of boiler blow down water is 180oC, boiler efficiency is 80% and
GCV of F.oil is 10,000 kCal/kg. Feed water temp.= 30oC
7
_________________________
Paper 2 Set B Key
Answer:
Present blow down quantity = 10 x (2.5/100) = 0.25 Ton/hr
Blow down quantity with controller = 10(1/100) = 0.1 Ton/hr

Reduction in Blow down = 0.25 0.1 = 0.15 ton/hr
Heat savings = 0.15 x 1000 x (180-30) = 22500 Kcal/hr
Equivalent F.oil savings = 22500/(10000*0.8) = 2.81 Kg/hr

Annual F.oil Savings = 2.81 x 8000 = 22500 kg or 22.5 T/yr
S-8 For 3
combustion of 125 m /hr Methane gas, estimate quantity of air
required with 10% excess air. Density of methane gas is 0.6 kg/m3
Answer:
CH4 + 2O2 ------------- CO2 + 2H2O

16 64
For 16 kg of Methane require 64 kg of Oxygen or (64/0.23) 278 kg of air

125 m3/hr methane = 125 x 0.6 = 75 kg of Methane
So, 75 kg of methane require = (75/16) x 278 = 1303.125 kg/hr of Stochiometric
air .
With 10% excess air the Actual air required = (1+(10/100)) * 1303.125
= 1433.43 kg/hr
-------- End of Section - II ---------
8
_________________________
Paper 2 Set B Key

L-1 An oil fired boiler has the following operating parameters
Steam Generation = 5 T/hr

2
Steam Pressure = 8 kg/cm
o
Steam Enthalpy = 660 kcal/kg
o
Saturation temperature = 170 C
Boiler efficiency = 80%
GCV of Oil = 10,000kCal/kg
Steam Quality = Dry Saturated
Calculate fuel oil consumption per hour

If the dryness fraction becomes 0.7, calculate fuel oil consumption per hour
assuming same boiler efficiency
Answer:
a)
Boiler efficiency = Q X (hs - hf) X 100 / q x GCV of oil
80 = 5000 x (660 60) x 100 / q x
10,000 q = 375 kg/hr
b)
80 = [3500 x (660 60) + 1500 (170 60)] x 100 / q x 10,000
q = 283.12 kg/hr
L-2 Explain the significance of heat to power ratio. Under what circumstances is
cogeneration attractive?
Answer:
Heat to power ratio is one of the most technical parameters influencing the selection of
the type of cogeneration system. The heat to power ratio of the facility should match with
the characteristics of the cogeneration system to be installed.I t is defined as the ratio of
thermal energy to the electricity required and expressed as kW th/kWe.The plant may
therefore be setup to supply part or all of the site heat and electricity loads or an excess
of either may be exported if a suitable customer is available.
9
_________________________
Paper 2 Set B Key
Cogeneration is most attractive under following conditions:

Demand for steam and power is balanced.
Peaks and troughs in demand can be managed.
The ratio of heat to power required by a site may vary during different times of the day
and seasons of the year. Importing power from grid can makeup shortfall in electrical
output from cogeneration plant and firing standby boilers can satisfy additional heat
demand. Many large cogeneration units utilize supplementary firing of exhaust gases in
order to modify the heat to power ratio of the system to match site loads.
L-3 An uninsulated 100 mm pipe of 200m length carries steam at 10 kg/cm2. The surface
temperature measured is 1650C. Find out the annual cost saving achieved by insulating
it with 50 mm. insulating material, which will bring the surface temperature down to 60 0C.
The boiler efficiency is 85%,the fuel oil (with GCV of 10000 Kcal/kg) cost is Rs.20,000 /
tonne and ambient air temperature is 300C and annual operating hour is 8000 hours.
Answer:
Ts = 1650C
Ta = 300C
Existing heat loss (By formulae) = 2261.25 kCal/hr.m2
Heat loss in modified system (S2) (By formulae) = 345 kCal/hr.m2
Existing pipe dimension = 100 mm & 200 m length

Existing surface area (A1) = 3.14 x 0.1 x 200 = 62.8 m2
Surface area after insulation = 3.14 x 0.2 x 200 = 125.6m2
Total heat loss in existing system = 62.8 x 2261.25 = 142006.5 Kcal/hr.
Total heat loss in modified system = 125.6 x 345 = 43332 Kcal/hr
Reduction in heat loss = 142006.5 43332 = 98674.5 Kcal/hr.

Total annual heat loss = 98674.5 x 8000
= 7893.96 x 105 Kcal
Calorific value of fuel = 10000 Kcal/
kg Boiler Efficiency = 85%
Annual fuel oil saving = 7893.9 x 105 /1000 x
0.8 = 92869 kg/year
Annual cost saving = 92869 x 20000/1000
10
_________________________
Paper 2 Set B Key
Annual cost saving = Rs.18,57,380/-
L-4 (a) Explain the important properties of ceramic fibre.

(b) Name five general requirements of refractory material.
Answer:
Lower Thermal Conductivity: This allows construction of thinner linings.

Lower Heat Storage : Less heat absorption due to lower density.
Good thermal shock resistance: Allows faster heating and cooling.
Mechanical Resilience: This allows prefabrication.
Low installation Cost.
Simple Maintenance.
Higher Thermal Efficiency: Allows more accurate and uniform temperature.
The general requirements of a refractory material can be summed up as :
Ability to withstand high temperatures.

Ability to withstand sudden changes of temperatures.
Ability to withstand action of molten metal slag, glass, hot gases, etc.
Ability to withstand load at service conditions.
Ability to withstand load and abrasive forces.
Low coefficient of thermal expansion.
Should be able to conserve heat.
Should not contaminate the material with which it comes into contact.
L-5 (a) Calculate the blow down rate for a boiler with an evaporation rate of 4 tons/hr, if
the maximum permissible TDS in boiler water is 3500 ppm and with 20 % make
up water addition. The feed water TDS is around 350 ppm.
(b) Steam at a pressure of 15 kg/cm2g is flashed to a lower pressure of 2 kg/cm 2g. If
the steam flow rate is 2000 kg/hr. Calculate the % of flash steam and flow rate of
flash steam?

2
2
Latent heat of steam at 2 kg/cm2g : 526 kCal/kg
Answer:
a) Blow down (%) = Feed water TDS x % Makeup/ Permissible TDS in Boiler
11
_________________________
Paper 2 Set B Key
Percentage blow down = 350 x 20/3500 = 1.99 %

If boiler evaporation rate is 4000 kg/hr then required blow down rate is:
= 4000 x 1.99 / 100 = 79.6 kg /hr
b) The flash steam quantity can be calculated from the following

formula: % Flash steam = S1 S2/ L2
Substituting values= (200-120)/526 =80/526 =15.2%

Flash steam quantity: 2000*(15.2/100) = 304 kg/hr.
L-6 List ten energy conservation opportunities available in a boiler system
Answer :
Stack Temperature
Excess air control
Combustion air pre heating
Automatic Blowdown
Radiation and convection heat loss
Variable speed control for blowers and pumps
Proper boiler loading
Incomplete combustion and unburnt losses
12
_________________________
Regn No: _________________
Name: ___________________
(To be written by the candidate)
th
9 NATIONAL CERTIFICATION EXAMINATION December, 2009
FOR
ENERGY MANAGERS AND ENERGY AUDITORS

Section - I: OBJECTIVE TYPE Marks: 50 x 1 = 50

Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB pencil, as per
instructions
1 The material used to control SOx in the FBC boiler is

a) lime b) alumina c) silica d) limestone
2 Carpet loss occurs in

a) coal combustion b) atomization of oil c) furnaces d) coal storage
3 In industrial applications the commonly used trap for main steam lines is
a) thermostatic trap b) inverted bucket trap
c) thermodynamic trap d) open bucket trap
Mark the best choice of insulation material for electric heat treatment furnace among the following
a) glass wool b) calcium silicate c) fire bricks d) ceramic fibre

1
_______________________
5 The low combustion temperature in FBC boilers results in minimal formation of

a) CO b) SOx c) NOx d) CO2
6 For same inlet conditions of the steam which of the following will generate the maximum power
c) extraction-cum-condensing turbine d) extraction-cum-back pressure turbine
7 Demineralisation of water is the process to remove

a) dissolved oxygen b) dissolved salts c) carbon-dioxide d) chlorine
8 In a glass industry waste heat is used for power generation. This type of cogeneration is called

o
9 If the furnace temperature is T ( K) and the area of opening is A, quantity of radiation loss in a
reheating furnace is directly proportional to
4 b) T 4 2
a) T c) A d) A
10 Water hammer is common in

a) water pipes b) condensate pipes
c) steam pipes with steam and condensate d) main steam lines with good traps
11 Which of the following requires the least amount of oxygen/ kg of substance for combustion
a) methane b) carbon c) sulphur d) hydrogen
12 Good opportunity for energy savings from continuous blow down of boiler is by
a) recovery of flash steam for use in deaerator
b) using the blow down steam to run steam turbine

c) reusing the hot water so formed as make-up water
13 Which of the following benefits is not achieved by maximizing condensate recovery?
a) minimization of boiler exit flue gas temperature b) maximization of boiler output
c) reduction in water treatment costs d) reduction in energy input costs

14 Furnace wall heat loss does not depend on
c) material of stock to be heated d) brick thermal conductivity of wall
15 Which fuel requires the lowest amount of excess air for combustion?
a) pulverised coal b) bagasse c) fuel oil d) natural gas.
One kg of wood contains 20% moisture and 5% hydrogen by weight. How much water is evaporated
during complete combustion of one kg of wood?
2
_______________________
17 Which data is not required to calculate the efficiency of boiler by indirect method?
a) flue gas temperature b) ambient temperature
c) calorific value of fuel d) blow down rate

18 The pour point of furnace oil is
o o o o
a) 100 C b) 25 C c) 50 C d) 20 C
19 Which property is the most important for an insulating brick?

a) mechanical strength b) chemical resistance
c) compact strength d) porosity

20 In which of the following equipment is stored heat used for preheating combustion air
a) convective recuperator b) radiation recuperator
21 Turndown ratio for oil fired burners is the ratio of
a) air to fuel input
b) maximum fuel input to actual fuel input

c) maximum air input to minimum air input
d) maximum fuel input to minimum fuel input with same excess air
22 Flame flickering occurs in an oil fired burner because of
a) oil not preheated b) moisture in oil
c) oil pressure not sufficient d) high excess air
23 The unit of specific heat is

a) kCal/kg b) kCal/m
3 o
c) kCal/kg C d) kCal
24 LPG is predominantly a mixture of propane and ___

a) isopropane b) methane c) ethane d) butane
25 The amount of oxygen required to burn one kg of hydrogen is

a) 3 b) 9 c) 8 d) 0.5
26 An axial compressor is used in conjunction with which of the following

a) back pressure steam turbine b) condensing turbine
c) gas turbine d) none of the above

27 If the pressure of saturated steam is reduced through a pressure reducing valve
a) enthalpy of evaporation will reduce b) it will get superheated
c) enthalpy will reduce d) it will produce wet steam
28 What is the average yield in re-rolling mill furnace?

a) 40-50% b) 70-80% c) 80-85% d) 90-95%
29 Radiation losses from a boiler practically

a) increase with increase in its % loading b) decrease with increase in its % loading
c) are independent of its % loading d) none of the above.
3
_______________________
30 Scale losses in reheating furnaces will

c) decrease with excess air d) have no relation with excess air

31 Ceramic fibre gives the maximum energy savings when used in
a) continuous furnace b) annealing furnace c) arc furnace d) re-heating furnace
32 Air compressor alone consumes about _____ of the energy generated in a gas turbine
a) 5-10% b) 10-20% c) 20-30% d) 50-60%
33 Drain pockets are provided in a steam line for

a) effective removal of line condensate b) effective removal of steam
c) removal of dirt d) checking of steam line

34 Which of the following heat recovery equipment works on a vapour compression cycle?
35 Maximum heat transfer to the stock in a reheating furnace is by

a) radiation b) conduction c) convection d) none of these
36 What should be the appropriate coal size for fixed grate coal firing?
a) 25-50 mm b) 50-75 mm c) 75-100 mm d) 100-125 mm
37 Which type of the following co-generation system has high heat-to-power ratio?
a) gas turbine b) back pressure turbine

38 When 100 kg of fuel with 60% carbon is burnt with theoretical air, the mass of CO 2 released will
be
a) 319 kg b) 4400 kg c) 4500 kg d) 220 kg
39 The efficiency of a typical FBC boiler is of the order of

a) 80% b) 30% c) 40% d) 70%


41 In a chain grate coal firing system primary air pressure is 75 mmWC. What should be the
secondary air pressure with respect to primary air pressure?
a) lower b) same c) double d) more than double
42 The pressure in the heating zone of a furnace should be

a) slightly positive b) slightly negative
c) highly negative d) highly positive
4
_______________________
43 Which of the following will be an ideal heating medium for heat transfer in a heat exchanger?
c) dry saturated steam d) wet steam
44 Which of these fuels has the highest heating value?

a) LPG b) methane c) hydrogen d) diesel oil
o o o o
a) 40 C b) 60 C c) 90 C d) 110 C
46 For coal fired boilers the flame length is influenced by

a) moisture b) ash content c) volatile matter d) fixed Carbon
47 The difference in temperature between steam and condensate is the principle of operation in a
a) temperature trap b) thermodynamic trap
c) thermostatic trap d) orifice type trap
48 Fluidized bed combustion takes place in the temperature range of

0 0 0 0
49 In an equipment with steam consumption of 1 ton/hr, the steam trap capacity will be
a) < 1 ton/hr b) equal to 1 ton/ hr c) 1.5 ton/hr d) 2 ton/hr


S-1 An oil fired boiler with a rated capacity of 12 ton/hr steam generation is switched over to rice
husk firing. The boiler is de-rated to 7 ton/hr. List down five major reasons for de-rating.
Ans: (a) The external combustion zone reduces radiation heat transfer
Rice husk ash deposition in heat transfer area
High excess air as compared to oil firing
Moisture content and fuel quality variation
Boiler furnace temperature drops down during ash cleaning.
(1 Mark each)
5
_______________________
S-2 What are the disadvantages of direct method of boiler efficiency evaluation over the
indirect method?
Ans: Disadvantage of Direct Method

Does not indicate individual losses
Any small error in measurement would lead to large variation in efficiency levels
(1 Mark each)
S-3 The efficiency of a billet heating furnace with an output of 15 tonne/ hr was 32%. Find out
the specific fuel consumption in litres/ tonne of billet heating and total fuel consumption
per hour as per data given below:
Billet heating furnace:
o
Initial temp. = 50 C
o
Final temp. = 1150 C
o
Specific heat of billet = 0.12 kCal/ kg C
Density of fuel oil = 0.95 kg/ litre
GCV of fuel oil = 10,000 kCal/kg
Determine the specific fuel consumption in litres/ tonne and total fuel consumption in
litres/hr.
Ans. MgCp t
= ---------------
Mf X GCV
(1 Mark)
Fuel consumption per tonne S.F.C. 1000 X 0.12 X (1150 50) / 0.32 X 10000
41.25 kg/ hr
41.25 / 0.95
43.42 litres/ tonne
(2 Marks)
Fuel consumption for 15 TPH production = 15 X 43.42 = 651.3 litres/hr

(2 Marks)
S-4 A gas turbine was running with naphtha as a fuel. The following are the data collected
during the gas turbine operation:
a) Fuel (Naphtha) consumption = 360 kg/hr

b) GCV of naphtha fuel = 11500 kCal/kg
6
_______________________
c) Overall efficiency of gas turbine which

includes air compressor and alternator = 30 %
d) Cost of naphtha fuel = Rs 22000/ton
Find out the cost of generating one unit of electricity?
ANSWER:
Heat input to the turbine = 11500*360
= 4140000
Efficiency of gas turbine = 30 %
Gas Turbine Output = [(4140000*0.3)/860]
= 1444 kWh [3 marks]
Cost of generating 1444 units of electricity = 360 kgs * Rs 22
= Rs 7920
Cost of one unit of electricity generated = (7920)/1444
= Rs 5.49 [2 marks]
2
S-5 The fuel oil consumption in a 4 TPH oil fired boiler generating steam at 10 kgf/cm g is 300
litres/ hours. Its efficiency by indirect method was found to be 80%. Find out the
evaporation ratio and the steam generation rate with the following data:
Enthalpy of Steam 665 kCal/ Kg

Feed water temperature o
65 C
G.C.V. of fuel oil 10,000 kCal/ Kg
Density of oil 0.95 kg/ litre
Ans. Efficiency = ER (hs hw) / G.C.V

(1 Mark)
Boilere efficiency = 0.80
hg = Enthalpy of steam = 665 kCal / Kg.
hw = Feed water enthalpy = 65 kCal / Kg.
G.C.V. of oil = 10,000 kCal / Kg.
0.80 X 10,000
ER = ---------------- = 13.33
(665 65)
(2 Marks)
Steam generation = 13.33 X 300 X 0.95 = 3799 Kg / hr
(2 Marks)
S-6 State the stoichiometric combustion equation for methane (CH4).

How many kg of carbon dioxide will be generated by 8 kg of methane?
Ans CH4 + 202 CO2 + 2H2O

(2 Marks)
7
_______________________
16 Kg 64 44 36
16 Kg methane produces 44 Kg. CO2

8 Kg methane produces 22 Kg. CO2
(3 Marks)
S-7 An oil fired bogie type re-heating furnace has 2.5 meter width, 2.5 meter height and 6 meter
length. The furnace has 14 oil fired burners with 7 burners on each of the side walls. The
bogie height is 0.5 meter. Draw a sketch of one side wall indicating the location of
burners and chimney.
Ans:
2.5
mtr
To Chimney
Bogie 0.5 mtr
6 mtr
(5 Marks)
(Burner 3 marks, chimney 2 marks)
S-8 Mention five important areas which reduces yield in a re-rolling mill.
Ans. (i) High excess air

Non-uniform temperature
High scale losses
High negative furnace draft
Insufficient soaking of charge.
(1 Mark each)
------- End of Section - II ---------

8
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L-1 In a chemical process industry a coal fired boiler of 77% efficiency is proposed to be
replaced with paddy husk fired boiler of 67% efficiency. Calculate the fuel cost savings
for changing over to paddy husk?
GCV of coal = 4800 kCal/kg
Cost of coal = Rs 4000/MT
GCV of paddy husk = 3500 kCal/kg
Cost of paddy husk = Rs 2200/MT
Quantity of steam requirement = 20 TPH
Enthalpy of steam = 760 kCal/kg
Enthalpy of feed water =120 kCal/kg
Annual operating hours of boiler = 7000 hours
Ans
(A) For Paddy Husk Fired Boiler:

Heat content in the output steam = 20000*(760-120)
= 12800000 kCal/hr
Paddy husk requirement = (12800000)/(3500*0.67)
=5458 kg/hr.
Annual operating hours = 7000
Annual paddy husk consumption = 5458*7000
= 38206 MT
Annual cost of paddy husk = 38206* Rs 2200
=Rs 840.53 lakh [5 marks]
(B) For Coal Fired Boiler :
Coal requirement = (12800000)/(4800*0.77)
= 3463 kg/hr
Annual operating hours = 7000
Annual coal consumption = 3463 * 7000 = 24241 MT
Annual cost of coal = 24241 * Rs 4000
9
_______________________
= 969.64 lakh [4 marks]

Cost saving = { 969.64 840.53 }
= Rs 129.11 lakh. [2 marks]
L-2 List 10 energy saving measures in a steam distribution and utilization system.
Ans

Proper Air Venting
Condensate Recovery
Any other relevant options
(1 Mark each)
2 2
L-3 A process industry needs saturated steam at 5 kg/cm (g) and 10 kg/cm (g) pressure level for
2
process heating. A fluidized bed boiler generates steam at 22 kg/cm (g) pressure at the
2
rate of 24 TPH. 4 TPH of steam is reduced through PRDS for meeting the 10 kg/cm (g)
steam requirement. The balance steam is passed through a Back pressure steam
2
turbine. The turbine back pressure steam at 5 kg/cm (g) is sent to a process in the plant.
a) Mechanical Efficiency of steam turbine = 92 %

b) Losses in gear transmission = 4%
c) Efficiency of alternator = 96 %
2
d) The total heat of steam at turbine inlet condition at 22 kg/cm (g) = 708 kCal/kg
2
e) The total heat of steam at turbine outlet condition at 5 kg/cm (g) = 658 kCal/kg
Calculate the total power output from the system.
Ans.
Step 1:
Enthalpy drop across the turbine per kg of inlet steam (h1-h2)
(708-658)
50 kcal/kg
(2 Marks)
10
_______________________
Step 2:
Total steam flow rate through turbine = 20000 kg/hr
Total enthalpy drop across the turbine =20000*50=1000000 kcal/hr
(2 Marks)
Step 3:
Mechanical Efficiency of steam turbine = 92%
Efficiency of alternator = 96 %
% losses in gear transmission = 4%
Over all efficiency of the turbo alternator = 0.92 x 0.96 x 0.96= 0.848
= 84.8%
Energy output of turbine = 1000000 x 0.848 = 848000
Power output of the alternator = 848000/ 860 = 986 kW
(6 Marks)
L-4 In an engineering industry, a heat treatment electrical furnace is consuming 500 kWh per
batch. The Energy Manager of the company wanted to convert it to furnace oil firing for
cost savings. Estimate the furnace oil requirement in litres and cost savings, per batch,
considering the following data.
Calorific value of furnace oil : 10,000 kCal/kg
Specific gravity of furnace oil : 0.9
Efficiency of furnace oil fired furnace : 58 %
Cost of electricity : Rs 4.5/kWh
Cost of furnace oil : Rs 20/litre
Ans. Operating electrical load : 500 kWh

Useful heat (heat duty) : 500 x 860 x 0.70 = 301000 kCal/ batch
(2 Marks)
FO required for meeting useful heat : 301000/10000 = 30.1 kg
Efficiency of FO fired furnace : 58%
Net FO required to meet useful heat : 30.1 / 0.58 = 51.9 kg
= 51.9 / 0.9 = 57.6 liters/ batch
Estimated furnace oil quantity : 57.6 litres/ batch
(6 Marks)
Cost savings = (500 x 4.5) (57.6 x 20) = Rs. 1098/batch

(2 Marks)
L-5 Explain briefly with the schematic the following heat recovery devices.
Heat Pipe
Metallic recuperator
Plate heat exchanger
11
_______________________
Ans.
a) Heat pipe
structure and a working fluid. The capillary wick structure is integrally fabricated
into the interior surface of the container tube and sealed under vacuum. Thermal
energy applied to the external surface of the heat pipe is in equilibrium with its
own vapour as the container tube is sealed under vacuum. Thermal energy
applied to the external surface of the heat pipe causes the working fluid near the
surface to evaporate instantaneously. Vapour thus formed absorbs the latent
heat of vapourisation and this part of the heat pipe becomes an evaporator
region. The vapour then travels to the other end the pipe where the thermal
energy is removed causing the vapour to condense into liquid again, thereby
giving up the latent heat of the condensation. This part of the heat pipe works as
the condenser region. The condensed liquid then flows back to the evaporated
region.
(4 Marks)
A metallic radiation recuperator consists of two

concentric lengths of metal tubing. The inner
tube carries the hot exhaust gases while the
external annulus carries the combustion air
from the atmosphere to the air inlets of the
furnace burners. The hot gases are cooled by
the incoming combustion air which now carries
additional energy into the combustion chamber.
Radiation recuperator gets its name from the
fact that a substantial portion of the heat
transfer from the hot gases to the surface of the
inner tube takes place by radiative heat
transfer.
12
_______________________
(3 Marks)
c) Plate heat exchanger
A plate type heat exchanger consists of a series of separate parallel plates

forming thin flow pass. Each plate is separated from the next by gaskets and the
hot stream passes in parallel through alternative plates whilst the liquid to be
heated passes in parallel between the hot plates. To improve heat transfer the
plates are corrugated.
between every second plate while cold liquid at the top of the head is permitted to
pass downwards between the odd plates. When the directions of hot & cold fluids
are opposite, the arrangement is described as counter current. The plate heat
exchanger is a potential heat recovery device to recover heat from hot liquids and
hot effluents.
(3 Marks)
L-6 a) Explain why dry saturated steam is preferred over wet or superheated steam for industrial
process heating
Explain with the help of enthalpy equation the impact of dryness fraction on the enthalpy of
wet steam
Why should one use dry saturated steam at the lowest possible pressure for indirect steam
heating?
Ans a) Dry saturated steam is the preferred choice because:

Superheated steam gives up heat at a slower rate than saturated steam.
Dry steam alone condenses quickly, thereby providing a higher heat transfer rate.
(3 Marks)
13
_______________________
b) hg =hf + X x hfg
If the dryness fraction is low, then the enthalpy of wet steam will be lower as the
mass of water in the wet steam will be higher.
(4 Marks)
c) The latent heat of steam increases with reduction of steam pressure. At lower pressure
the latent heat is more which is mainly responsible for heat transfer.
(3 Marks)
14
_______________________
Paper 2 Set B Key
Regn No: _________________
Name: ___________________
th
8 NATIONAL CERTIFICATION EXAMINATION MAY, 2009
FOR
Paper 2: Energy Efficiency in Thermal Utilities
Date: 23.05.2009 Timings: 1400 to 1700 HRS Duration: 3 HRS Max. Marks: 150


Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB
pencil, as per instructions
1 The steam generation in a boiler is 16 tonnes for four hours. The oil consumption for the same
period is 1.3 Tonnes. The evaporation ratio is
a) 12.3 b) 11.5 c) 9.2 d) 14

O
3 When the furnace is operated below 370 C, then it is called
a) muffle furnace b) kiln c) oven d) all the above
4 In a CFBC Boiler the capture and recycling of bed materials is accomplished by

a) settling chamber b) cyclone c) back filter d) scrubber
One kg of wood contains 20% moisture and 5% Hydrogen by weight. How much water is evaporated
during complete combustion of one kg of wood?

1
_____________________
Bureau of Energy
Efficiency
Paper 2 Set B Key
6 The temperature at which refractory will deform under its own weight is its softening temperature
indicated by
a) melting point b) PCE c) reform temperature d) critical point
7 In FBC boiler the combustion is carried out at a temperature

a) closer to steam temperature b) at adiabatic combustion temperature
c) at and above ash fusion temperature d) below ash fusion temperature of fuel used
8 Thermo-compressor is commonly used for

a) compressing hot air b) upgrading low pressure steam
c) distillation d) reverse compression of CO2

a) drop in the contamination of feed water
b) greater purity of feed water

c) rise in the contamination of feed water
d) it has got no relation with the contamination of feed water
10 Ceramic fibre gives the maximum savings when used in
11 In a low temperature waste heat recovery system, which of the following device is the most
suitable
a) Economiser b) heat wheels c) regenerator d) ceramic recuperator
12 Which of the following will be the ideal pressure to be maintained in a reheating furnace
a) 20 mm b) +1 mm c) +30 mm d) +20 mm
13 Recuperator will be more efficient if the flow path of hot and cold fluids is in:
a) co-current mode b) counter current mode
c) cross current mode d) none of the above
14 The type of firing used for a pulverized coal fired boiler is

a) over firing b) tangential firing
c) vertical firing d) mixed firing for effective heat transfer
15 High % of carbon monoxide presence in the flue gas of boiler is an indicator of

16 The normal velocities encountered in pipes for saturated steam is

a) 60 to 80 m/sec b) 10-20 m/sec c) 5 to 10 m/sec d) 30 to 40 m/sec
17 Which is not a property of Ceramic fibre insulation

c) high heat storage d) thermal shock resistant
2
_____________________
Bureau of Energy
Efficiency
Paper 2 Set B Key
18 The purpose of venting air from steam systems is because air is a

a) insulator b) good conductor c) inert substance d) dilutant


20 In flue gas the theoretical CO2 is 15% and the measured CO2 is 9% by volume. The % excess
air is:
a) 66% b) 150% c) 25% d)20%
21 Which steam trap operates on the principle of difference in density between steam and
condensate
a) thermodynamic trap b) inverted Bucket c) thermostatic trap d) none of the above
22 Heat transfer rate for drying application will be less if we heat with
a) saturated steam b) dry steam c) superheated steam d) high pressure steam
23 Turndown ratio for oil fired burner is the ratio of

a) air to fuel

c) maximum fuel input over minimum fuel input at same percentage of excess air
d) maximum air input over minimum air input
24 An oil fired boiler is operating at 5% O2 in the flue gas. The percentage excess air supplied to the
boiler is approximately
a) 15 % b) 25 % c) 31 % d) 42 %
25 The amount of theoretical air required for complete combustion of one ton of coal as compared
to that required for one ton of fuel oil is:
a) higher b) lower c) equal d) none of the above
26 What type of steam is generally used for electrical power generation?

a) high pressure steam with super heat b) dry saturated steam
27 In a furnace, an oxygen rich combustion air (Oxygen 30% vol. and Nitrogen 70% vol) is
supplied instead of normal air (oxygen 21% vol. and Nitrogen 79% vol). By maintaining the
other parameters same, the % age of carbon dioxide in the flue gases will be
a) same b) lower c) higher d) zero
2 2
28 If saturated steam at a pressure of 20 Kg/cm (a) is reduced to 10 Kg/cm (a), through a pressure
reducing valve, the steam will
a) condense b) remain saturated
c) get superheated d) be a mixture of 50% steam and 50% condensate
The major limitation of metallic recuperator is a)
handling COx, NOx etc.
3
_____________________
Bureau of Energy
Efficiency
Paper 2 Set B Key
o
b) reduced life for handling temperature more than 650 C
c) manufacturing difficulty of the required design
30 The unit of specific gravity in SI system is ___________
3 3 2
a) N/m b) kgf/m c) kg/m d) no unit
31 The minimum capacity of any closed vessel which generates steam under pressure as covered
under Indian Boilers Regulation Act is
32 Capillary wick is a part of

a) heat pump b) heat wheel c) heat pipe d) regenerator
33 Pick the boiler, which can be considered as most combustion efficient?

a) fluidized bed combustion boiler b) lancashire boiler
c) stoker fired boiler d) chain grate boiler
34 Which of the following when added to alumino silicate helps to reduce the shrinkage level of
ceramic fibre
a) Zr O2 b) SiO2 c) Al2O3 d) CaSO4
35 The difference between mean solid and mean gas velocity in FBC boiler is called
36 When pure hydrogen is burnt with stoichiometric air, percentage CO 2 on volume basis in flue gas
on dry basis will be
a) 79% b) 21% c) 0% d) 100%
37 When 1 kg of pressurized hot water at 120C is supplied with 50 kCal of heat at same pressure,
its temperature will be
a) 220C b) 190C c) 170C d) 120C
38 Controlled wetting of coal (during the coal preparation) would result in

a) reduction in flue gas exit temperature b) decrease in the percentage of unburnt carbon
c) improper combustion d) increase in the fines of coal

39 The coefficient of thermal expansion of refractory material should be
40 The inlet gas temperature in a gas turbine is around

o o o o
a) 1700 C b) 1000 C c) 650 C d) 500 C
41 Oxygen (O2) percentage measurement by volume basis can be done by using:

a) ultrasonic tester b) potassium oxide probe
c) copper tubes d) zirconium oxide probe
42 In industrial applications the type of trap used for main steam lines are
4
_____________________
Bureau of Energy
Efficiency
Paper 2 Set B Key
a) thermodynamic b) thermostatic c) bimetallic d) float

43 Which of the following best indicates the overall efficiency of a Combined Cycle thermal power
plant?
a) 33 % b) 42 % c) 55% d) 60%
44 Which of the following is used as insulation in low temperature applications ?

a) ceramic fibre b) calcium silicate c) fibre glass d) polystyrene
45 The emissivity of ceramic coatings used in furnace

a) decreases with increase in temperature b) Increases with increase in temperature
c) remains constant irrespective of temperature d) decreases with increase in furnace pressure

o
46 The percentage raise in boiler efficiency by a 20 C raise in combustion air temperature is
a) 0.1% b) 0.2% c) 10% d) 1%
47 Instrument used for measuring temperature in a glass furnace is

a) Leaf type thermocouple b) Infrared pyrometer
c) Pt/Pt-Rh thermocouple with indicator d) Chrome alumnel thermocouple with indicator

48 The percentage efficiency of a reheating furnace, operating at 10 tonnes per hour and
consuming furnace oil of 230 kg/hour for reheating the material from 40 C to 1100 C (specific
heat of material is 0.13 kCal / kg C and calorific value of furnace oil is 10,000 kCal /kg) is
a) 60 b) 70 c) 80 d) 50
49 The percentage of energy consumed by air compressor in gas turbine plants is typically
a) 10% b) 22% c) 55% d) 80%
50 Which of the following is not required in the boiler efficiency evaluation by direct method
a) steam flow b) fuel flow c) feed water temperature d) O2 % in flue gas
-------- End of Section - I ---------
5
_____________________
Paper 2 Set B Key

S-1 Given the choice would you paint the outer surface of a reheating furnace black,
or with a shiny glossy colour (such as silver colour)? Explain.
Ans:
The emissivity of the outer surface should be kept to a minimum since the skin losses
would increase with high emissivity. A black colour acts like a black body with highest
emissivity, while a glossy and shiny aluminium foil has about the lowest emissivity.
Therefore, radiation loss is minimized. Shiny glossy colour, which has a lower emissivity
should be used.
S-2 A 5 MW DG Set is operating at 70% load. A waste heat recovery boiler is

2
installed to recover heat from exhaust gas to generate steam at 10 kg/cm .
Find out the quantity of steam generated annually after installing the waste
heat recovery boiler
Given Data:
o
Flue gas exit temperature := 500 C
o
Flue gas temperature after Waste heat recovery boiler =:250 C
o
Specific heat of flue gases = 0.25 kCal/kg/ C
Specific gravity of diesel oil = 0.85
Air to fuel ratio = 30 kg/kg
Specific fuel consumption = 4 kWh/liter
Enthalpy of steam at 10 kg/cm2 = 660 kCal/kg
o
Operating hours per year = 8000 hrs
Solution:
Average load of DG set = 5 x 0.7 = 3.5 MW or 3500 kW

Diesel consumption = 3500 x 0.85 /4 = 744 kg/hr
Heat available for WHR boiler = 744 x 30 x 0.25 (500 250) = 1395000 kCal/hr
2
Steam generation at 10 kg/cm = 1395000 / (660 30) = 2214 kg/hr or 2.2 tons/hr
Annual steam generation = 2.2. X 8000 = 17,600 tons /year.
6
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Paper 2 Set B Key
S-3 Calculate pressure drop in meters when pipe diameter is increased from 250 mm
to 350 mm for a length of 1000 meters. Water velocity is 2 m/s in the 250 mm
diameter pipe, and friction factor is 0.005..
2
Ans. Pressure drop = 4fLV
--------------
2gD
2
Pressure drop with 250 mm = 4 x 0.005 x 1000 x 2 / (2 x 9.81 x 0.250)
= 16.30 m
Velocity of water in pipe of 350 mm diameter = (0.25 x 0.25 x 2) /(0.35 x 0.35) = 1.02 m/s
2
Pressure drop with 350 mm = 4 x 0.005 x 1000 x 1.02 / (2 x 9.81 x0. 350)
= 3.02 m
Pressure drop reduction = 16.30 3.02 = 13.28 m
S-4 The evaporation ratio of a coal fired boiler is 5. Estimate boiler efficiency if
0
steam enthalpy is 650 kcal/kg; feed water temperature is 65 C and Calorific
Value of coal is 4000 kcal/kg.
Ans :
Boiler efficiency = output/input * 100
Boiler efficiency = 100 x Q (H-h) / (q x GCV)
= 5x (650-65) x 100
----------------------- = 73.13 %.
1 x 4000
S-5 Explain the difference between Flash Point and Pour Point of a liquid fuel?
Ans:
Flash Point
The flash point of a fuel is the lowest temperature at which the fuel can be heated so that
the vapour gives off flashes momentarily when an open flame is passed over it.
Pour Point
The pour point of a fuel is the lowest temperature at which it will pour or flow when cooled
under prescribed conditions. It is a very rough indication of the lowest temperature at which
fuel oil is readily pumpable.
S-6 What is the significance of volatile matters in case of solid fuels being used for
combustion?
7
_____________________
Paper 2 Set B Key
Ans :
Volatile matters are the methane, hydrocarbons, hydrogen and carbon monoxide, and
incombustible gases like carbon dioxide and nitrogen found in coal. Thus the volatile
matter is an index of the gaseous fuels present. Typical range of volatile matter is 20 to
35%.
Volatile Matter
Proportionately increases flame length, and helps in easier ignition of coal.
Sets minimum limit on the furnace height and volume.
Influences secondary air requirement and distribution aspects.
Influences secondary oil support
S-7 What is the major advantage of a self recuperative burner (SRB). For a SRB
the quantity of heat brought in by pre heated air is 2000 kCal/kg fuel and the
quantity ofheat taken away by exhaust gases is 4000 kCal per kg fuel. If the
calorific value of the fuel is 10,000 kCal/kg, find the % fuel saving rate?
Ans:
Self Recuperative Burners

Self-recuperative burners (SRBs) are based on traditional heat recovery techniques in that
the products of combustion are drawn through a concentric tube recuperator around the
burner body and used to pre-heat the combustion air
A major advantage of this type of system is that it can be retro-fitted to an existing furnace
structure to increase production capability without having to alter the existing exhaust gas
ducting arrangements. SRBs are generally more suited to heat treatment furnaces where
exhaust gas temperatures are lower and there are no stock recuperation facilities.
Estimation of fuel savings
By using preheated air for combustion, fuel can be saved. The fuel saving rate is given by
the following formula:
S = P X 100 /(F + P - Q)
where S: fuel saving rate, %

F: Calorific value of fuel (kCal/kg fuel)
quantity of heat brought in by preheated air (kCal/kg fuel)
quantity of heat taken away by exhaust gas (kCal/kg fuel)
S = 2000 X 100 / (10000 + 2000 - 4000)

S = 12.5 %
8
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Paper 2 Set B Key
S-8 What is clinker? List four factors which lead to clinker formation in case of
stationary grate coal fired boiler.
Clinker is a mass of rough, hard, slag-like material formed during combustion of coal due
to low fusion temperature of ash present in coal. Presence of silica, calcium oxide,
magnesium oxides etc. in ash lead to a low fusion temperature.
Factors leading to clinker formation are :

Low ash fusion temperature
Uneven size or more fines in coal
Combustion without raking the coal bed
Pre heated air used for combustion
-------- End of Section II ---------
9
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Paper 2 Set B Key

L-1 Calculate the steam generation requirement and fuel oil consumption for the co-
generation scheme depicted below
Assumption = Losses across turbine including steam loss = 3 million kCal/hr

GCV of fuel oil = 10,000 kCal/hr
Solution:
6
Heat in process steam = 80 x 1000x 660 = 52.8 x 10 kCal/hr
6
Heat equivalent to power generation = 17 x 1000 x 860 = 14.62 10 kCal/hr
6
Heat loss across turbine = 3 x 10 kCal/hr
6 6
Total Heat input to turbine = ( 52.8 + 14.62 + 3) x 10 kCal/hr = 70.42 x 10 kCal/hr
2 6
Equivalent steam generation at 100 kg/cm at 760 kCal/kg = 70.42 x 10 /
760 = 92.7 tons/hr

10
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Paper 2 Set B Key
Fuel Oil Consumption at 75% efficiency = [92.7 (760 80)]/ (0.75 x 10000)
=8.40 tons/hr
L-2 In an engineering industry, resistance heating type furnace was used for heat
treatment of the product. The power consumption of the furnace at 1/3 load
and full load is 860 kWh and 1600 kWh per cycle respectively. The furnace
heat treatment cycle and loading of the furnace was analysed. The details are
as follows:
Furnace capacity : 180 kW

Loading capacity of furnace : 10 Tonnes
Heat treatment cycle : Heating up to 650 C 6 hours
: Soaking at 650 C 8 hours
: Cooling in furnace 4 hours
Quantity of the stock to be treated : 1500T/year
Evaluate the energy savings by optimum (full loading) loading?
Solution Sp. Power consumption of stock:

Load in furnace (1/3) = 10 x 1/3
= 3.3 MT
rd
Power consumption for 1/3 load = 860 kWh/cycle
rd
Sp. Power consumption at 1/3 load = 860/3.3
= 260.6 kWh/MT
Load in the furnace (full) = 10 MT

Power consumption at full load = 1600 kWh/cycle
Sp. Power consumption at full load = 1600/10
= 160 kWh/MT
Reduction in power consumption at optimum load (full load)

260.6 160
100.6 kWh/MT
Annual stock production = 1000 T
By operating furnace with each batch of 10T (full load)

Reduction in power consumption = 1500 x 100.6
= 150900 kWh /year
L-3 Analyse the diagram as given below and calculate:

Boiler Efficiency by direct method
Water Temperature in the condensate tank
11
_____________________
Paper 2 Set B Key
Estimate fuel loss due to the drop in feed water temperature, assuming the
boiler efficiency to be the same
Given that:
Enthalpy of steam at 10kg/cm2 = 665 kCal/kg
Furnace Oil consumption = 600 liters/hr
Specific Gravity of furnace oil = 0.89
G.C.V. of furnace oil = 10,000 kCal/kg
Solution : Oil Consumption = 600 x 0.89 = 534 kg/hr
1) Boiler Efficiency = 7000 (665 - 60) X 100/ 534 X 10000

79.3 %
Feed water temperature in condensate tank
o
[5000 x 95 + 2000 x 28]/ 7000 = 76 C
Fuel Loss = [ 7000 x (76 60)]/ 10000 x 0.793 = 14 kg/hr
L-4 A textile plant has an extensive network and the steam condensate is not being
recovered. The plant management is planning to recover the condensate and
generate flash steam for use as low pressure process steam for fuel
economy. The following are the parameters about the system.
Condensate quantity 1000 kg/hr

Condensate Pressure 10 bar
Cost of steam Rs 1100/ T
Annual operating hours 6000
12
_____________________
Paper 2 Set B Key
Low pressure process steam (flash steam) pressure 2 bar

Sensible heat of condensate at 10 bar 188 kCal/kg
Latent heat of steam at 2 bar 518 kCal/kg
Boiler Efficiency 80 %
GCV of fuel oil 10,200 kCal/kg
Specific Gravity of fuel oil 0.92
o
Condensate temperature when recovered 95 C
o
Make up water temperature 35 C
Calculate the Quantity of flash steam which can be recovered, and the annual fuel
oil savings on account of condensate recovery
Solution :
a) Flash steam available % = S1- S2/(L2)

Where: S1 is the sensible heat of higher pressure condensate.
S2 is the sensible heat of the steam at lower pressure
L2 is the latent heat of flash steam (at lower pressure).
% of Flash steam recoverable = (188 135)/518 = 10.2 %
Quantity of flash steam recovered from condensate = 1000 x 0.102 = 102 kg/hr
Condensate available for recovery after flash steam = 1000 102 = 898 kg/hr
Heat recovered = 898 x (95 35 ) = 53880 kCal/hr
Oil saved = 53880 x 6000 / (0.80 x 10200) = 39.62 tons/yr
L-5 What is a steam phase diagram? Draw the steam phase diagram and mark the
following:
Critical Point
Two phase region
Saturated liquid line
Saturated vapor line
Lines of constant pressure
Super heated region
Liquid region
Solution: The relationship between the enthalpy and the temperature at various different
pressures, is known as a phase diagram
13
_____________________
Paper 2 Set B Key
L-6 A pulp and paper industry has a conventional stoker fired water tube boiler. In
view of the poor quality of coal being received the company decides to retrofit the
existing boiler with a fluidized bed coal fired combustion systems. What would be
the important aspects to be considered in the retrofit project. Also list down
categorically four changes to be incorporated ?
Solution Retrofitting fluidized bed coal fired combustion systems to conventional boilers
have been carried out successfully both in India and abroad. The important aspects to be
considered in retrofit projects are:
Water/steam circulation design
Furnace bottom-grate clearance
Type of particulate control device
Fan capacity
Availability of space.
Retrofitting of a fluidized bed combustor to a conventional stoker fired water tube

boiler may involve:
The replacement of grate by a distributor plate with short stand pipes for
admitting air from the wind box located underneath.
Installation of stand pipes to remove ash from the bed.
Provision of horizontal hair pin tubes in the bed with a pump for forced
circulation from the boiler drum.
Modification of crusher to size the coal/limestone mixture for pneumatic
under bed injection of the mixture.
It may be emphasized that conversion of a conventional coal fired system to a fluidized bed
combustion system can be accomplished without effecting major changes, after making a
cost-benefit analysis. Oil fired boilers can also be converted to coal fired fluidized bed
combustion systems.
-------- End of Section III ---------
14
_____________________
Paper 2 Set A Key
Regn No: _________________
Name: ___________________
th
8 NATIONAL CERTIFICATION EXAMINATION MAY, 2009
FOR
Paper 2: Energy Efficiency in Thermal Utilities
Date: 23.05.2009 Timings: 1400 to 1700 HRS Duration: 3 HRS Max. Marks: 150


Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB pencil,
as per instructions
1 The amount of theoretical air required for complete combustion of one ton of coal as compared
to that required for one ton of fuel oil is:
a) higher b) lower c) equal d) none of the above
2 2
2 If saturated steam at a pressure of 20 Kg/cm (a) is reduced to 10 Kg/cm (a), through a pressure
reducing valve, the steam will
a) condense b) remain saturated
c) get superheated d) be a mixture of 50% steam and 50% condensate
3 The unit of specific gravity in SI system is ___________

3 3 2
a) N/m b) kgf/m c) kg/m d) no unit
4 In a furnace, an oxygen rich combustion air (Oxygen 30% vol. and Nitrogen 70% vol) is
supplied instead of normal air (oxygen 21% vol. and Nitrogen 79% vol). By maintaining the
other parameters same, the % age of carbon dioxide in the flue gases will be
a) same b) lower c) higher d) zero
5 What type of steam is generally used for electrical power generation?

1
_____________________
Bureau of Energy
Efficiency
Paper 2 Set A Key
a) high pressure steam with super heat b) dry saturated steam
6 In a low temperature waste heat recovery system, which of the following device is the most
suitable
a) Economiser b) heat wheels c) regenerator d) ceramic recuperator
7 Heat transfer rate for drying application will be less if we heat with
a) saturated steam b) dry steam c) superheated steam d) high pressure steam
8 An oil fired boiler is operating at 5% O2 in the flue gas. The percentage excess air supplied to the
boiler is approximately
a) 15 % b) 25 % c) 31 % d) 42 %
9 Which of the following is used as insulation in low temperature applications ?

a) ceramic fibre b) calcium silicate c) fibre glass d) polystyrene
10 The coefficient of thermal expansion of refractory material should be

11 One kg of wood contains 20% moisture and 5% Hydrogen by weight. How much water is

a) drop in the contamination of feed water
b) greater purity of feed water

c) rise in the contamination of feed water
d) it has got no relation with the contamination of feed water
13 Pick the boiler, which can be considered as most combustion efficient?
a) fluidized bed combustion boiler b) lancashire boiler
c) stoker fired boiler d) chain grate boiler
14 Instrument used for measuring temperature in a glass furnace is

a) Leaf type thermocouple b) Infrared pyrometer
c) Pt/Pt-Rh thermocouple with indicator d) Chrome alumnel thermocouple with indicator

15 Recuperator will be more efficient if the flow path of hot and cold fluids is in:
a) co-current mode b) counter current mode
c) cross current mode d) none of the above
Which of the following best indicates the overall efficiency of a Combined Cycle thermal power plant?
a) 33 % b) 42 % c) 55% d) 60%
2
_____________________
Paper 2 Set A Key
17 When pure hydrogen is burnt with stoichiometric air, percentage CO 2 on volume basis in flue gas
on dry basis will be
a) 79% b) 21% c) 0% d) 100%

19 High % of carbon monoxide presence in the flue gas of boiler is an indicator of

20 The difference between mean solid and mean gas velocity in FBC boiler is called
21 The minimum capacity of any closed vessel which generates steam under pressure as covered
under Indian Boilers Regulation Act is
22 The temperature at which refractory will deform under its own weight is its softening temperature
indicated by
a) melting point b) PCE c) reform temperature d) critical point
23 When 1 kg of pressurized hot water at 120C is supplied with 50 kCal of heat at same pressure,
its temperature will be
a) 220C b) 190C c) 170C d) 120C
24 The purpose of venting air from steam systems is because air is a

a) insulator b) good conductor c) inert substance d) dilutant
25 Oxygen (O2) percentage measurement by volume basis can be done by using:

a) ultrasonic tester b) potassium oxide probe
c) copper tubes d) zirconium oxide probe
26 Turndown ratio for oil fired burner is the ratio of

a) air to fuel

c) maximum fuel input over minimum fuel input at same percentage of excess air
d) maximum air input over minimum air input
27 The type of firing used for a pulverized coal fired boiler is
a) over firing b) tangential firing
c) vertical firing d) mixed firing for effective heat transfer

o
28 The percentage raise in boiler efficiency by a 20 C raise in combustion air temperature is
a) 0.1% b) 0.2% c) 10% d) 1%
29 The steam generation in a boiler is 16 tonnes for four hours. The oil consumption for the same
period is 1.3 Tonnes. The evaporation ratio is
3
_____________________
Bureau of Energy
Efficiency
Paper 2 Set A Key
a) 12.3 b) 11.5 c) 9.2 d) 14
30 The normal velocities encountered in pipes for saturated steam is

a) 60 to 80 m/sec b) 10-20 m/sec c) 5 to 10 m/sec d) 30 to 40 m/sec
31 In industrial applications the type of trap used for main steam lines are
a) thermodynamic b) thermostatic c) bimetallic d) float
32 Which steam trap operates on the principle of difference in density between steam and
condensate
a) thermodynamic trap b) inverted Bucket c) thermostatic trap d) none of the above
33 Which of the following will be the ideal pressure to be maintained in a reheating furnace
a) 20 mm b) +1 mm c) +30 mm d) +20 mm
O
34 When the furnace is operated below 370 C, then it is called
a) muffle furnace b) kiln c) oven d) all the above
35 The percentage efficiency of a reheating furnace, operating at 10 tonnes per hour and
consuming furnace oil of 230 kg/hour for reheating the material from 40 C to 1100 C (specific
heat of material is 0.13 kCal / kg C and calorific value of furnace oil is 10,000 kCal /kg) is
a) 60 b) 70 c) 80 d) 50
36 The emissivity of ceramic coatings used in furnace

a) decreases with increase in temperature b) Increases with increase in temperature
c) remains constant irrespective of temperature d) decreases with increase in furnace pressure

37 Which is not a property of Ceramic fibre insulation
c) high heat storage d) thermal shock resistant
38 In a CFBC Boiler the capture and recycling of bed materials is accomplished by
a) settling chamber b) cyclone c) back filter d) scrubber
39 In FBC boiler the combustion is carried out at a temperature

a) closer to steam temperature b) at adiabatic combustion temperature
c) at and above ash fusion temperature d) below ash fusion temperature of fuel used


41 The percentage of energy consumed by air compressor in gas turbine plants is typically
a) 10% b) 22% c) 55% d) 80%
42 Capillary wick is a part of

a) heat pump b) heat wheel c) heat pipe d) regenerator
4
_____________________
Paper 2 Set A Key
43 Thermo-compressor is commonly used for

a) compressing hot air b) upgrading low pressure steam
c) distillation d) reverse compression of CO2

44 Which of the following is not required in the boiler efficiency evaluation by direct method
a) steam flow b) fuel flow c) feed water temperature d) O2 % in flue gas
45 The inlet gas temperature in a gas turbine is around

o o o o
a) 1700 C b) 1000 C c) 650 C d) 500 C
46 Controlled wetting of coal (during the coal preparation) would result in

a) reduction in flue gas exit temperature b) decrease in the percentage of unburnt carbon
c) improper combustion d) increase in the fines of coal

47 Ceramic fibre gives the maximum savings when used in
48 The major limitation of metallic recuperator is

a) handling COx, NOx etc.
o
b) reduced life for handling temperature more than 650 C
c) manufacturing difficulty of the required design
49 Which of the following when added to alumino silicate helps to reduce the shrinkage level of
ceramic fibre
a) Zr O2 b) SiO2 c) Al2O3 d) CaSO4
50 In flue gas the theoretical CO2 is 15% and the measured CO2 is 9% by volume. The % excess
air is:
a) 66% b) 150% c) 25% d)20%
-------- End of Section - I ---------
5
_____________________
Paper 2 Set A Key

S-1 Explain the difference between Flash Point and Pour Point of a liquid fuel?
ANS:
Flash Point
The flash point of a fuel is the lowest temperature at which the fuel can be heated so that
the vapour gives off flashes momentarily when an open flame is passed over it.
Pour Point
The pour point of a fuel is the lowest temperature at which it will pour or flow when cooled
under prescribed conditions. It is a very rough indication of the lowest temperature at which
fuel oil is readily pumpable.
S-2 What is clinker? List four factors which lead to clinker formation in case of
stationary grate coal fired boiler.
ANS :
Clinker is a mass of rough, hard, slag-like material formed during combustion of coal due
to low fusion temperature of ash present in coal. Presence of silica, calcium oxide,
magnesium oxides etc. in ash lead to a low fusion temperature.
Factors leading to clinker formation are :
Low ash fusion temperature
Uneven size or more fines in coal
Combustion without raking the coal bed
Pre heated air used for combustion
S-3 What is the significance of volatile matters in case of solid fuels being used for
combustion?
ANS :
Volatile matters are the methane, hydrocarbons, hydrogen and carbon monoxide, and
incombustible gases like carbon dioxide and nitrogen found in coal. Thus the volatile
matter is an index of the gaseous fuels present. Typical range of volatile matter is 20 to
35%.
Volatile Matter
Proportionately increases flame length, and helps in easier ignition of coal.
Sets minimum limit on the furnace height and volume.
6
_____________________
Paper 2 Set A Key
Influences secondary air requirement and distribution aspects.

Influences secondary oil support
S-4 Given the choice would you paint the outer surface of a reheating furnace black,
or with a shiny glossy colour (such as silver colour)? Explain.
ANS :
The emissivity of the outer surface should be kept to a minimum since the skin losses
would increase with high emissivity. A black colour acts like a black body with highest
emissivity, while a glossy and shiny aluminium foil has about the lowest emissivity.
Therefore, radiation loss is minimized. Shiny glossy colour, which has a lower emissivity
should be used.
S-5 What is the major advantage of a self recuperative burner (SRB). For a SRB the
quantity of heat brought in by pre heated air is 1000 kCal/kg fuel and the
quantity of heat taken away by exhaust gases is 4000 kCal per kg fuel. If the
calorific value of the fuel is 10,000 kCal/kg, find the % fuel saving rate?
ANS :
Self Recuperative Burners

Self-recuperative burners (SRBs) are based on traditional heat recovery techniques in that
the products of combustion are drawn through a concentric tube recuperator around the
burner body and used to pre-heat the combustion air
A major advantage of this type of system is that it can be retro-fitted to an existing furnace
structure to increase production capability without having to alter the existing exhaust gas
ducting arrangements. SRBs are generally more suited to heat treatment furnaces where
exhaust gas temperatures are lower and there are no stock recuperation facilities.
Estimation of fuel savings
By using preheated air for combustion, fuel can be saved. The fuel saving rate is given by
the following formula:
S = P X 100 /(F + P - Q)
where S: fuel saving rate, %

F: Calorific value of fuel (kCal/kg fuel)
quantity of heat brought in by preheated air (kCal/kg fuel)
quantity of heat taken away by exhaust gas (kCal/kg fuel)
S = 1000 X 100 / (10000 + 1000 - 4000)

S = 14.28 %
7
_____________________
Paper 2 Set A Key
S-6 A 5 MW DG Set is operating at 70% load. A waste heat recovery boiler is

2
installed to recover heat from exhaust gas to generate steam at 10 kg/cm . Find
out the quantity of steam generated annually after installing the waste heat
recovery boiler
Given Data:
o
Flue gas exit temperature = 500 C
o
Flue gas temperature after Waste heat recovery boiler = 250 C
o
Specific fuel consumption = 4 kWh/liter
Enthalpy of steam at 10 kg/cm2 = 660 kCal/kg
o
ANS :
Solution:

Diesel consumption = 3500 x 0.85 /4 = 744 kg/hr
Heat available for WHR boiler = 744 x 30 x 0.25 x (500 250) = 1395000 kCal/hr
2
Annual steam generation = 2.2. X 6000 = 13,200 tons /year.
S-7 The evaporation ratio of a coal fired boiler is 4. Estimate boiler efficiency if
0
steam enthalpy is 650 kCal/kg; feed water temperature is 65 C and Calorific
Value of coal is 4000 kCal/kg.
ANS:
Boiler efficiency = output/input * 100
= 4x (650-65) x 100
----------------------- = 58.5 %.
1 x 4000
8
_____________________
Paper 2 Set A Key
S-8 Calculate pressure drop in meters when pipe diameter is increased from 250 mm
to 350 mm for a length of 500 meters. Water velocity is 2 m/s in the 250 mm
diameter pipe, and friction factor is 0.005.
2
Ans. Pressure drop = 4fLV
--------------
2gD
2
Pressure drop with 250 mm = 4 x 0.005 x 500 x 2 / (2 x 9.81 x 0.250)
= 8.155 m
Velocity of water in pipe of 350 mm diameter = (0.25 x 0.25 x 2) /(0.35 x 0.35) = 1.02 m/s
2
Pressure drop with 350 mm = 4 x 0.005 x 500 x 1.02 / (2 x 9.81 x0. 350)
= 1.51 m
Pressure drop reduction = 8.15 1.51 = 6.64 m
-------- End of Section II ---------
9
_____________________
Paper 2 Set A Key

L-1 A pulp and paper industry has a conventional stoker fired water tube boiler. In
view of the poor quality of coal being received the company decides to retrofit the
existing boiler with a fluidized bed coal fired combustion systems. What would be
the important aspects to be considered in the retrofit project. Also list down
categorically four changes to be incorporated ?
Solution Retrofitting fluidized bed coal fired combustion systems to conventional boilers
have been carried out successfully both in India and abroad. The important aspects to be
considered in retrofit projects are:
Water/steam circulation design
Furnace bottom-grate clearance
Type of particulate control device
Fan capacity
Availability of space.
Retrofitting of a fluidized bed combustor to a conventional stoker fired water tube

boiler may involve:
The replacement of grate by a distributor plate with short stand pipes for
admitting air from the wind box located underneath.
Installation of stand pipes to remove ash from the bed.
Provision of horizontal hair pin tubes in the bed with a pump for forced
circulation from the boiler drum.
Modification of crusher to size the coal/limestone mixture for pneumatic
under bed injection of the mixture.
It may be emphasized that conversion of a conventional coal fired system to a fluidized

bed combustion system can be accomplished without effecting major changes, after
making a cost-benefit analysis. Oil fired boilers can also be converted to coal fired fluidized
bed combustion systems.
L-2 Analyse the diagram as given below and calculate:
Boiler Efficiency by direct method

Water Temperature in the condensate tank
Estimate fuel loss due to the drop in feed water temperature, assuming the boiler
efficiency to be the same
10
_____________________
Paper 2 Set A Key
Given that:
Enthalpy of steam at 10kg/cm2 = 665 kCal/kg
Furnace Oil consumption = 600 liters/hr
Specific Gravity of furnace oil = 0.89
G.C.V. of furnace oil = 10,000 kCal/kg
Solution : Oil Consumption = 600 x 0.89 = 534 kg/hr
1) Boiler Efficiency = 7000 (665 - 60) X 100/ 534 X 10000 = 79.3 %
2) Feed water temperature in condensate tank

o o
= [5000 x 95 + 2000 x 28]/ 7000 = 75.85 C = 76 C
3) Fuel Loss = [ 7000 x (76 60)]/ 10000 x 0.793 = 14 kg/hr
L-3 What is a steam phase diagram? Draw the steam phase diagram and mark the
following: 60oC
Critical Point
Two phase region
Saturated liquid line
d. Saturated vapor line
Lines of constant pressure
Super heated region
Liquid region
Solution: The relationship between the enthalpy and the temperature at various different
pressures, is known as a phase diagram
11
_____________________
Paper 2 Set A Key
L-4 Calculate the steam generation requirement and fuel oil consumption for the co-
generation scheme depicted below
Assumption = Losses across turbine including steam loss = 3 million kCal/hr
GCV of fuel oil = 10,000 kCal/kg
12
_____________________
Paper 2 Set A Key
Solution:
6
Heat in process steam = 80 x 1000x 660 = 52.8 x 10 kCal/hr
6
Heat equivalent to power generation = 17 x 1000 x 860 = 14.62 10 kCal/hr
6
Heat loss across turbine = 3 x 10 kCal/hr
6 6
Total Heat input to turbine = (52.8 + 14.62 + 3) x 10 kCal/hr = 70.42 x 10 kCal/hr
6
Equivalent steam generation at 100 kg/cm 2 at 760 kCal/kg = 70.42 x 10 / 760
= 92.7 tons/hr
Fuel Oil Consumption at 80% efficiency = [92.7 (760 80)]/ (0.8 x 10000)
= 7.8 tons/hr
L-5 A textile plant has an extensive stream distribution network and the steam
condensate is not being recovered. The plant management is planning to
recover the condensate and generate flash steam for use as low pressure
process steam for fuel economy. The following are the parameters about the
system.
Condensate quantity 1000 kg/hr

Condensate Pressure 10 bar
Cost of steam Rs 1100/ T
Annual operating hours 8000
Low pressure process steam (flash steam) pressure 2 bar
Latent heat of steam at 2 bar 518 kCal/kg
Boiler Efficiency 82 %
GCV of fuel oil 10,200 kCal/kg
Specific Gravity of fuel oil 0.92
o
Condensate temperature when recovered 95 C
o
Make up water temperature 35 C
Calculate the Quantity of flash steam which can be recovered, and the annual fuel oil
savings on account of condensate recovery
Solution :
a) Flash steam available % = S1- S2/(L2)
Where: S1 is the sensible heat of higher pressure condensate.
S2 is the sensible heat of the steam at lower pressure
L2 is the latent heat of flash steam (at lower pressure).
% of Flash steam recoverable = (188 135)/518 = 10.2 %
13
_____________________
Paper 2 Set A Key
Quantity of flash steam recovered from condensate = 1000 x 0.102 = 102 kg/hr
Condensate available for recovery after flash steam = 1000 102 = 898 kg/hr
Heat recovered = 898 x (95 35 ) = 53880 kCal/hr
Oil saved = 53880 x 8000 / (0.82 x 10200) = 51.2 tons/yr
L-6 In an engineering industry, resistance heating type furnace was used for heat
treatment of the product. The power consumption of the furnace at 1/3 load
and full load is 860 kWh and 1600 kWh per cycle respectively. The furnace heat
treatment cycle and loading of the furnace was analysed. The details are as
follows:
Furnace capacity : 180 kW

Loading capacity of furnace : 10 Tonnes
Heat treatment cycle : Heating up to 650 C 6 hours
: Soaking at 650 C 8 hours
: Cooling in furnace 4 hours
Quantity of the stock to be treated : 1000T/year
Evaluate the annual energy savings at full load operation of the furnace.
Solution Sp. Power consumption of stock:

Load in furnace (1/3) = 10 x 1/3
= 3.3 MT
rd
Power consumption for 1/3 load = 860 kWh/cycle
rd
Sp. Power consumption at 1/3 load = 860/3.3
= 260.6 kWh/MT
Load in the furnace (full) = 10 MT
Power consumption at full load = 1600 kWh/cycle
Sp. Power consumption at full load = 1600/10
= 160 kWh/MT
Reduction in power consumption at optimum load (full load)

260.6 160
100.6 kWh/MT
Annual stock production = 1000 T

By operating furnace with each batch of 10T (full load)
Reduction in power consumption = 1000 x 100.6
= 100600 kWh /year
-------- End of Section III ---------
14
_____________________
Regn No: _________________

Name: ___________________
th
10 NATIONAL CERTIFICATION EXAMINATION July, 2010
FOR


instructions
1. Which of the following fuels needs minimum stoichiometric air for combustion?
a) coal b) natural gas c) LPG d) fuel oil
2. Which parameter influences flame profile most?

a) fixed carbon b) volatile matter c) carbon/hydrogen ratio d) none of the above
3. Natural draft in a combustion system is produced by

a) fuel firing rate b) stack temperature c) stack height d) stack temperature and height
4. The efficiency of a boiler was improved from 70% to 80%. The % fuel savings achieved are
a) 12.5% b) 18% c) 25% d) none of the above
5. Which of the following is the best way to assess boiler losses?

a) benchmarking evaporation ratio b) indirect efficiency evaluation
c) direct efficiency evaluation d) none of the above

6. What is the appropriate fuel size in a coal fired FBC boiler?
1
_______________________
a) 25-50 mm b) 50-75 mm c) 6-10 mm d) less than 5 mm
7. Waste heat recovery systems with a high LMTD results in

a) higher heat transfer area b) lower heat transfer area c) higher u-factor d) none of the above
8. A steam trap helps to

a) block steam and allow condensate b) block condensate and allow steam
c) block condensate and allow air and steamd) recover flash steam
9. Which property is most important for a fire brick?
a) high porosity b) thermal stability at high temperature
c) low bulk density d) chemical resistance
10. NOX formation chances are least in
a) FBC boilers b) pulverised fuel fired boilers c) furnace oil fired boilers d) stoker fired boilers
11. Flash steam quantity per kg of condensate depends upon

a) condensate pressure only b) condensate pressure and flow
c) condensate pressure and flash steam pressure d) none of the above
12. Which of the following waste heat recovery systems is of thermal storage type?
a) ceramic recuperator b) metallic recuperator c) regenerative burner d) waste heat boiler
13. A boiler trial indicated 2% O2 at boiler exit and 7% O2 at stack. The in-leak air quantity between
these two measurement is
a) 25% b) 40% c) 50% d) 5%
14. Spontaneous combustion is a loss area in

a) fuel oil storage b) natural gas storage c) furnace hearth d) coal storage
15. Which of the following fuel requires the largest amount of excess air for complete combustion?
16. Which of the following is one of the components of LPG?

a) methane b) iso-octane c) hexane d) propane
17. Enthalpy of evaporation of steam will be higher at

2 2 2 2
a) 2 kg/cm b) 8 kg/cm c) 12 kg/cm d) 20 kg/cm
18. The element that does not contribute to heating value during combustion process is
a) nitrogen b) sulphur c) hydrogen d) carbon
19. Which of the following is not one of the 3 Ts of combustion?

a) time b) temperature c) turbulence d) tertiary
20. Which of the following is not required in the boiler efficiency evaluation by direct method?
a) steam flow b) fuel flow c) feed water temperature d) oxygen % in the flue gas
21. The concentration of solids in a boiler is controlled by
2
_______________________
a) steam venting b) blow down c) air venting d) deaeration

22. Soot on boiler tubes is formed by
a) poor water treatment b) low steam pressure c) high excess air d) incomplete combustion
23. Which of the following will be ideal heating medium for heat transfer in a heat exchanger?
a) superheated steam b) saturated steam
c) high pressure condensate d) condensate at atmospheric pressure
24. Insulating material made by blending and melting of alumina and silica is known as
a) ceramic fibre b) high alumina brick c) fire brick d) insulating brick
25. Which of the following cannot be fired in a gas turbine?

a) natural gas b) LPG c) naptha d) coal
26. The waste heat boiler application is not suitable for which of the following?
a) gas turbine b) diesel engine c) furnaces d) dryers
27. A thermal insulator has

a) low thermal conductivity b) high thermal conductivity
c) high convection coefficient d) low convection coefficient
28. The dry saturated steam when throttled to a lower pressure will
a) become wet b) become superheated c) remain dry saturated d) become condensate
29. Which type of steam trap operates on the principal of difference in temperature of steam and
condensate?
a) thermodynamic trap b) inverted bucket c) thermostatic trap d) none of the above

c) emissivity of external wall surface d) stock to be heated
31. Emissivity is a measure of materials ability to
a) only absorb heat b) only radiate heat c) absorb and radiate heat d) none of the above
32. Removal of dissolved gases from the boiler feed water is called
a) descaling b) deaeration c) deoxidation d) none of the above
33. Which of the following boiler type has the lowest permissible boiler drum TDS concentration?
a) low pressure water tube boiler b) fire tube boiler c) Lancashire boilerd) all of the above
34. Velocity of steam in a pipe does strongly depend on

a) number of bends and valves in the pipe b) specific volume of steam
c) length of the pipe d) none of the above
35. Regenerators are widely used in
a) glass melting furnace b) reheating furnace c) baking ovens d) heat treatment furnace
3
_______________________
36. In a CFBC boiler, the capture and recycling of bed materials is accomplished by
a) bag filters b) settling chamber c) cyclone d) scrubber system
37. The coefficient of thermal expansion of refractory materials should be

a) low b) medium c) high d) very high
38. The purpose of venting air from steam system is because air is
a) an insulator b) a good conductor c) an inert substance d) incompressible

a) high pressure air b) low pressure steam c) high pressure steam d) high pressure condensate
40. Scale losses of stock in reheating furnace will

a) increase with increase of CO2 in combustion gases b) increase with increase in excess air
c) decrease with increase in excess air d) have no relation with excess air
a) 540 kCal/kg b) zero c) infinite d) equal to sensible heat
42. For combustion, controlled wetting of coal (during the coal preparation) would result in
a) reduction in flue gas exit temperatures b) decrease in the percentage of unburnt carbon
c) coal fines carryover d) increase in the coal fines
43. Fluidized bed combustion results in _________ SOx and NOx emissions
a) increased b) decreased c) no effect on d) elimination of
44. The limit to reduction of stack temperature in an oil fired boiler is influenced by
a) oil temperature b) air temperature c) % carbon in oil d) % sulphur in oil
45. Which type of turbine has high heat-to-power ratio?

a) gas turbine b) back pressure turbine c) extraction condensing turbine d) reciprocating engine
46. The highest percentage of sulphur is present in

a) FO b) LDO c) LSHS d) kerosene
47. Furnace oil contains 84% carbon by weight. How many kg of CO 2 does complete combustion of 1
a) 2.4 b) 4.0 c) 3.6 d) 3.1
48. The furnace bed temperature of a fluidized bed boiler is about

a) 850C b) 1100C c) 700C d) 1000C
49. Which data is not required to calculate the efficiency of boiler by indirect method
a) blow down rate b) ambient temperature c) calorific value of fuel d) flue gas temperature
50. For transporting steam to long distance, the best quality of steam is
c) slightly wet steam d) very high pressure steam
4
_______________________

S-1 What is draft and briefly explain its importance in boilers and furnaces?
Ans: Draft is the difference of pressure producing air flow through a boiler furnace, flue and
chimney.
2 Marks
The function of draft in a combustion system is to exhaust the products of combustion
into the atmosphere overcoming the pressure drop across the boiler tubes, baffles,
economizer, flue duct bends, air pollution control system etc. if draft is not properly
maintained it affects the combustion system and results in high energy consumption.
3 Marks
S-2 What is meant by air venting in a steam system and what is its purpose?
Ans: When steam is first admitted to a pipe/equipment after a period of shut down, the
pipe/equipment is full of air. Further amounts of air and other non condensable gases will
enter with the steam, although the proportions of these gases are normally very small
compared with the steam. When the steam condenses, these gases will accumulate in
pipes and heat exchangers. Precautions should be taken to discharge them.
The consequence of not removing air increases heatup time and reduces plant efficiency
and process performance. The presence of air affects heat transfer.
5 Marks
o o
S-3 In a heat exchanger, steam is used to heat 3 kl/hr of furnace oil from 30 C to 100 C. The
o
specific heat of furnace oil is 0.22 kCal/ kg/ C and the density of furnace oil is 0.95.
2
How much steam per hour is needed if steam at 4 kg/cm with latent heat of 510 kCal/ kg
is used.
If steam cost is Rs. 4.0/kg and electrical energy cost is Rs.6.0/kWh, which type of
heating would be more economical in this particular case? (assume no losses in
electrical and steam heating process)
Ans: Total heat required = m Cp T

(3 x 1000 x 0.95) x 0.22 x (100-30)
43890 kcal/hr
1 Mark
Amount of steam required = 43890/510
5
_______________________
= 86 kg/hr
Steam cost = 86 x Rs.4
= Rs. 344/hr
2 Marks
Amount of electricity required = 43890/860
51 kWh
51 x Rs. 6
Rs.306/ hr
Electrical heating will be more economical

2 Marks
S-4 Write short notes on economic insulation thickness for energy efficiency.
Ans: Insulation of any system means capital expenditure. Hence an important factor in any
insulation system is to analyse the thermal insulation with respect to cost. The
effectiveness of insulation follows the law of decreasing returns. Hence, there is a
definite economic limit to the insulation thickness, which is justified. Excess thickness is
uneconomical and cannot be recovered through heat savings. Each industry has
different cost of heat loss due to variation in fuel cost and boiler efficiency. These values
can be used for calculating economic thickness of insulation, where thickness for a given
set of circumstances, which results in the lowest overall cost of insulation and heat loss
combined economic insulation thickness.
Note : figure is optional

5 Marks
S-5 For a 8 TPH capacity boiler, estimate the rise in temperature of water in an economizer. The
flue gas temperature decreases from 315 C to 210 C in the economiser. Air to fuel ratio
and evaporation ratio of the boiler are 20 kg of air/kg of fuel and 12 respectively. Assume
condensate recovery and boiler blow down is nil. Specific heat of flue gas: 0.23 kCal/kg
o
C
Ans: For 1 kg of fuel steam generated is = 12 kg

2 Marks
6
_______________________
21 x 0.23 x (315-210) = 12 x 1 x T
T = 42.26 C
3 Marks
S-6 The evaporation ratio of a coal fired boiler is 5.1. Estimate boiler efficiency if steam enthalpy
0
is 650 kCal/kg; feed water temperature is 80 C and calorific value of coal is 4500
kcal/kg.
Boiler efficiency = output/input x 100

2 Marks
= 5.1 x (650-80) x 100

----------------------- = 64.6%
1 x 4500
3 Marks
S-7 Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing
Turbine Cogeneration systems (Note: no explanation required).
S-8 A 5 MW DG Set is operating at 80 % load. A waste heat recovery boiler is installed to

2
recover heat from exhaust gas to generate steam at 10 kg/cm . Find out the quantity of
steam generated annually after installing the waste heat recovery boiler
Given Data:
o
Flue gas exit temperature = 450 C
o
o
Specific fuel consumption = 4.2 kWh/liter
2
Enthalpy of steam at 10 kg/cm = 660 kCal/kg
o
7
_______________________
Solution:
1 Mark
Diesel consumption = 4000 x 0.85 /4.2 = 809.52 kg/hr

1 Mark
Heat available for WHR boiler = [809.52 + (809.52 x 28)] x 0.25 (450 230) = 1291184
kCal/hr
1 Mark
2
Annual steam generation = 2.152 X 7500 = 16,140 tons /year.
2 Marks
2.5 Marks for each figure
------- End of Section - II ---------

L-1 A furnace is used to heat the stock. The stock is charged through a door, which is always
kept open. The door size is 800 mm x 800 mm. The furnace wall thickness is 400 mm.
The furnace operating temperature is 1260 C.
Calculate the hourly direct radiation heat loss through openings? Convert the heat loss in
terms of oil equivalent loss if GCV of oil is 10250 kCal/kg.
Other data are as under:

2
Blackbody radiation corresponding to 1260 C = 30 kCal/cm /hr
Emissivity = 0.82
Factor of radiation = 0.7
Ans: Area of opening = 80 cm x 80 cm

2
= 6400 cm
2 Marks
The factor of radiation = 0.7
Emissivity = 0.82
Total heat loss through opening
Black body radiation x Area of opening x factor of radiation x Emissivity
30 x 6400 x 0.7 x 0.82
1,10,208 kCal/hr
6 Marks
Equivalent oil loss = 110208/10250
8
_______________________
10.75 kg/hr
2 Marks
L-2 In a steam system, mention three types of classification of steam traps and give their
principle of operation. Give one example for each type.
Ans: Mechanical trap
Principle of operation is difference in density between steam and condensate

The different mechanical traps are
Open bucket (or)
Inverted bucket (or)
Float type
3 Marks
Thermodynamic trap
Principle of operation is difference in thermodynamic properties between steam and

condensate
The different thermodynamic traps are
Disc type
4 Marks
Thermostatic trap
Principle of operation is difference in temperature between steam and condensate. The

different thermostatic traps are
Bimetallic type
3 Marks
L-3 An oil fired reheating furnace has an operating temperature of around 1200 C. The average
fuel oil (FO) consumption is 420 litres/hour. The flue gas exit temperature after the air
preheater is 320C. Find out the percentage sensible heat loss in exhaust gases.

Specific gravity of oil 0.92
Calorific value of oil 9300 kCal/kg
Average O2 percentage in flue gas 13%
Theoretical air required 14 kg of air to burn 1 kg of oil
Ambient temperature o
40 C
Specific heat of flue gas 0.25 kCal/kgC
Ans: Energy input = 420 lph

420 x 0.92 = 386.4 kg/hr
386.4 x 9300
3593520 kCal/hr
2 Marks
Corresponding excess air = (%O2/ (21-O2)) x 100

(13/ (21-13)) x 100
162 %
2 Marks
Theoretical air required = 14 kg of air to burn 1 kg of oil
9
_______________________
Actual air required = 14 x (1+1.62) kg/kg of oil

= 36.68 kg/kg of oil
2 Marks
Sensible heat loss in flue gas = m x Cp x T
m = mass of flue gas

= 36.68 + 1
Cp = Specific heat of flue gas

= 0.25
=Temperature of flue gas ambient temperature

320C - 40C
280C
Heat loss = 37.68 x 0.25 x (320 -40)

37.68 x 0.25 x 280
2637.6 kCal/kg of oil
2637.6 x 386.4
1019168 kCal/hr
2 Marks
as % heat loss to input energy (1019168 x 100)/(3593520)
28.36%
2 Marks
L-4 What is the need for boiler blow down? Explain intermittent and continuous blow down.
Ans: Water contains certain percentage of dissolved solids. The percentage of dissolved
solids found in boiler water depend on the untreated feed water quality, the treatment
process and the boiler operating procedures, as the feed water evaporate in to steam,
dissolved solids concentrate in the boiler either in dissolved or suspended state. Above
certain level of concentration, these solids encourage foaming and cause carry over of
water in to the steam. This leads to scale formation inside the boiler, resulting in localized
overheating and ending finally in tube failure.
If in therefore necessary to control the level of concentration of the solids and this is
achieved by the process of blowing down, where a certain volume of water in blown off
and is automatically replaced by feed water thus maintaining the optimum level of total
dissolved solids (TDS)in the water .
4 Marks
The intermittent blow down in given by manually operating a valve fitted to discharge
pipe at the lowest point of boiler shell to reduce parameters with in prescribed limits so
that steam quality is not likely to be affected.
3 Marks
The continuous blow down is a steady and constant dispatch of small stream of
concentrated boiler water and replacement by steady and constant inflow of feed water.
This ensures constant TDS and steam purity at a given steam load .once blow down
valve is set for a given conditions there is no need for regular operator intervention.
10
_______________________
3 Marks
L-5 List ten of energy conservation opportunities in an oil fired reheating furnace?
Ans:
Complete combustion with minimum excess air
Correct heat distribution.
Operating at the desired temperature
Reducing heat losses from furnace opening
Maintaining correct amount of furnace draught
Optimum capacity utilization
Waste heat recovery from the flue gas
Minimum refractory losses
Use of ceramic coating
Maintaining proper cycle time
1 Mark for each point
Note: Any other relevant point may also be given marks
given below:
Component %
Carbon 40
Hydrogen 7
Nitrogen 0.5
Oxygen 50.5
Sulphur 0.5
Ash 1.5
Using the basic combustion equations estimate the theoretical air requirement for 100 kg
of dry fuel fired:
Ans: Basic equations:

C + O2 = CO2
2H2 + O2 = 2H2O
S + O2 = SO2
2 Marks
Theoretical amount of air for combustion
12 kg carbon requires 32 kg of oxygen forming 44 kg of CO2.
1 kg carbon requires 32/12=2.67 kg O2.
(40)C + (2.67x40) O2 = (146.67) CO2

2 Marks
4 kg of Hydrogen requires 32 kg of oxygen.1 kg of Hydrogen requires 8 kg of oxygen.

(7) H2 + (7x8) O2 = (63) H2O
11
_______________________
2 Marks
32 kg Sulfur requires 32 kg oxygen to form 64 kg of SO2. 1 kg Sulfur requires 1 kg

Oxygen.
(0.5) S + (0.5) O2 = (1) SO2

2 Marks
Oxygen to be supplied = 163.17-50.5 = 112.6 kg
Amount of air to be supplied =112.6 x100/23
= 490 kg
2 Marks
12
_______________________
Regn No: _________________

Name: ___________________
th
10 NATIONAL CERTIFICATION EXAMINATION July, 2010
FOR


instructions
1. A boiler trial indicated 2% O2 at boiler exit and 7% O2 at stack. The in-leak air quantity between
these two measurement is
a) 25% b) 40% c) 50% d) 5%
2. A steam trap helps to

a) block steam and allow condensate b) block condensate and allow steam
c) block condensate and allow air and steamd) recover flash steam
3. A thermal insulator has
a) low thermal conductivity b) high thermal conductivity
c) high convection coefficient d) low convection coefficient
4. Emissivity is a measure of materials ability to
a) only absorb heat b) only radiate heat c) absorb and radiate heat d) none of the above
Enthalpy of evaporation of steam will be higher at

2 2 2 2
a) 2 kg/cm b) 8 kg/cm c) 12 kg/cm d) 20 kg/cm
1
_______________________
6. Flash steam quantity per kg of condensate depends upon

a) condensate pressure only b) condensate pressure and flow
c) condensate pressure and flash steam pressure d) none of the above
7. Fluidized bed combustion results in _________ SOx and NOx emissions
a) increased b) decreased c) no effect on d) elimination of
8. For combustion, controlled wetting of coal (during the coal preparation) would result in
a) reduction in flue gas exit temperatures b) decrease in the percentage of unburnt carbon
c) coal fines carryover d) increase in the coal fines
9. For transporting steam to long distance, the best quality of steam is
c) slightly wet steam d) very high pressure steam
10. Furnace oil contains 84% carbon by weight. How many kg of CO 2 does complete combustion of 1
a) 2.4 b) 4.0 c) 3.6 d) 3.1

c) emissivity of external wall surface d) stock to be heated
12. In a CFBC boiler, the capture and recycling of bed materials is accomplished by
a) bag filters b) settling chamber c) cyclone d) scrubber system
13. Insulating material made by blending and melting of alumina and silica is known as
a) ceramic fibre b) high alumina brick c) fire brick d) insulating brick

a) 540 kCal/kg b) zero c) infinite d) equal to sensible heat
15. Natural draft in a combustion system is produced by

a) fuel firing rate b) stack temperature c) stack height d) stack temperature and height
16. NOX formation chances are least in

a) FBC boilersb) pulverised fuel fired boilers c) furnace oil fired boilersd) stoker fired boilers
17. Regenerators are widely used in

a) glass melting furnaceb) reheating furnace c) baking ovens d) heat treatment furnace
18. Removal of dissolved gases from the boiler feed water is called
a) descaling b) deaeration c) deoxidation d) none of the above
19. Spontaneous combustion is a loss area in

a) fuel oil storage b) natural gas storage c) furnace hearth d) coal storage
Soot on boiler tubes is formed by
a) poor water treatment b) low steam pressure c) high excess air d) incomplete combustion
2
_______________________
21. Scale losses of stock in reheating furnace will

a) increase with increase of CO2 in combustion gases b) increase with increase in excess air
c) decrease with increase in excess air d) have no relation with excess air
22. The coefficient of thermal expansion of refractory materials should be
a) low b) medium c) high d) very high
23. The concentration of solids in a boiler is controlled by

a) steam venting b) blow down c) air venting d) deaeration
24. The dry saturated steam when throttled to a lower pressure will
a) become wet b) become superheated c) remain dry saturated d) become condensate
25. The efficiency of a boiler was improved from 70% to 80%. The % fuel savings achieved are
a) 12.5% b) 18% c) 25% d) none of the above
26. The element that does not contribute to heating value during combustion process is
a) nitrogen b) sulphur c) hydrogen d) carbon
27. The furnace bed temperature of a fluidized bed boiler is about

a) 850C b) 1100C c) 700C d) 1000C
28. The highest percentage of sulphur is present in

a) FO b) LDO c) LSHS d) kerosene
29. The limit to reduction of stack temperature in an oil fired boiler is influenced by
a) oil temperature b) air temperature c) % carbon in oil d) % sulphur in oil
30. The purpose of venting air from steam system is because air is
a) an insulator b) a good conductor c) an inert substance d) incompressible
31. The waste heat boiler application is not suitable for which of the following?
a) gas turbine b) diesel engine c) furnaces d) dryers

a) high pressure air b) low pressure steam c) high pressure steam d) high pressure condensate
33. Velocity of steam in a pipe does strongly depend on

a) number of bends and valves in the pipe b) specific volume of steam
c) length of the pipe d) none of the above
34. What is the appropriate fuel size in a coal fired FBC boiler?
a) 25-50 mm b) 50-75 mm c) 6-10 mm d) less than 5 mm
35. Waste heat recovery systems with a high LMTD results in

a) higher heat transfer area b) lower heat transfer area c) higher u-factor d) none of the above
36. Which data is not required to calculate the efficiency of boiler by indirect method
a) blow down rate b) ambient temperature c) calorific value of fuel d) flue gas temperature
3
_______________________
37. Which of the following boiler type has the lowest permissible boiler drum TDS concentration?
a) low pressure water tube boiler b) fire tube boiler c) Lancashire boiler d) all of the above
38. Which of the following cannot be fired in a gas turbine?

a) natural gas b) LPG c) naptha d) coal
39. Which of the following fuel requires the largest amount of excess air for complete combustion?
40. Which of the following fuels needs minimum stoichiometric air for combustion?
a) coal b) natural gas c) LPG d) fuel oil
41. Which of the following is not one of the 3 Ts of combustion?

a) time b) temperature c) turbulence d) tertiary
42. Which of the following is not required in the boiler efficiency evaluation by direct method?
a) steam flow b) fuel flow c) feed water temperature d) oxygen % in the flue gas
43. Which of the following is one of the components of LPG?

a) methane b) iso-octane c) hexane d) propane
44. Which of the following is the best way to assess boiler losses?
a) benchmarking evaporation ratiob) indirect efficiency evaluation
c) direct efficiency evaluation d) none of the above
45. Which of the following waste heat recovery systems is of thermal storage type?
a) ceramic recuperator b) metallic recuperator c) regenerative burner d) waste heat boiler
46. Which of the following will be ideal heating medium for heat transfer in a heat exchanger?
47. Which parameter influences flame profile most?

a) fixed carbon b) volatile matter c) carbon/hydrogen ratio d) none of the above
48. Which property is most important for a fire brick?

a) high porosity b) thermal stability at high temperature
c) low bulk density d) chemical resistance
49. Which type of steam trap operates on the principal of difference in temperature of steam and
condensate?
a) thermodynamic trap b) inverted bucket c) thermostatic trap d) none of the above
50. Which type of turbine has high heat-to-power ratio?

a) gas turbine b) back pressure turbine c) extraction condensing turbine d) reciprocating engine
4
_______________________

S-1 A 5 MW DG Set is operating at 80 % load. A waste heat recovery boiler is installed to

2
recover heat from exhaust gas to generate steam at 10 kg/cm . Find out the quantity of
steam generated annually after installing the waste heat recovery boiler
Given Data: = 450 C

o
Flue gas exit temperature
o
o
Specific fuel consumption = 4.2 kWh/liter
2
Enthalpy of steam at 10 kg/cm = 660 kCal/kg
o
Solution:
1 Mark
Diesel consumption = 4000 x 0.85 /4.2 = 809.52 kg/hr

1 Mark
Heat available for WHR boiler = [809.52 + (809.52 x 28)] x 0.25 (450 230) = 1291184
kCal/hr
1 Mark
2
Annual steam generation = 2.152 X 6000 = 12,912 tons /year.
2 Marks
S-2 For a 8 TPH capacity boiler, estimate the rise in temperature of water in an economizer. The
flue gas temperature decreases from 315 C to 200 C in the economiser. Air to fuel ratio
and evaporation ratio of the boiler are 20 kg of air/kg of fuel and 12 respectively. Assume
condensate recovery and boiler blow down is nil. Specific heat of flue gas: 0.23 kCal/kg
o
C
Ans: For 1 kg of fuel steam generated is = 12 kg

5
_______________________

2 Marks
21 x 0.23 x (315-200) = 12 x 1 x T
T = 46.29 C
3 Marks
S-3 What is draft and briefly explain its importance in boilers and furnaces?
Ans: Draft is the difference of pressure producing air flow through a boiler furnace, flue and
chimney.
2 Marks
The function of draft in a combustion system is to exhaust the products of combustion
into the atmosphere overcoming the pressure drop across the boiler tubes, baffles,
economizer, flue duct bends, air pollution control system etc. if draft is not properly
maintained it affects the combustion system and results in high energy consumption.
3 Marks
S-4 The evaporation ratio of a coal fired boiler is 5.1. Estimate boiler efficiency if steam enthalpy
0
is 650 kCal/kg; feed water temperature is 40 C and calorific value of coal is 4500
kcal/kg.
Boiler efficiency = output/input x 100

2 Marks
= 5.1 x (650-40) x 100

----------------------- = 69.13%
1 x 4500
3 Marks
S-5 Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing
2.5 Marks for each figure

6
_______________________
S-6 What is meant by air venting in a steam system and what is its purpose?
Ans: When steam is first admitted to a pipe/equipment after a period of shut down, the
pipe/equipment is full of air. Further amounts of air and other non condensable gases will
enter with the steam, although the proportions of these gases are normally very small
compared with the steam. When the steam condenses, these gases will accumulate in
pipes and heat exchangers. Precautions should be taken to discharge them.
The consequence of not removing air increases heatup time and reduces plant efficiency
and process performance. The presence of air affects heat transfer.
5 Marks
o o
S-7 In a heat exchanger, steam is used to heat 3 kl/hr of furnace oil from 30 C to 100 C. The
o
specific heat of furnace oil is 0.22 kCal/ kg/ C and the density of furnace oil is 0.95.
2
How much steam per hour is needed if steam at 4 kg/cm with latent heat of 510 kCal/ kg
is used.
If steam cost is Rs.4.0/kg and electrical energy cost is Rs.7.0/kWh, which type of heating
would be more economical in this particular case? (assume no losses in electrical and
steam heating process)

(3 x 1000 x 0.95) x 0.22 x (100-30)
43890 kcal/hr
1 Mark
Amount of steam required = 43890/510

= 86 kg/hr
= Rs. 344/hr
2 Marks
Amount of electricity required = 43890/860
51 kWh
51 x Rs. 7
Rs.357/ hr
Steam heating will be more economical

2 Marks
S-8 Write short notes on economic insulation thickness for energy efficiency.
Ans: Insulation of any system means capital expenditure. Hence an important factor in any
insulation system is to analyse the thermal insulation with respect to cost. The
effectiveness of insulation follows the law of decreasing returns. Hence, there is a
definite economic limit to the insulation thickness, which is justified. Excess thickness is
uneconomical and cannot be recovered through heat savings. Each industry has
different cost of heat loss due to variation in fuel cost and boiler efficiency. These values
7
_______________________
can be used for calculating economic thickness of insulation, where thickness for a given
set of circumstances, which results in the lowest overall cost of insulation and heat loss
combined economic insulation thickness.
Note : figure is optional

5 Marks
------- End of Section - II ---------

L-1 What is the need for boiler blow down? Explain intermittent and continuous blow down.
Ans: Water contains certain percentage of dissolved solids. The percentage of dissolved
solids found in boiler water depend on the untreated feed water quality, the treatment
process and the boiler operating procedures, as the feed water evaporate in to steam,
dissolved solids concentrate in the boiler either in dissolved or suspended state. Above
certain level of concentration, these solids encourage foaming and cause carry over of
water in to the steam. This leads to scale formation inside the boiler, resulting in localized
overheating and ending finally in tube failure.
If in therefore necessary to control the level of concentration of the solids and this is
achieved by the process of blowing down, where a certain volume of water in blown off
and is automatically replaced by feed water thus maintaining the optimum level of total
dissolved solids (TDS)in the water .
4 Marks
The intermittent blow down in given by manually operating a valve fitted to discharge
pipe at the lowest point of boiler shell to reduce parameters with in prescribed limits so
that steam quality is not likely to be affected.
3 Marks
8
_______________________
The continuous blow down is a steady and constant dispatch of small stream of
concentrated boiler water and replacement by steady and constant inflow of feed water.
This ensures constant TDS and steam purity at a given steam load .once blow down
valve is set for a given conditions there is no need for regular operator intervention.
3 Marks
L-2 List ten of energy conservation opportunities in an oil fired reheating furnace?
Ans:
Correct heat distribution.
Reducing heat losses from furnace opening
Waste heat recovery from the flue gas
Use of ceramic coating
Maintaining proper cycle time
1 Mark for each point
Note: Any other relevant point may also be given marks
given below:
Component %
Carbon 40
Hydrogen 7
Nitrogen 0.5
Oxygen 40.5
Sulphur 0.5
Ash 11.5
Using the basic combustion equations estimate the theoretical air requirement for 100 kg
of dry fuel fired:
Ans: Basic equations:
C + O2 = CO2
2H2 + O2 = 2H2O
S + O2 = SO2
2 Marks
Theoretical amount of air for combustion

12 kg carbon requires 32 kg of oxygen forming 44 kg of CO2.
1 kg carbon requires 32/12=2.67 kg O2.

9
_______________________
(40)C + (2.67x40) O2 = (146.67) CO2

2 Marks
4 kg of Hydrogen requires 32 kg of oxygen.1 kg of Hydrogen requires 8 kg of oxygen.
(7) H2 + (7x8) O2 = (63) H2O

2 Marks
32 kg Sulfur requires 32 kg oxygen to form 64 kg of SO2. 1 kg Sulfur requires 1 kg

Oxygen.
(0.5) S + (0.5) O2 = (1) SO2
2 Marks
Oxygen to be supplied = 163.17-40.5 = 102.6 kg
Amount of air to be supplied =102.6 x100/23
= 446.08 kg
2 Marks
L-4 In a steam system, mention three types of classification of steam traps and give their
principle of operation. Give one example for each type.
Ans: Mechanical trap
Principle of operation is difference in density between steam and condensate

The different mechanical traps are
Open bucket (or)
Inverted bucket (or)
Float type
3 Marks
Thermodynamic trap
Principle of operation is difference in thermodynamic properties between steam and

condensate
The different thermodynamic traps are
Disc type
4 Marks
Thermostatic trap
Principle of operation is difference in temperature between steam and condensate. The

different thermostatic traps are
Bimetallic type
3 Marks
L-5 An oil fired reheating furnace has an operating temperature of around 1200 C. The average
fuel oil (FO) consumption is 450 litres/hour. The flue gas exit temperature after the air
preheater is 320C. Find out the percentage sensible heat loss in exhaust gases.
10
_______________________

Specific gravity of oil 0.92
Calorific value of oil 10000 kCal/kg
Average O2 percentage in flue gas 13%
Theoretical air required 14 kg of air to burn 1 kg of oil
Ambient temperature o
40 C
Specific heat of flue gas 0.25 kCal/kgC
Ans: Energy input = 450 lph

= 450 x 0.92 = 414 kg/hr
= 414 x 10000
= 41,40,000 kCal/hr
2 Marks
Corresponding excess air = (%O2/ (21-O2)) x 100
= (13/ (21-13)) x 100
= 162 %
2 Marks
Theoretical air required = 14 kg of air to burn 1 kg of oil
Actual air required = 14 x (1+1.62) kg/kg of oil
2 Marks
Sensible heat loss in flue gas = m x Cp x T
m = mass of flue gas
= 36.68 + 1
Cp = Specific heat of flue gas
= 0.25
=Temperature of flue gas ambient temperature

320C - 40C
280C
Heat loss = 37.68 x 0.25 x (320 -40)

37.68 x 0.25 x 280
2637.6 kCal/kg of oil
2637.6 x 414
1091966.4 kCal/hr
2 Marks
as % heat loss to input energy (1091966.4 x 100)/(4140000)
26.4%
2 Marks
L-6 A furnace is used to heat the stock. The stock is charged through a door, which is always
kept open. The door size is 700 mm x 700 mm. The furnace wall thickness is 400 mm.
The furnace operating temperature is 1260 C.
11
_______________________
Calculate the hourly direct radiation heat loss through openings? Convert the heat loss in
terms of oil equivalent loss if GCV of oil is 10000 kCal/kg.
Other data are as under: 2

= 30 kCal/cm /hr
Blackbody radiation corresponding to 1260 C
Emissivity = 0.82
Factor of radiation = 0.7
Ans: Area of opening = 70 cm x 70 cm

2
= 4900 cm
2 Marks
The factor of radiation = 0.7
Emissivity = 0.82
Total heat loss through opening
Black body radiation x Area of opening x factor of radiation x Emissivity
30 x 4900 x 0.7 x 0.82
84,378 kCal/hr
6 Marks
Equivalent oil loss = 84,378/10000
8.43 kg/hr
2 Marks
12
_______________________
Regn No: _________________

Name: ___________________
th
11 NATIONAL CERTIFICATION EXAMINATION February, 2011
FOR


instructions
1. Liquid fuel density is measured by an instrument called

a) tachometer b) hydrometer c) anemometer d) none of the above
2. When the liquid LPG evaporates the volume of gas occupied will be about
a) 25 times b) 250 times c) 100 times d) None of the above
3. The air to natural gas (stoichiometric) ratio, by volume, for complete combustion varies between
a) 14:1 to 15:1 b) 7:1 to 8:1 c) 9.5:1 to 10:1 d) None of the above
4. The draft caused solely by the difference in weight between the column of hot gas inside the
chimney and column of outside air is known as;
a) balanced draft b) induced draft c) forced draft d) natural draft
The type of boiler in which water passes through the tubes and hot gases pass outside the tubes is
known as;
1
_______________________
a) water tube b) fire tube c) packaged boiler d) none of the above

6. CO2 percentage (by volume) measurement in flue gases can be done by using;
a) ultrasonic probe b) potassium oxide probe
c) portable fyrite d) zirconium oxide probe
7. For optimum combustion of fuel oil, O2 percentage in flue gases should be maintained at;
a) 2-3% b) 14-15% c) 21-23% d) none of the above
8. The mode of heat transfer from hot body to cold body without a conveying medium is;
a) conduction b) radiation c) convection d) none of the above
9. A recuperator in a furnace is used to extract heat from flue gases for preheating;
a) the charge b) fuel oil c) air for combustion of fuel d) feed water
10. In a Mollier diagram, the point at which the saturated liquid and saturated vapour lines meet is
known as the;
a) vapour point b) liquid point c) critical point d) sub-critical point
11. The steam pressure drop in a steam pipe is inversely proportional to the _____ of pipe diameter
th th th d) none of above
a) 4 power b) 6 power c) 5 power
12. The best quality of steam for indirect process heating is;
a) dry saturated steam b) super heated steam c) wet steam d) super critical steam
13. The emissivity of conventional refractories used in a furnace;

a) increases with increase in temperature b) decreases with increase in temperature
c) remains constant d) decreases with increase in furnace pressure

14. The main constituent of natural gas, accounting for about 95% of the total volume, is;
a) methane b) iso-octane c) propane d) hexane
15. Steam generated in a boiler is 36 tonnes in 3 hours. Fuel consumption in the same period is 1
tonne per hour. Continuous blow down is 8% of feed water input. The boiler evaporation ratio is;
a) 12 b) 11.7 c) 36 d) 24
16. Heat loss through furnace openings is directly proportional to;

a) fourth power of furnace temperature b) fourth power of absolute furnace temperature
c) absolute furnace temperature d) square of absolute furnace temperature

17. A power generation system which uses first a gas turbine followed by a steam turbine is called;
a) topping cycle b) combined cycle c) Brayton cycle d) bottoming cycle
18. Magnesite, chrome magnesite and dolomite are ________ type of refractory;
a) acidic b) basic c) neutral d) none of the above
19. In a steam system, the purpose of venting air is because air is a;

a) good conductor b) inert substance c) dilutant d) insulator
2
_______________________
20. Latent heat at the critical point of a steam phase diagram is;
a) 640 kCal/kg b) zero c) 540 kCal/kg d) 584 kCal/kg
21. What is the most effective way to avoid ambient air infiltration into a fuel fired furnace;
a) slight negative pressure should be maintained b) operate at about 90% capacity
c) increase the chimney height d) slight positive furnace pressure should be

maintained
o
22. Which loss is the highest in a typical forging furnace operating at 1300 C?
a) flue gas loss b) wall loss c) cooling water loss d) unavoidable opening loss
23. Scale losses in a reheating furnace will;

c) have no relation with excess air d) decrease with excess air

24. Molecular weight of SO2 in kg/kg mole is;
a) 34 b) 32 c) 12 d) 44
25. A process plant needs 4 bar and 15 bar steam in addition to electric power. The most suitable co-
generation option for this process plant among the following, will be;
a) extraction cum back pressure turbine b) back pressure turbine
c) condensing turbine d) none of the above

26. Proximate analysis of a fuel is determination of
a) carbon, hydrogen, nitrogen, sulphur, moisture b) Fixed carbon, ash, volatile matter and moisture
c) higher calorific value d) lower calorific value

27. Suitable atomizing viscosity of furnace oil (100 Redwood seconds-1) for use in LAP/MAP burners
requires an oil preheating temperature of about;
o o o o
a) 80 C b) 105 C c) 125 C d) 135 C
28. With increase in the percentage of excess air for combustion of coal, percentage of CO 2 in flue gas.
29. The presence of Calcium and Magnesium Bicarbonates in boiler feed water would form:
a) acidic solution b) alkaline solution c) neutral solution d) none of the above
30. F & A (from and at) rating of the boiler is the amount of steam generated from;
a) water at 0 C to saturated steam at 100 C
b) water at feed water temperature to saturated steam at 100 C

c) water at 100 C to saturated steam at 100 C
d) water at ambient temperature to saturated steam at 100 C
2 o
31. Condensate, at pressure of 4 kg/cm and 160 C temperature, when exposed to atmosphere will;
a) fully convert into flash steam b) partially convert into flash steam
c) remain as condensate d) immediately cool down to ambient temperature

The lowest level of excess air is required in a;
3
_______________________

33. Velocity of steam in steam pipe is directly proportional to;

c) length of pipe d) diameter of the pipe

2 2
34. As the pressure of steam increases from 4 kg/cm to 8 kg/cm , the value of total enthalpy and latent
heat of steam respectively;
a) increases & remains the same b) increases & decreases
c) decreases & increases d) decreases & remains the same
35. The difference in temperature between steam and condensate refers to the principle of operation of
a;
a) thermodynamic trap b) thermostatic trap c) orifice type trap d) float trap
36. Pinch analysis uses the ______ law of Thermodynamics

a) first b) second c) third d) both first & second
37. Which of the following is not a property of ceramic fibre insulation?

38. The working media in a thermocompressor is

a) electricity b) compressed air c) high temperature oil d) steam
39. The turbine heat rate is expressed as

a) kWh/kCal b) kg/kCal c) kCal/kWh d) none of the above
40. Auxiliary power consumption for coal preparation will be highest in a;

a) stoker fired boiler b) AFBC boiler c) CFBC boiler d) pulverized coal fired boiler
41. In a heat exchanger, for the same heat duty, higher the heat transfer coefficient;
a) higher will be the heat transfer area needed b) higher will be the LMTD
c) lower will be the heat transfer area needed d) lower will be the LMTD
42. Correction factor for LMTD is commonly applicable for;
a) parallel flow type b) counter flow type c) cross flow type d) both (a) and (b)
43. Alumina is a .. type of refractory.

44. Which of the following does not contribute to steam savings

a) insulation of steam pipe lines b) superheated steam for indirect process heating
c) providing dry steam for process d) none of the above
a) butane b) propane c) hydrogen d) coal
4
_______________________
46. In a cogeneration system, with extraction condensing turbine, the highest heat rate is recorded
when;
a) maximum power output and maximum extraction to process
b) maximum power output and normal extraction to process

c) maximum power output and minimum extraction to process
47. A bottoming cycle is one in which fuel is used for producing
a) power primarily followed by byproduct heat output
b) heat primarily followed by byproduct power output

c) power, heat and refrigeration simultaneously
48. In a reheating furnace, soaking time of a cycle depends typically on;
a) excess air level b) preheat temperature of charge
c) thickness of the charged material d) furnace atmosphere

49. A supercritical boiler has parameters beyond critical point which refers to;
0
a) 221.2 bar (a) pressure and 374.18 C temperature
0
b) 246 bar (a) pressure and 538 C temperature
0
c) 306 bar (a) pressure and 598 C temperature
0
d) 170 bar (a) pressure and 538 C temperature
a) drop in the total dissolved solids in boiler water b) more steam generation
c) rise in the total dissolved solids in boiler water d) greater purity of feed water
5
_______________________
th
FOR
o
All questions are compulsory

S-1 Briefly explain the working of a thermic fluid heater and its advantages over steam heating
system
Ans
In thermic fluid heaters, a specific type of oil synthetic/mineral is used as heat carrier.
o
This fluid can be heated upto 300 C at atmospheric pressure. In comparison steam
would require a pressure of 85 bars to obtain this temperature.
The heaters are made with coils of seamless tubes. The thermal fluid is heated during
the flow through the tubes. The heat is transferred to the fluid as radiant heat in the
combustion chamber, where the inner cylindrical tube coil and a flat tube coil form the
chamber wall and the bottom respectively. The hot thermic fluid is circulated to various
process equipments such as dryers, heaters, deodouriser etc. where it gives up the heat.
0
The return oil at a temperature 10 to 20 C less comes back to the thermic fluid heater to
get heated up again. The circulation is carried out by a thermic fluid circulation pump.
The thermic fluid heater operates between two temperature ranges. Once the upper limit
is reached the burner is switched OFF or goes into the low fire mode. In the case of solid
fuel fired system the ID fan switches OFF on reaching the upper limit. When the
temperature reaches the lower limit due to heat transfer in the process, the burners
come ON again and in case of solid fuels, the ID fan comes ON again.
There are several advantages in using thermic fluids compared to steam systems. The
most obvious advantages are as follows
High temperature operation at atmospheric pressure

6
_______________________
Optional temperature level set points

No supply of treated water and hence no heat loss due to condensate flash steam
No risk of corrosion
Easy to operate
S-2 A boiler generates steam at the rate of 20 tonnes/hr consuming 4 ton/hr of coal having a
gross calorific value of 4200 kCal/kg. Calculate the evaporation ratio and efficiency of the
boiler if the enthalpy of the generated steam is 650 kCal/kg and feed water temperature
o
is 60 C.
Ans:
Evaporation ratio means kilogram steam generated for kilogram of fuel consumed.
Evaporation ratio = (20/4) = 5

Efficiency of the boiler = 20*1000*(650-60)*100
4*1000*4200
= 70.23%
S-3 List down five energy conservation measures in steam system
Ans:
Fix steam leaks and condensate leaks.

Use back pressure steam turbines to produce lower steam pressures.
Use dry steam for indirect process heating.
Maintain lowest acceptable process steam pressures.
Remove or blank off all redundant steam piping.
Preheat boiler feed-water.
Inspect steam traps regularly and repair malfunctioning traps promptly.
Consider recovery of flash steam
Use waste steam for water heating.
Reduce work done by steam
ANY OTHER RELEVANT POINT
S-4 The efficiency of a boiler on GCV basis is 85%. The fuel contains 1% moisture and 12%
hydrogen. The GCV of fuel is 10,500 kCal/kg. What is the boiler efficiency on the basis
of net calorific value?
7
_______________________
Ans:
NCV = GCV [9*(%age of Hydrogen in fuel/100) + (%age of Moisture in fuel/100)*584]

NCV = 10500 [9* (12/100) + (1.0/100)*584]
= 9863 kCal/kg.
Boiler efficiency on NCV=85*10500/9863 =90.48%
S-5 For combustion of 500 lit/hr of furnace oil, estimate combustion air quantity per hour with
20% excess air. Specific gravity of furnace oil 0.95. (Fuel analysis: C - 84%, H -12%, S -
3% O - 1%)
Ans:
C + O2 ---- CO2 ( 0.84 * 32/12) 2.24 kg of O2/kg of C

12 + 32 --- 44
H + O2 ---- H2O ( 0.12 x 16/2) 0.96 kg of O2/ kg of H
2 + 16 ---18
S + O2 ---- SO2 ( 0.03 *32/32) - 0.03 kg of O2 / kg of S
32 + 32 --64
Total O2 required = ( 2.24 + 0.96 + 0.03 0.01) = 3.22 kg of O2/kg fuel

= ( 3.22 / 0.23 = 14 kg of air)
Excess air = 20%
Air supplied = ( 1 + 0.2) x 14 = 16.8 kg of air / kg of oil

Quantity of F.oil = 500 lit/hr ( 500 x 0.95) = 475 kg/hr
Total quantity of air required = 475 x 16.8 = 7980 kgs of air /hr
S-6 What is meant by critical point of steam and give two advantages of Super Critical boilers?
Ans:
The critical point is the highest temperature at which liquid can exist. Any compression at
constant temperature above the critical point will not produce a phase change.
Compression at constant temperature below the critical point however, will result in
liquefaction of the vapour as it passes from the superheated region into the wet steam
region. The critical point occurs at 374.15C and 221.2 bar (a) for steam and at this point
the latent heat of steam is zero.
Advantages of super critical boiler
Higher Heat Transfer Rate

More Flexible in accepting load variations
Greater ease of operation
8
_______________________
High thermal efficiency of 40-42%

The absence of two phase mixture minimize the problem of erosion and corrosion
Steadier Pressure level
S-7 What is meant by trigeneration? Explain how trigeneration can be applied in a hotel
using DG set continuously for power generation.
Ans:
Trigeneration refers to simultaneous generation of steam (heat), power and refrigeration
through integrated systems. Industries requiring electricity, steam and cooling such as
food processing and cold storages find the concepts of tri-generation very attractive.
In a Hotel, power can be generated from DG sets and with the waste heat, steam can be
generated. This steam can be used for both Vapour absorption system for generating
chiller water for AC applications and also for generating hot water .
S-8 Calculate the induction melting furnace efficiency from the following melt cycle data
Mild steel (MS) scrap charged : 1500 kg

0
Specific heat of MS : 0.682 kJ/kg C
Latent heat of MS : 272 kJ/kg
0
MS melting temperature : 1650 C
0
Inlet MS charge temperature : 40 C
Electricity consumed during cycle : 1020 kWh
Ans:
Theoretical energy required for melting = 1500 (0.682 x (1650 40) + 272)/3600 kWh
= 570.8 kWh
Actual input = 1020 kWh

Furnace efficiency = 570.8 x 100 / 1020
= 56%
------- End of Section - II ---------

9
_______________________
L-1 A steam pipeline of 100 mm outer diameter is not insulated for 100 meters and supplying
2
steam at 10 kg/cm . Find out the annual fuel savings if the line is properly insulated with
65 mm insulating material. Assume 7000 hours/year of operation.
Given:
Boiler efficiency - 85%
Fuel Oil cost - Rs.32,000/tonne
Calorific Value of fuel oil - 10,300 kCal/kg
Surface temperature without insulation o
- 180 C
o
Surface temperature after insulation - 75 C
o
Ambient temperature - 30 C
Ans:
Existing heat loss = {10 + (Ts Ta)/20} x (Ts Ta)
= 2625 kCal/hr per Square meter
Heat loss after insulation = ( 10 + (75 30)/20 } x (75 30)
= 551.25 kCal/hr Sq. m

Surface Area Existing = 3.14 D L
= 3.14 x 0.1 x 100 = 31.4 Square meter

Surface Area after insulation = 3.14 x 0.23 x 100 = 72.2 Square meter
Heat loss existing = 2625 x 31.4 = 82, 425 kCal/hr
Heat loss after insulation = 551.25 x 72.2 = 39, 811 kCal/hr
(82,425 - 39,811) x 7,000 x 32,000

Annual savings
10,300 x 1000 x 0.85
= Rs. 10.9 Lakhs
L-2 Briefly explain the working principle of any two of the following
Condenser in a steam power plant

Distillation tower in a refinery
Multi-effect Evaporator
Ans:
Condenser: In steam applications, condenser is associated with condensing steam turbines and
with ejector systems. In steam turbine applications, condenser remove significant
amount of latent heat from the exhaust steam allowing it to be recovered as condensate.
In steam ejector applications, condenser increases the effectiveness of the ejector by
condensing both the motive steam and condensable pulled from the process.
10
_______________________
Condensers are supplied with cooling water that circulates through condenser tubes
providing a cool surface area that causes steam condensation.
Distillation tower : The petroleum refining and chemical manufacturing industries use large
amount of steam to facilitate the separation of crude oil or chemical feed stocks into
various components. This separation process relies on difference in the boiling points of
these various components. Steam is injected into bottom of these towers to reduce the
partial pressure of the hydrocarbons, which facilitates their separation and to reduce
coke formation on tray tower surfaces.
Multi-effect Evaporator : In multi-effect Evaporator, the latent heat of the vapour product of an
effect is used to heat the following effect. Effects are thus numbered beginning with the
one heated by steam. It will have the highest pressure. Vapour from effect I will be used
top heat effect II, which consequently will operate at low pressure. This continues
throughout the train, pressure drops through the sequence so that the hot vapour will
travel from one effect to the next.
L-3 a) Briefly explain the significance of LMTD in a heat exchanger
In a double pipe heat exchanger hot fluid is entering at 330 C and leaving at 170 C. Cold
fluid enters at 30 C and leaves at 120 C. Calculate LMTD, if the flow is counter current.
Ans:
The driving force for any heat transfer process is the temperature difference between two fluids.
In the heat transfer process, the temperature of the two fluids keep changing as they
pass through the heat exchange, for which some types of average temperature is
needed. The average temperature difference through the heat exchange is described by
the log mean temperature difference (LMTD). The larger the temperature difference, the
smaller the required heat exchange area and vice versa.
LMTD Counter current flow
t1 = 330 120 = 210 C

t2 = 170 30 = 140 C
LMTD = t1 t2
ln t1
t2
= 210140 = 172.64 C
ln 210
140
L-4 In a chlor alkali plant, 120 TPD caustic solution at 33% concentration is dried to 50%
concentration. The existing single effect evaporator, where steam input to moisture
removal ratio is 1.0 kg/kg is proposed to be replaced by a triple effect evaporator where
the ratio of steam input to moisture removal is 0.4 kg/kg. Calculate annual fuel cost
11
_______________________
savings for 300 days operation at an evaporation ratio of 12 in the oil fired boiler and
cost of FO Rs. 30,000/Tonne.
Ans.:
Dry caustic = 120 TPD x 0.33
= 40 TPD
Inlet moisture / day = (120 40) = 80 TPD
Outlet moisture / day = 40 / 0.5 - 40
= 80 TPD 40.0
Moisture removed/ day = 40 TPD
Initial steam consumption at 1 kg/kg = 40 TPD
Steam consumption with triple effect evaporator at 0.4 kg/kg

= 40 x 0.4
= 16 TPD
Steam savings per day = 40 - 16
= 24 TPD
FO savings / day at evaporation ratio of 12
= 2 TPD
Rupee savings per day at Rs. 30,000/MT = Rs. 60,000
Annual monetary savings at 300 days working = Rs. 180 Lakhs
L-5 Write short notes on any two of the following
Wet preservation method for boilers

Reverse osmosis
Reciprocating engine co-generation system
Ans:
Wet preservation method for boilers: In the wet method the boiler is filled to the normal level
with water at a pH of 10.5 to 11. Hydrazine to the extent of 200 ppm is to be dosed with
the water. The unit is to be steamed in service to ensure uniform
concentration of boiler water throughout the unit and to eliminate dissolved oxygen from
water. Sodium sulphite (Na2SO3), which acts as a de-oxygenerator, can also be used as
an alternative to hydrazine and the sulphite concentration has to be maintained at 300-
400 ppm.
Analysis of boiler water should be carried out frequently. If the hydrazine concentration in
water happens to drop below 50 ppm, the water in the drum should be lowered to the
normal operating level and an appropriate quantity of chemicals should be dosed to
bring back 200 the concentration of hydrazine or sodium sulphite. The boiler should be
steamed to circulate chemicals to uniform concentration.
Reverse osmosis: When solutions of differing concentrations are separated by a semi-permeable

membrane, water from less concentrated solution passes through the membrane to dilute the
liquid of high concentration, which is called osmosis. If the solution of high concentration is
pressurized, the process is reversed and the water from
12
_______________________
the solution of high concentration flows to the weaker solution. This is known as reverse
osmosis.
Reciprocating engine co-generation system: Also known as internal combustion (I. C.)
engines, these cogeneration systems have high power generation efficiencies in
comparison with other prime movers. There are two sources of heat for recovery:
exhaust gas at high temperature and engine jacket cooling water system at low
temperature. As heat recovery can be quite efficient for smaller systems, these systems
are more popular with smaller energy consuming facilities, particularly those having a
greater need for electricity than thermal energy and where the quality of heat required is
not high, e.g. low pressure steam or hot water.
L-6 a) Write short notes on hot blast cupola
In an industry an electrical oven consuming 1000 kWh/batch is proposed for replacement by

a fuel fired oven. Calculate the simple payback period for the following data:
Number of batches / year = 4000

Efficiency of electric oven = 80%
Efficiency of FO fired oven = 55%
Cost of FO = Rs. 30,000/Tonne
GCV of FO = 10200 kCal/kg
Electricity cost = Rs. 5.0 /kWh
Investment for FO fired oven = Rs. 125 Lakhs
Ans:
HotBlastCupola
Thetemperatureofexhaustgasofacupolaisashighas800C,makingitpossibletopreheat
blastairuptoashighas400Cbyheatexchange.Inaddition,boththesensibleandlatentheatof
exhaustgascanberecycledforpreheatingblastairbycombustionofCOgasincludedinexhaust
gas.Whenblastairispreheatedto300Corhigher,thesensibleheatofblastairisaddedtoheat
input,activatingcombustionofcoke,leadingtotheriseincombustiontemperature
b) The useful heat per batch required = 1000 x 860 x 0.8

= 688000 kCal/batch
FO input per batch = 688000 / (0.55 x 10200)
= 122.6 kg
Electricity cost per batch = Rs. 5 x 1000
= Rs. 5000
FO cost per batch = 122.6 x Rs. 30
= Rs. 3678
13
_______________________
Cost savings per batch = Rs. 1322

Annual cost savings at 4000 batches = Rs. 52,88,000
Initial investment = Rs. 125 lakhs
Simple payback period = 2.23 years
14
_______________________
Regn No: _________________

Name: ___________________
th
FOR


instructions
1. With increase in the percentage of excess air for combustion of coal, percentage of CO 2 in flue gas.

a) butane b) propane c) hydrogen d) coal
4. Which of the following does not contribute to steam savings

a) insulation of steam pipe lines b) superheated steam for indirect process heating
c) providing dry steam for process d) none of the above
o
Which loss is the highest in a typical forging furnace operating at 1300 C?
a) flue gas loss b) wall loss c) cooling water loss d) unavoidable opening loss
1
_______________________
6. When the liquid LPG evaporates the volume of gas occupied will be about
a) 25 times b) 250 times c) 100 times d) None of the above
7. What is the most effective way to avoid ambient air infiltration into a fuel fired furnace;
a) slight negative pressure should be maintained b) operate at about 90% capacity
c) increase the chimney height d) slight positive pressure should be maintained

8. Velocity of steam in steam pipe is directly proportional to;
9. The working media in a thermocompressor is

a) electricity b) compressed air c) high temperature oil d) steam
10. The type of boiler in which water passes through the tubes and hot gases pass outside the tubes is
known as;
a) water tube b) fire tube c) packaged boiler d) none of the above
11. The turbine heat rate is expressed as

a) kWh/kCal b) kg/kCal c) kCal/kWh d) none of the above
12. The steam pressure drop in a steam pipe is inversely proportional to the _____ of pipe diameter
th th th d) none of above
a) 4 power b) 6 power c) 5 power
13. The presence of Calcium and Magnesium Bicarbonates in boiler feed water would form:
14. The mode of heat transfer from hot body to cold body without a conveying medium is;
15. The main constituent of natural gas, accounting for about 95% of the total volume, is;
a) methane b) iso-octane c) propane d) hexane
16. The lowest level of excess air is required in a;

17. The emissivity of conventional refractories used in a furnace;

a) increases with increase in temperature b) decreases with increase in temperature
c) remains constant d) decreases with increase in furnace pressure

18. The draft caused solely by the difference in weight between the column of hot gas inside the
chimney and column of outside air is known as;
a) balanced draft b) induced draft c) forced draft d) natural draft
19. The difference in temperature between steam and condensate refers to the principle of operation of
a;
2
_______________________
a) thermodynamic trap b) thermostatic trap c) orifice type trap d) float trap
20. The best quality of steam for indirect process heating is;
a) dry saturated steam b) super heated steam c) wet steam d) super critical steam
21. The air to natural gas (stoichiometric) ratio, by volume, for complete combustion varies between
a) 14:1 to 15:1 b) 7:1 to 8:1 c) 9.5:1 to 10:1 d) None of the above
22. Suitable atomizing viscosity of furnace oil (100 Redwood seconds-1) for use in LAP/MAP burners
requires an oil preheating temperature of about;
o o o o
a) 80 C b) 105 C c) 125 C d) 135 C
23. Steam generated in a boiler is 36 tonnes in 3 hours. Fuel consumption in the same period is 1
tonne per hour. Continuous blow down is 8% of feed water input. The boiler evaporation ratio is;
a) 12 b) 11.7 c) 36 d) 24
24. Scale losses in a reheating furnace will;

c) have no relation with excess air d) decrease with excess air

25. Proximate analysis of a fuel is determination of
a) carbon, hydrogen, nitrogen, sulphur, moisture b) Fixed carbon, ash, volatile matter and moisture
c) higher calorific value d) lower calorific value

26. Pinch analysis uses the ______ law of Thermodynamics
a) first b) second c) third d) both first & second
27. Molecular weight of SO2 in kg/kg mole is;

a) 34 b) 32 c) 12 d) 44
28. Magnesite, chrome magnesite and dolomite are ________ type of refractory;
29. Liquid fuel density is measured by an instrument called

a) tachometer b) hydrometer c) anemometer d) none of the above
30. Latent heat at the critical point of a steam phase diagram is;
a) 640 kCal/kg b) zero c) 540 kCal/kg d) 584 kCal/kg
31. In a steam system, the purpose of venting air is because air is a;

a) good conductor b) inert substance c) dilutant d) insulator
32. In a reheating furnace, soaking time of a cycle depends typically on;

a) excess air level b) preheat temperature of charge
c) thickness of the charged material d) furnace atmosphere

33. In a Mollier diagram, the point at which the saturated liquid and saturated vapour lines meet is
3
_______________________
known as the;
a) vapour point b) liquid point c) critical point d) sub-critical point
34. In a heat exchanger, for the same heat duty, higher the heat transfer coefficient;
a) higher will be the heat transfer area needed b) higher will be the LMTD
c) lower will be the heat transfer area needed d) lower will be the LMTD
35. In a cogeneration system, with extraction condensing turbine, the highest heat rate is recorded
when;
a) maximum power output and maximum extraction to process
b) maximum power output and normal extraction to process

c) maximum power output and minimum extraction to process
36. Heat loss through furnace openings is directly proportional to;
a) fourth power of furnace temperature b) fourth power of absolute furnace temperature
c) absolute furnace temperature d) square of absolute furnace temperature

37. For optimum combustion of fuel oil, O2 percentage in flue gases should be maintained at;
a) 2-3% b) 14-15% c) 21-23% d) none of the above
38. F & A (from and at) rating of the boiler is the amount of steam generated from;
a) water at 0 C to saturated steam at 100 C
b) water at feed water temperature to saturated steam at 100 C

c) water at 100 C to saturated steam at 100 C
d) water at ambient temperature to saturated steam at 100 C
39. Correction factor for LMTD is commonly applicable for;
a) parallel flow type b) counter flow type c) cross flow type d) both (a) and (b)
2 o
40. Condensate, at pressure of 4 kg/cm and 160 C temperature, when exposed to atmosphere will;
a) fully convert into flash steam b) partially convert into flash steam
c) remain as condensate d) immediately cool down to ambient temperature

41. CO2 percentage (by volume) measurement in flue gases can be done by using;
a) ultrasonic probe b) potassium oxide probe
c) portable fyrite d) zirconium oxide probe
42. Auxiliary power consumption for coal preparation will be highest in a;

a) stoker fired boiler b) AFBC boiler c) CFBC boiler d) pulverized coal fired boiler
2 2
43. As the pressure of steam increases from 4 kg/cm to 8 kg/cm , the value of total enthalpy and latent
heat of steam respectively;

44. Alumina is a .. type of refractory.
4
_______________________
45. A supercritical boiler has parameters beyond critical point which refers to;
0
a) 221.2 bar (a) pressure and 374.18 C temperature
0
b) 246 bar (a) pressure and 538 C temperature
0
c) 306 bar (a) pressure and 598 C temperature
0
d) 170 bar (a) pressure and 538 C temperature
a) drop in the total dissolved solids in boiler water b) more steam generation
c) rise in the total dissolved solids in boiler water d) greater purity of feed water
47. A recuperator in a furnace is used to extract heat from flue gases for preheating;
a) the charge b) fuel oil c) air for combustion of fuel d) feed water
48. A process plant needs 4 bar and 15 bar steam in addition to electric power. The most suitable co-
generation option for this process plant among the following, will be;
a) extraction cum back pressure turbine b) back pressure turbine
c) condensing turbine d) none of the above

49. A power generation system which uses first a gas turbine followed by a steam turbine is called;
a) topping cycle b) combined cycle c) Brayton cycle d) bottoming cycle
A bottoming cycle is one in which fuel is used for producing
power primarily followed by byproduct heat output

heat primarily followed by byproduct power output
power, heat and refrigeration simultaneously
none of the above
End of Section I .
5
_______________________
th
FOR
All questions are compulsory


S-1 Calculate the induction melting furnace efficiency from the following melt cycle data

0
Specific heat of MS : 0.682 kJ/kg C
0
MS melting temperature : 1650 C
0
Inlet MS charge temperature : 40 C
Electricity consumed during cycle : 980 kWh
Ans:
Theoretical energy required for melting = 1500 (0.682 x (1650 40) + 272)/3600 kWh
= 570.8 kWh
Actual input = 980 kWh

Furnace efficiency = 570.8 x 100 / 980
= 58.3%
S-2 What is meant by trigeneration? Explain how trigeneration can be applied in a hotel
using DG set continuously for power generation.
Ans:
Trigeneration refers to simultaneous generation of steam (heat), power and refrigeration
through integrated systems. Industries requiring electricity, steam and cooling such as
food processing and cold storages find the concepts of tri-generation very attractive.
6
_______________________
In a Hotel, power can be generated from DG sets and with the waste heat, steam can be
generated. This steam can be used for both Vapour absorption system for generating
chiller water for AC applications and also for generating hot water .
S-3 What is meant by critical point of steam and give two advantages of Super Critical boilers?
Ans:
The critical point is the highest temperature at which liquid can exist. Any compression at
constant temperature above the critical point will not produce a phase change.
Compression at constant temperature below the critical point however, will result in
liquefaction of the vapour as it passes from the superheated region into the wet steam
region. The critical point occurs at 374.15C and 221.2 bar (a) for steam and at this point
the latent heat of steam is zero.
Advantages of super critical boiler
Higher Heat Transfer Rate

More Flexible in accepting load variations
Greater ease of operation
High thermal efficiency of 40-42%
The absence of two phase mixture minimize the problem of erosion and corrosion
Steadier Pressure level
S-4 For combustion of 500 lit/hr of furnace oil, estimate combustion air quantity per hour with
20% excess air. Specific gravity of furnace oil 0.9. (Fuel analysis: C - 84%, H -12%, S -
3% O - 1%)
Ans:
C + O2 ---- CO2 ( 0.84 * 32/12) 2.24 kg of O2/kg of C

12 + 32 --- 44
H + O2 ---- H2O ( 0.12 x 16/2) 0.96 kg of O2/ kg of H
2 + 16 ---18
S + O2 ---- SO2 ( 0.03 *32/32) - 0.03 kg of O2 / kg of S
32 + 32 --64
Total O2 required = ( 2.24 + 0.96 + 0.03 0.01) = 3.22 kg of O2/kg fuel

= ( 3.22 / 0.23 = 14 kg of air)
Excess air = 20%
Air supplied = ( 1 + 0.2) x 14 = 16.8 kg of air / kg of oil

Quantity of F.oil = 500 lit/hr ( 500 x 0.9) = 450 kg/hr
Total quantity of air required = 475 x 16.8 = 7560 kgs of air /hr
7
_______________________
S-5 The efficiency of a boiler on GCV basis is 85%. The fuel contains 1% moisture and 12%
hydrogen. The GCV of fuel is 10,000 kCal/kg. What is the boiler efficiency on the basis
of net calorific value?
Ans:
NCV = GCV [9*(%age of Hydrogen in fuel/100) + (%age of Moisture in fuel/100)*584]

NCV = 10000 [9* (12/100) + (1.0/100)*584]
= 9363 kCal/kg.
Boiler efficiency on NCV = 85*10000/9363 =90.8%
S-6 List down five energy conservation measures in steam system
Ans:
Fix steam leaks and condensate leaks.

Use back pressure steam turbines to produce lower steam pressures.
Use dry steam for indirect process heating.
Maintain lowest acceptable process steam pressures.
Remove or blank off all redundant steam piping.
Preheat boiler feed-water.
Inspect steam traps regularly and repair malfunctioning traps promptly.
Consider recovery of flash steam
Use waste steam for water heating.
Reduce work done by steam
ANY OTHER RELEVANT POINT
S-7 A boiler generates steam at the rate of 20 tonnes/hr consuming 4 ton/hr of coal having a
gross calorific value of 4500 kCal/kg. Calculate the evaporation ratio and efficiency of the
boiler if the enthalpy of the generated steam is 650 kCal/kg and feed water temperature
o
is 60 C.
Ans:
Evaporation ratio means kilogram steam generated for kilogram of fuel consumed.
Evaporation ratio = (20/4) = 5

Efficiency of the boiler = 20*1000*(650-60)*100
8
_______________________
4*1000*4500
= 65.5%
S-8 Briefly explain the working of a thermic fluid heater and its advantages over steam heating
system
Ans
In thermic fluid heaters, a specific type of oil synthetic/mineral is used as heat carrier.
o
This fluid can be heated upto 300 C at atmospheric pressure. In comparison steam
would require a pressure of 85 bars to obtain this temperature.
The heaters are made with coils of seamless tubes. The thermal fluid is heated during
the flow through the tubes. The heat is transferred to the fluid as radiant heat in the
combustion chamber, where the inner cylindrical tube coil and a flat tube coil form the
chamber wall and the bottom respectively. The hot thermic fluid is circulated to various
process equipments such as dryers, heaters, deodouriser etc. where it gives up the heat.
0
The return oil at a temperature 10 to 20 C less comes back to the thermic fluid heater to
get heated up again. The circulation is carried out by a thermic fluid circulation pump.
The thermic fluid heater operates between two temperature ranges. Once the upper limit
is reached the burner is switched OFF or goes into the low fire mode. In the case of solid
fuel fired system the ID fan switches OFF on reaching the upper limit. When the
temperature reaches the lower limit due to heat transfer in the process, the burners
come ON again and in case of solid fuels, the ID fan comes ON again.
There are several advantages in using thermic fluids compared to steam systems. The
most obvious advantages are as follows
High temperature operation at atmospheric pressure

Optional temperature level set points
No supply of treated water and hence no heat loss due to condensate flash steam
No risk of corrosion
Easy to operate
------- End of Section - II ---------

9
_______________________
a) Wet preservation method for boilers

Reverse osmosis
Reciprocating engine co-generation system
Ans:
Wet preservation method for boilers: In the wet method the boiler is filled to the normal level
with water at a pH of 10.5 to 11. Hydrazine to the extent of 200 ppm is to be dosed with
the water. The unit is to be steamed in service to ensure uniform
concentration of boiler water throughout the unit and to eliminate dissolved oxygen from
water. Sodium sulphite (Na2SO3), which acts as a de-oxygenerator, can also be used as
an alternative to hydrazine and the sulphite concentration has to be maintained at 300-
400 ppm.
Analysis of boiler water should be carried out frequently. If the hydrazine concentration in
water happens to drop below 50 ppm, the water in the drum should be lowered to the
normal operating level and an appropriate quantity of chemicals should be dosed to
bring back 200 the concentration of hydrazine or sodium sulphite. The boiler should be
steamed to circulate chemicals to uniform concentration.
Reverse osmosis: When solutions of differing concentrations are separated by a semi-

permeable membrane, water from less concentrated solution passes through the
membrane to dilute the liquid of high concentration, which is called osmosis. If the
solution of high concentration is pressurized, the process is reversed and the water from
the solution of high concentration flows to the weaker solution. This is known as reverse
osmosis.
Reciprocating engine co-generation system: Also known as internal combustion (I. C.)
engines, these cogeneration systems have high power generation efficiencies in
comparison with other prime movers. There are two sources of heat for recovery:
exhaust gas at high temperature and engine jacket cooling water system at low
temperature. As heat recovery can be quite efficient for smaller systems, these systems
are more popular with smaller energy consuming facilities, particularly those having a
greater need for electricity than thermal energy and where the quality of heat required is
not high, e.g. low pressure steam or hot water.
L-2 a) Write short notes on hot blast cupola
In an industry an electrical oven consuming 1000 kWh/batch is proposed for replacement by

a fuel fired oven. Calculate the simple payback period for the following data:
Number of batches / year = 4000

Efficiency of electric oven = 80%
Efficiency of FO fired oven = 55%
Cost of FO = Rs. 30,000/Tonne
GCV of FO = 10200 kCal/kg
10
_______________________
Electricity cost = Rs. 5.0 /kWh

Investment for FO fired oven = Rs. 100 Lakhs
Ans:
Hot Blast Cupola
The temperature of exhaust gas of a cupola is as high as 800 C, making it possible to

preheat blast air up to as high as 400 C by heat exchange. In addition, both the sensible
and latent heat of exhaust gas can be recycled for preheating blast air by combustion of
CO gas included in exhaust gas. When blast air is preheated to 300 C or higher, the
sensible heat of blast air is added to heat input, activating combustion of coke, leading to
the rise in combustion temperature
b) The useful heat per batch required = 1000 x 860 x 0.8

= 688000 kCal/batch
FO input per batch = 688000 / (0.55 x 10200)
= 122.6 kg
Electricity cost per batch = Rs. 5 x 1000
= Rs. 5000
FO cost per batch = 122.6 x Rs. 30
= Rs. 3678
Cost savings per batch = Rs. 1322
Annual cost savings at 4000 batches = Rs. 52,88,000
Initial investment = Rs. 100 lakhs
Simple payback period = 1.89 years
L-3 In a chlor alkali plant, 120 TPD caustic solution at 33% concentration is dried to 50%
concentration. The existing single effect evaporator, where steam input to moisture
removal ratio is 1.0 kg/kg is proposed to be replaced by a triple effect evaporator where
the ratio of steam input to moisture removal is 0.4 kg/kg. Calculate annual fuel cost
savings for 300 days operation at an evaporation ratio of 12 in the oil fired boiler and
cost of FO Rs. 32,000/Tonne.
Ans.:
Dry caustic = 120 TPD x 0.33
= 40 TPD
Inlet moisture / day = (120 40) = 80 TPD
Outlet moisture / day = 40 / 0.5 - 40
= 80 TPD 40.0
Moisture removed/ day = 40 TPD
Initial steam consumption at 1 kg/kg = 40 TPD
Steam consumption with triple effect evaporator at 0.4 kg/kg

= 40 x 0.4
11
_______________________
= 16 TPD
Steam savings per day = 40 - 16
= 24 TPD
FO savings / day at evaporation ratio of 12
= 2 TPD
Rupee savings per day at Rs. 32,000/MT = Rs. 64,000
Annual monetary savings at 300 days working = Rs. 192 Lakhs
L-4 a) Briefly explain the significance of LMTD in a heat exchanger
In a double pipe heat exchanger hot fluid is entering at 330 C and leaving at 170 C. Cold
fluid enters at 30 C and leaves at 120 C. Calculate LMTD, if the flow is counter current.
Ans:
The driving force for any heat transfer process is the temperature difference between two fluids.
In the heat transfer process, the temperature of the two fluids keep changing as they
pass through the heat exchange, for which some types of average temperature is
needed. The average temperature difference through the heat exchange is described by
the log mean temperature difference (LMTD). The larger the temperature difference, the
smaller the required heat exchange area and vice versa.
LMTD Counter current flow
t1 = 330 120 = 210 C

t2 = 170 30 = 140 C
LMTD = t1 t2
ln t1
t2
= 210140 = 172.64 C
ln 210
140
L-5 Briefly explain the working principle of any two of the following
Condenser in a steam power plant

Distillation tower in a refinery
Multi-effect Evaporator
Ans:
Condenser: In steam applications, condenser is associated with condensing steam turbines and
with ejector systems. In steam turbine applications, condenser remove
12
_______________________
significant amount of latent heat from the exhaust steam allowing it to be recovered as
condensate. In steam ejector applications, condenser increases the effectiveness of the
ejector by condensing both the motive steam and condensable pulled from the process.
Condensers are supplied with cooling water that circulates through condenser tubes
providing a cool surface area that causes steam condensation.
Distillation tower : The petroleum refining and chemical manufacturing industries use large
amount of steam to facilitate the separation of crude oil or chemical feed stocks into
various components. This separation process relies on difference in the boiling points of
these various components. Steam is injected into bottom of these towers to reduce the
partial pressure of the hydrocarbons, which facilitates their separation and to reduce
coke formation on tray tower surfaces.
Multi-effect Evaporator : In multi-effect Evaporator, the latent heat of the vapour product of an
effect is used to heat the following effect. Effects are thus numbered beginning with the
one heated by steam. It will have the highest pressure. Vapour from effect I will be used
top heat effect II, which consequently will operate at low pressure. This continues
throughout the train, pressure drops through the sequence so that the hot vapour will
travel from one effect to the next.
Marks: 5 x 2 ( for any two of the above)
L-6 A steam pipeline of 100 mm outer diameter is not insulated for 100 meters and supplying
2
steam at 10 kg/cm . Find out the annual fuel savings if the line is properly insulated with
65 mm insulating material. Assume 8000 hours/year of operation.
Given:
Boiler efficiency - 85%
Fuel Oil cost - Rs.32,000/tonne
Calorific Value of fuel oil - 10,300 kCal/kg
o
Surface temperature without insulation - 180 C
o
Surface temperature after insulation - 75 C
o
Ambient temperature - 30 C
Ans:
Existing heat loss = {10 + (Ts Ta)/20} x (Ts Ta)
= 2625 kCal/hr per Square meter
Heat loss after insulation = ( 10 + (75 30)/20 } x (75 30)
= 551.25 kCal/hr Sq. m

Surface Area Existing = 3.14 D L
= 3.14 x 0.1 x 100 = 31.4 Square meter

Surface Area after insulation = 3.14 x 0.23 x 100 = 72.2 Square meter
Heat loss existing = 2625 x 31.4 = 82, 425 kCal/hr
Heat loss after insulation = 551.25 x 72.2 = 39, 811 kCal/hr
13
_______________________
Annual savings (82,425 - 39,811) x 8,000 x 32,000

10,300 x 1000 x 0.85
= Rs. 12.46 Lakhs
14
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Paper 2 Set A Key
Regn No: _________________

Name: ___________________
th
FOR
ENERGY MANAGERS & ENERGY AUDITORS October, 2011
Date: 15.10.2011 Timings: 14:00 - 17:00 HRS Duration: 3 HRS Max. Marks: 150

instructions
1. The density of a substance relative to water is called

a) viscosity b) specific gravity c) dew point d) pour point
2. Which of the following is not a unit of viscosity

a) Engler b) Rankine c) Saybolt d) Redwood
o
3. The amount of heat required to raise the temperature of 1 kg of a substance by 1 C is
called
a) sensible heat b) latent heat c) specific heat d) net calorific value
4. Which among the following fuels is likely to contain maximum percentage of sulphur?
a) kerosene b) diesel oil c) LSHS d) furnace oil
5. Which of the following grades of Indian coal will have the highest calorific value?
a) B b) F c) A d) E
6. Which of the following is not measured in proximate analysis?

a) volatile matter b) fixed carbon c) sulphur d) ash
7. Which of the following is not measured in the ultimate analysis of a fuel ?
1
_______________________
Paper 2 Set A Key
a) oxygen b) fixed carbon c) sulphur d) nitrogen
8. Carpet loss is associated with

a) combustion of coal b) storage of coal c) combustion of oil d) storage of natural gas
9. Which of the following is not true with respect to improper sizing of coal
a) results in poor combustion b) lower excess air resulting in lesser stack loss
c) increase of unburnts in ash d) lower thermal efficiency

10. Which of the following fuel constituents releases maximum amount of heat per kg during
combustion ?
a) hydrogen b) carbon c) sulphur d) nitrogen
11. Which is the statement that is true of a fire tube boiler

a) has a single steam drum b) fire is in the tubes
c) water in the tubes d) has multiple steam drums

12. Coal is not burnt in suspension in
a) fluidised bed boiler b) chain-grate boler
c) spreader stoker boiler d) pulverised fuel fired boiler

13. Which of the following is considered in the calculation of Evaporation ratio?
a) calorific value of fuel b) latent heat of steam c) fuel quantity d) all of the above
14. When solutions of differing concentrations are separated by a semi-permeable membrane,

water from less concentrated solution passes through the membrane to dilute the liquid of
high concentration. This is called
a) reverse osmosis b) ion exchange c) softening d) osmosis
15. Flash steam can be recovered from

Which of these is not true of critical point of steam/water mixture ?
o
the temperature at critical point is 374.15 C
the pressure at critical point is 221.2 bar
saturated liquid and saturated vapour lines meet at critical point
enthalpy of evaporation is maximum at critical point
2
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Paper 2 Set A Key
17. The head loss due to friction in a pipe is

a) directly proportional to the diameter b) directly proportional to the gravitational constant
c) inversely proportional to the velocity d) directly proportional to the square of velocity

18. Select the wrong statement with respect to steam traps
a) discharges condensate as soon as it is formed
b) does not allow steam to escape

c) capable of discharging air and other incondensable gases
d) does not allow condensate to escape
19. Heat transfer in a furnace is effected by
a) radiation from flame b) radiation from furnace walls
c) convection due to movement of hot gases over the stock d) all of the above
20. In a coke fired cupola, carbon monoxide is produced in the
a) preheating zone b) reducing zone
c) combustion zone d) melting zone

21. In an oil fired heat treatment furnace which of the following is not required to determine its
efficiency by direct method
a) weight of input material b) oxygen percentage in flue gas
c) fuel consumption d) calorific value of fuel

22. Which of the following may not help in energy efficient furnace operation?
a) maintaining a positive draft inside the furnace
b) minimizing refractory losses

c) complete combustion with maximum excess air
d) use of ceramic fibre in batch type furnace
23. Select the wrong statement with respect to furnace operations
a) the burner flame should not touch the stock
b) air infiltration leads to oxidation of billets

c) ceramic fibre linings are used in the exterior of the furnace
4
d) heat loss through openings is proportional to T
24. The effectiveness of a heat exchanger does not depend on
a) specific heat of hot fluid b) Inlet temperature of hot fluid
c) LMTD d) Inlet temperature of cold fluid
3
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Paper 2 Set A Key
25. Pinch analysis uses the _____ law of thermodynamics

a) First b) Second c)Third d) Both (a) & (b)
26. In a counter-flow heat exchanger, cold fluid enters at 30C and leaves at 50C, whereas
the hot fluid enters at 150C and leaves at 130C. The LMTD is
a) 100C b) 280C c) 0C d) 20
27. What is the best-suited pump for pumping heavy fuel oil?
a) centrifugal pump b) gear pump c) diaphragm pump d) plunger pump
28. Which of the following components in fuel limits exit flue gas temperature in a boiler waste
heat recovery system?
a) hydrogen content b) volatile matter c) sulphur content d) ash content
29. Which of the following requires the largest amount of oxygen/kg of substance for
combustion?
a) carbon b) hydrogen c) sulphur d) nitrogen
30. A paper plant needs steam at 3.5 bar and 10.5 bar in addition to electric power. The most
suitable choice among the following will be
a) condensing turbine b) bottoming cycle

31. An increase in the steam pressure from 3 bar to 10 bar, will result in a decrease of
a) sensible heat b) enthalpy of steam c) saturation temperatured) specific volume
32. Chemical used for dozing boiler drum to reduce dissolved gases is
a) hydrazine b) chlorine c) alum d) all of the above
33. Saturated steam when throttled to a lower pressure results in

a) wet steam b) super heated steam c) super critical steam d) same state of steam
34. Radiation losses from the surface of a boiler practically

c) are independent of its loading d) none of the above

35. In oil fired boiler, the measured CO2 in flue gas is 11 % by volume against the theoretical
CO2 of 15.5% . The percentage excess air will be
a) 40.9% b) 38.7% c) 240.9% d) none of the above
36. Which of the following fuel fired steam boiler will have the least evaporation ratio?
a) coal b) bagasse c) oil d) gas
4
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Paper 2 Set A Key
37. ____ indicates the softening temperature of the refractory

a) refractoriness under load (RUL) b) cold crushing strength
c) pyrometric cone equivalent (PCE) d) porosity
38. An increase in bulk density of a refractory increases its
a) volume stability b) heat capacity c) resistance to slag penetration d) all of the above
39. The insulation material used for medium temperature application is

a) calcium silicate b) polyurethane c) wood d) mica
40. A coal fired FBC boiler can operate at ___ excess air
a) 3 4 % b) 20 -25 % c) 30 40 % d) 10 15 %
41. The balance draft furnace is one using

a) induced draft fan and chimney b) induced draft fan and forced draft fan
c) forced draft fan and chimney d) without induced and forced draft fans
42. Higher excess air in an oil fired furnace would result in
a) increased furnace temperature b) increase in CO2 presence in flue gas
c) reduced flame temperature d) all of the above
43. ________ is the commonly employed flux in a cupola furnace
a) calcium carbide b) fluorspar c) limestone d) any of the above
44. By installing a recuperator ,1% fuel reduction is possible for every ___ reduction in flue
gas temperature
a) 5C b) 33C c) 22C d) 10C

2 2
a) Joules b) W/m C c) Watt/sec d) kCal/m /hr
46. Which among the following uses a working fluid for heat recovery ?
a) heat pipe b) recuperator c) heat wheel d) regenerator
47. Which of the following is most suitable for high temperature waste heat recovery ?
a) heat wheel b) heat pump c) heat pipe d) recuperator
48. Among the following, cogeneration concept is not applicable to which type of industry?
a) sugar b) paper & pulp c) refinery d) refractory
49. A device used to convert low pressure steam to high pressure steam is called
a) heat pump b) heat pipe c) thermocompressord) economizer
50. The unit of thermal conductivity is

2o o 2 o o
a) W / m C b) W C / m c) W / m C d) W C / m
5
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Paper 2 Set A Key

instructions


53. The amount of heat required to raise the temperature of 1 kg of a substance by 1oC is
called
a) B b) F c) A d) E



combustion ?

6
_______________________
Paper 2 Set A Key


a) calorific value of fuel b) latent heat of steam c) fuel quantity d) all of the above


66. Which of these is not true of critical point of steam/water mixture ?

o
a) the temperature at critical point is 374.15 C
b) the pressure at critical point is 221.2 bar

c) saturated liquid and saturated vapour lines meet at critical point
d) enthalpy of evaporation is maximum at critical point




In an oil fired heat treatment furnace which of the following is not required to determine its
7
_______________________
Paper 2 Set A Key

Which of the following may not help in energy efficient furnace operation?
maintaining a positive draft inside the furnace

minimizing refractory losses
complete combustion with maximum excess air
use of ceramic fibre in batch type furnace
Select the wrong statement with respect to furnace operations
the burner flame should not touch the stock

air infiltration leads to oxidation of billets
ceramic fibre linings are used in the exterior of the furnace
4
heat loss through openings is proportional to T
The effectiveness of a heat exchanger does not depend on

8
_______________________
Paper 2 Set A Key

a) 100C b) 280C c) 0C d) 20
a) centrifugal pump b) gear pump c) diaphragm pump d) plunger pump
combustion?

81. An increase in the steam pressure from 3 bar to 10 bar, will result in a decrease of
a) sensible heat b) enthalpy of steam c) saturation temperatured) specific volume



85. In oil fired boiler, the measured CO2 in flue gas is 11 % by volume against the theoretical
CO2 of 15.5% . The percentage excess air will be
9
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Paper 2 Set A Key
87. ____ indicates the softening temperature of the refractory


a) 3 4 % b) 20 -25 % c) 30 40 % d) 10 15 %

gas temperature
a) 5C b) 33C c) 22C d) 10C

2 2
a) Joules b) W/m C c) Watt/sec d) kCal/m /hr
100 The unit of thermal conductivity is

2o o 2 o o
b) W / m C b) W C / m c) W / m C d) W C / m
10
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Paper 2 Set A Key

S-1 The specification of furnace oil from lab analysis is given below,
Carbon : 82.7 %
Hydrogen : 14.5 %
Oxygen : 0.9 %
Sulphur : 0.8 %
Water : 0.45 %
Ash content : 0.65 %
If actual mass of air supplied to the furnace is 16.5 kg/kg of furnace oil, calculate
the % of excess air supplied to the furnace.
Ans Theoretical air required for complete combustion

= ((11.6 * C) + (34.8 * (H2 - O2 / 8)) + (4.35 * S)) / 100
= ((11.6 * 82.7) + (34.8 * (14.5 0.9/8)) + (4.35 * 0.8)) / 100
= 14.63 kg / kg of FO
Actual mass of air supplied = 16.5 Kg/Kg of FO
Actual mass of air supplied = (1 + Excess air) * (Theoretical air)
(1 + Excess air) = 16.5 / 14.63
(1 + Excess air) = 1.1278

Excess air = 0.1278
Excess air supplied , % = 12.78
S-2 3
In a dryer, 100 m /hr of hot thermic fluid is circulated at 270C. The thermic fluid
heater fired by coal, operates at a range of 20C. Estimate the coal requirement if
the thermal efficiency of the heater is 65% and GCV of the coal is 4200 kCal/hr.
Consider specific heat & density of the thermic fluid to be 0.55 kCal/kgC & 820
3
kg/m respectively.
11
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Paper 2 Set A Key
Ans Absorbed heat in thermic fluid = m * Cp * del T

Absorbed heat in thermic fluid = (100 * 820) * 0.55 * 20
Absorbed heat in thermic fluid = 902000 Kcal/hr

Thermal efficiency of the heater = absorbed duty / heat duty
Mass of coal required = absorbed duty / (efficiency * calorific value of coal)

Mass of coal required = 902000 / (0.65 * 4200)
Mass of coal required =330.4 kg/hr
S-3 A heat exchanger is to be designed to condense a vapour at the rate of 8.5

o
kg/sec which is available at its saturation temperature of 80 C. The latent heat of
o
condensation of vapour is 550 kJ/kg. The cooling water at 20 C and a flow rate of
62 kg/sec is used to remove the heat. Determine the LMTD of the heat exchanger.
Heat of condensation = heat gained by the liquid

Mv x hfgv = Mc x Cpc x ( Tout Tin)
8.5 x 550 = 62 x 4.2 x ( Tout 20)
o
Tout = 37.95 C
LMTD = (80 20) (80 37.95)
Ln (60/42.5)
o
= 50.49 C
S-4 List five energy saving measures in an oil fired reheating furnace
12
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Paper 2 Set A Key
Ans
S-5 a) Why de-superheating is done in Pressure Reducing Desuperheating Stations?
b) Why individual trapping is preferred over group trapping in a steam

distribution system ?
ANS a) A reduction in steam pressure through a pressure reducing valve (PRV) is an isenthalpic
process. Saturated steam when reduced to a lower pressure results in super heated
steam. Since process requires only saturated steam, de-superheating is often
required, to compensate for superheat gained in PRV application due to isenthalpic
expansion.
The steam consumption of a number of units is never the same at a moment of time
and therefore the pressure in the various steam spaces will also be different. It
follows that the pressure at the drain outlet of a heavily loaded unit will be less than in
the case of one that is lightly loaded. Now, if all these units are connected to a
common steam trap, the condensate from the heavily loaded and therefore lower
pressure steam space finds it difficult to reach the trap as against the higher pressure
condensate produced by lightly or partly loaded unit. The only satisfactory
arrangement, thus would be to drain each steam space with own trap and then
connect the outlets of the various traps to the common condensate return main.
S-6 List down five advantages of FBC boiler.
ANS Solution (any 5 five of the following):
1.High efficiency FBC boilers can operate with overall efficiency of 84%
2.Reduction in boiler size high heat transfer rate over a small heat transfer area
3.Fuel flexibility can be operated with variety of fuels
4.Ability to burn low grade

fuel 5.Ability to burn fines
6.Pollution control addition of limestone/dolomite can greatly minimise SO2 formation

7.Low corrosion and erosion
13
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Paper 2 Set A Key
8.No clinker formation

9.Less excess air
10.Simple operation, quick startup
11.Fast response to load fluctuations
12.No soot blowing
13.Provision of automatic coal and ash handling systems
14.Provision of automatic ignition system
15.High reliability
16.Reduced maintenance
17.Quick response to changing demand
18.High efficiency of power generation
S-7 a) Why steam is most preferred heating media in process industries?

b) Why saturated steam is preferred over superheated or wet steam for indirect
heating in a process?
ANS Steam is most preferred for following reasons

Very high heat content
Gives up heat at constant temperature
Produced from water (cheap, plentiful)
Clean, odorless, tasteless
Its heat can be used over and over
Can generate power, then used for heating
Can be readily distributed, easily controlled
Saturated steam has a high heat transfer coefficient It immediately releases the latent
heat on contacting the cold surface. So heat transfer is faster and at uniform
temperature. Superheated steam has a low heat transfer coefficient and first it has to
give up it superheat which happens slowly and then once it reaches the saturation state
it gives up the latent heat. So it takes more time to heat with superheated steam. Hence
saturated steam is preferred.
S-8 For a 5 tonne/hour capacity furnace oil fired boiler, estimate the rise in
temperature of water in an economizer, which brings down the flue gas
o
temperature from 310 C to 180 C. Air to fuel ratio and evaporation ratio of the
boiler are 20 and 10 respectively. Assume condensate recovery is nil. Specific
O
heat of flue gas is 0.23 kCal/kg C
14
_______________________
Paper 2 Set A Key
For 1 kg of fuel steam generated is = 10 kg

21 x 0.23 x (310-180) = 10 x 1 x T
T = 62.8 C
------- End of Section - II ---------
15
_______________________
Paper 2 Set A Key

L-1 An oil fired boiler is generating 30 T/hr Steam and operates for 8000 hrs/year. The TDS
in boiler feed water was reduced from 500 ppm to 200 ppm. The maximum
permissible limit of TDS in the boiler is 3000 ppm and make up water is 10%.
Temperature of the blow down water is 170C and boiler feed water temperature is
40C. GCV of fuel is 10000 kCal/kg and efficiency of the boiler is 80%.
Calculate the savings in fuel oil per annum due to reduction in the blow down
ANS Blow down % = Feed water TDS * % make up water * 100 / (maximum permissible
TDS in boiler water Feed water TDS)
Initial blow down = 500 * 10 / (3000 500)

Initial blow down = 2.0 %
Improved blow down = 200 * 10 / (3000 200)

Improved blow down = 0.71 %
Reduction in blow down = 2.0 0.71

Reduction in blow down = 1.29 %
Reduction in blow down = 1.29 * 30 * 1000 / 100

Reduction in blow down = 387 kg/hr
Heat savings = 387 * 1 * (170 40)

Heat savings = 50310 kcal/hr
Fuel Oil saving = 50310 / (10000 * 0.8) = 6.28 kg/hr
= 6.28 * 8000 hr = 50.24 MT / annum
L-2 a) Draw the schematics of a heat pump system and state two examples of heat
pump applications.
b) An oil fired boiler has the following operating parameters
Steam generation : 5 T/hr
Steam pressure : 8 kg/cm
2
16
_______________________
Paper 2 Set A Key

Steam enthalpy : 660 kCal/kg
Steam Saturation temperature : 170 C
GCV of fuel oil : 9550 kCal/kg
Consumption of fuel oil : 300 kg/hr
Calculate the boiler efficiency if the dryness fraction is 0.8.
ANS a) Refer Book 3, Page No. 229-230

b) Steam generated = 5 T/hr
Dry steam = 4 T/hr

Wet steam = 1 T/hr
Total heat of the steam = 4000 * (660-50) + 1000*1*(170 50)
6
Total heat of the steam = 2.56 * 10 Kcal/hr
Boiler Efficiency = Heat of steam / (mass of fuel * calorific value)
Boiler Efficiency = 2.56 * 106 / (300 * 9550) * 100

Answer:
Boiler Efficiency = 89.3 %
17
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Paper 2 Set A Key
L-3 In a crude distillation unit of a refinery, 50 MetricTonne/hr of crude is heated using

saturated steam in a heat exchanger from 35C to 85C. Plant is operating for 8000
hrs/annum. Consider specific heat of the crude as 0.631 kCal/kgC. The plant has
two steam headers operating at 3 bar and 8 bar respectively, passing nearby the
heat exchanger. Cost of steam is same for both 3 bar and 8 bar @ Rs.4.50/kg
As an Energy Manager, which of the following options will you recommend to the
unit based on the annual cost of steam?
a) Utilising 3 bar steam
b) Utilising 8 bar steam
Given: Data from steam table:
Steam Enthalpy kCal/kg

Pressure, Water Evaporation Steam
bar
3.0 133 517 650
8.0 171 489 660
ANS Heat gain in crude = m * Cp * del T

Heat gain in crude = 50 * 1000 * 0.631 * (85 35)
Heat gain in crude = 1577500 kCal/hr
Heat gain in crude = heat loss in steam
Heat loss in steam = mass of the steam * latent heat of steam
Option A:
3 bar pressure steam having 517 Kcal/kg of latent heat

Mass of the steam = 1577500 / 517
Mass of the steam = 3051 kg / hr

Cost of steam expenditure = 3051 * 8000 * 4.5
Cost of steam expenditure = 10.98 Cr
Option B:

Mass of the steam = 3225 kg / hr

Cost of steam expenditure = 3226 * 8000 * 4.5
Answer:
Option A is recommended as it is found to be economical (Steam @ 3 bar pressure) since

the expenditure per annum is less when compared to Option B.
18
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Paper 2 Set A Key
L-4 Make an illustrative sketch of the followings
simple back pressure turbine

double extraction back pressure turbine
double extraction condensing turbine
gas turbine combined cycle
ANS
a) b) (c)
d)
19
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Paper 2 Set A Key
L-5 In a counter flow heat exchanger, water is being chilled by sodium chloride brine.
The rate of flow of the brine is 2.7 kg/s and that of the water is 1.58 kg/s. Estimate
the temperature to which the water is cooled if the brine enters at 8 C and leaves
at 10 C, and if the water enters the exchanger at 38 C. Calculate the area of the
2
heat exchanger surface if the overall heat transfer co-efficient is 100 J/m sC.
Consider the specific heat of brine and water is 3.38 & 4.18 kJ/kgC respectively.
ANS Heat gain by brine = heat lost by water
2.7 * 3.38 * (10-(-8)) = 1.58 * 4.18 * (38 T)
T = 13.2 C
i) Water leaves the exchanger at 13.2C
ii) LMTD of counter flow pattern
T (38 10)(13.2 (8)

LMTD
(3810
ln
(13.2 (8)
T 6.8 = 24.4 C
LMTD
ln1.32
Q = m*Cp* Del T = U * A * LMTD

2.7 * 3.38 * (10 (-8)) * 1000 = 100 * A * 24.4
A = 67.3 m2
Area of the heat exchanger surface is 67.3 m2

general requirements of refractory material for furnace application
causes of boiler tube leakages
thermocompressor
heat pipe
ANS a) Requirements of refractory material
Abilitytowithstandhightemperatures.
Abilitytowithstandsuddenchangesoftemperatures.
Abilitytowithstandactionofmoltenmetalslag,glass,hotgases,etc.
Abilitytowithstandloadatserviceconditions.
Abilitytowithstandloadandabrasiveforces.
Lowcoefficientofthermalexpansion.
Shouldbeabletoconserveheat.
Shouldnotcontaminatethematerialwithwhichitcomesintocontact.
20
_______________________
Paper 2 Set A Key
b) Tube failures can be attributed to design, manufacturing, operational, maintenance and

ageing related aspects. The tube failures mechanisms can be classified as Mechanical,
chemical, metallurgical & in adequate quality compliance.
Mechanical causes
Mechanical damage of tubes takes place due to fly ash erosion, steam impingement from
soot blowers, falling clinker and fuel particles. The Mechanical damage increases the
stress level leading to tube failure.
Chemical causes
Water side and fire side corrosion failure of tubes occurs due to phenomenon like caustic
gouging, hydrogen embrittlement, pitting, and stress corrosion cracking while fire side
corrosion is often due to high as well as low temperature effects
Metallurgical causes
In high temp components like superheaters, reheaters creep damage occurs due to
overheating wherein the tube material loses its strength and failure occurs by stress
rupture. Weld joint failures by cracking and fatigue failures by vibration, thermal and
corrosion phenomenon are other reasons for metallurgical related tube failures.
Quality assurance gaps
Tube failures are also known to occur due to

inadequate quality assurance procedures during
design/manufacturing of boiler tubes. Due care during
material procurement, adoption of healthy fabrication
practices, good operation and maintenance practices
in tube manufacturing would help to minimize tube
leakages and achieve high availability.
c) Thermocompressor
In many of the steam utilization equipment where

condensate comes out at high pressure, a major
portion of it flashes into low pressure steam which
goes wasted. Using a thermocompressor it becomes
feasible to compress this low pressure steam by high
pressure steam and reuse it as a medium pressure
steam in the process. The major energy in steam is in
its latent heat value and thus thermocompressing
would give a large improvement in waste heat
recovery.
Thermocompressors are designed to accurately mix
lower-pressure steam with higher-pressure steam.
The higher-pressure motive steam entrains the
21
_______________________
Paper 2 Set A Key
lower pressure steam and increases its pressure. The motive steam is introduced through
the nozzle of the thermocompressor. As the nozzle opens, the high velocity motive steam
draws the lower-pressure steam into the thermocompressor body. An exchange of
momentum occurs as the steam flows are mixed and the mixed flow is accelerated to high
velocity with a uniform profile in the mixing chamber of the thermocompressor. As the
mixed flow enters the diffuser section, the diffuser flow area gradually increases to allow
the velocity of the mixed flow to be reduced. As the velocity is reduced, the steam
pressure increases. At the end of the diffuser, the discharge steam pressure is higher than
the lower-pressure suction flow entering the thermocompressor. A figure of
thermocompressor is shown in Figure 3.7. A typical application is in evaporators where the
boiling steam is recompressed and used as heating steam.
d) Heat Pipe
A heat pipe can transfer up to 100 times more thermal energy than copper, the best known
conductor. In other words, heat pipe is a thermal energy absorbing and transferring system
and have no moving parts and hence require minimum maintenance.
The Heat Pipe comprises of three elements a sealed container, a capillary wick structure
and a working fluid. The capillary wick structure is integrally fabricated into the interior
surface of the container tube and sealed under vacuum. Thermal energy applied to the
external surface of the heat pipe is in equilibrium with its own vapour as the container tube
is sealed under vacuum. Thermal energy applied to the external surface of the heat pipe
causes the working fluid near the surface to evaporate instantaneously. Vapour thus
formed absorbs the latent heat of vapourisation and this part of the heat pipe becomes an
evaporator region. The vapour then travels to the other end the pipe where the thermal
energy is removed causing the vapour to condense into liquid again, thereby giving up the
latent heat of the condensation. This part of the heat pipe works as the condenser region.
The condensed liquid then flows back to the evaporated region. A figure of Heat pipe is
shown in Figure

22
_______________________
Paper 2 Set B Key
Regn No: _________________

Name: ___________________
th
FOR
ENERGY MANAGERS & ENERGY AUDITORS October, 2011

instructions
1. ________ indicates the softening temperature of the refractory



a) 3 4 % b) 20 -25 % c) 30 40 % d) 10 15 %


An increase in the steam pressure from 3 bar to 10 bar, will result in a decrease of
a) sensible heat b) enthalpy of steam c) saturation temperature d) specific volume

1
_______________________
Paper 2 Set B Key
gas temperature
a) 5C b) 33C c) 22C d) 10C





a) 100C b) 280C c) 0C d) 20
18. In an oil fired heat treatment furnace which of the following is not required to determine its
In oil fired boiler, the measured CO2 in flue gas is 11 % by volume against the theoretical CO 2
of 15.5% . The percentage excess air will be
2
_______________________
Paper 2 Set B Key



23. Select the wrong statement with respect to furnace operations

a) the burner flame should not touch the stock
b) air infiltration leads to oxidation of billets

c) ceramic fibre linings are used in the exterior of the furnace
4
d) heat loss through openings is proportional to T

o
25. The amount of heat required to raise the temperature of 1 kg of a substance by 1 C is
called




a) Joules 2
b) W/m C c) Watt/sec 2
d) kCal/m /hr
3
_______________________
Paper 2 Set B Key

32. The unit of thermal conductivity is

2o o 2 o o
a) W / m C b) W C / m c) W / m C d) W C / m
a) centrifugal pump b) gear pumpc) diaphragm pump d) plunger pump


combustion ?
a) B b) F c) A d) E

a) calorific value of fuel b) latent heat of steamc) fuel quantity d) all of the above
4
_______________________
Paper 2 Set B Key

48. Which of the following may not help in energy efficient furnace operation?
a) maintaining a positive draft inside the furnace
b) minimizing refractory losses
c) complete combustion with maximum excess air
d) use of ceramic fibre in batch type furnace
combustion?
Which of these is not true of critical point of steam/water mixture?
o
the temperature at critical point is 374.15 C
the pressure at critical point is 221.2 bar
saturated liquid and saturated vapour lines meet at critical point
enthalpy of evaporation is maximum at critical point
End of Section I .

S-1 a) Why de-superheating is done in Pressure Reducing Desuperheating Stations?
5
_______________________
Paper 2 Set B Key
b) Why individual trapping is preferred over group trapping in a steam

distribution system ?
ANS a) A reduction in steam pressure through a pressure reducing valve (PRV) is an isenthalpic
process. Saturated steam when reduced to a lower pressure results in super heated
steam. Since process requires only saturated steam, de-superheating is often
required, to compensate for superheat gained in PRV application due to isenthalpic
expansion.
The steam consumption of a number of units is never the same at a moment of time
and therefore the pressure in the various steam spaces will also be different. It
follows that the pressure at the drain outlet of a heavily loaded unit will be less than in
the case of one that is lightly loaded. Now, if all these units are connected to a
common steam trap, the condensate from the heavily loaded and therefore lower
pressure steam space finds it difficult to reach the trap as against the higher pressure
condensate produced by lightly or partly loaded unit. The only satisfactory
arrangement, thus would be to drain each steam space with own trap and then
connect the outlets of the various traps to the common condensate return main.
S-2 List down five advantages of FBC boiler.
ANS Solution (any 5 five of the following):
1.High efficiency FBC boilers can operate with overall efficiency of 84%
2.Reduction in boiler size high heat transfer rate over a small heat transfer area
3.Fuel flexibility can be operated with variety of fuels
4.Ability to burn low grade

fuel 5.Ability to burn fines
6.Pollution control addition of limestone/dolomite can greatly minimise SO2 formation

7.Low corrosion and erosion
8.No clinker formation

9.Less excess air
10.Simple operation, quick startup

11.Fast response to load fluctuations
12.No soot blowing
13.Provision of automatic coal and ash handling systems

14.Provision of automatic ignition system
15.High reliability
16.Reduced maintenance
17.Quick response to changing demand
6
_______________________
Paper 2 Set B Key
18.High efficiency of power generation
S-3 a) Why steam is most preferred heating media in process industries?
b) Why saturated steam is preferred over superheated or wet steam for indirect
heating in a process?
a)
ANS
steam is most preferred for following reasons
Very high heat content
Gives up heat at constant temperature
Produced from water (cheap, plentiful)
Clean, odorless, tasteless
Its heat can be used over and over
Can generate power, then used for heating
Can be readily distributed, easily controlled
b)
Saturated steam has a high heat transfer coefficient It immediately releases the latent
heat on contacting the cold surface. So heat transfer is faster and at uniform
temperature. Superheated steam has a low heat transfer coefficient and first it has to
give up it superheat which happens slowly and then once it reaches the saturation state
it gives up the latent heat. So it takes more time to heat with superheated steam. Hence
saturated steam is preferred.
S-4 For a 5 tonne/hour capacity furnace oil fired boiler, estimate the rise in
temperature of water in an economizer, which brings down the flue gas
o
temperature from 280 C to 180 C. Air to fuel ratio and evaporation ratio of the
boiler are 20 and 10 respectively. Assume condensate recovery is nil. Specific
O
heat of flue gas is 0.23 kCal/kg C
For 1 kg of fuel steam generated is = 10 kg
21 x 0.23 x (280-180) = 10 x 1 x T
T = 48.3 C
_______________________
Paper 2 Set B Key
S-5 The specification of furnace oil from lab analysis is given below,
Carbon : 82.7 %
Hydrogen : 14.5 %
Oxygen : 0.9 %
Sulphur : 0.8 %
Water : 0.45 %
Ash content : 0.65 %
If actual mass of air supplied to the furnace is 20.5 kg/kg of furnace oil, calculate
the % of excess air supplied to the furnace.
Ans Theoretical air required for complete combustion

= ((11.6 * C) + (34.8 * (H2 - O2 / 8)) + (4.35 * S)) / 100
= ((11.6 * 82.7) + (34.8 * (14.5 0.9/8)) + (4.35 * 0.8)) / 100
= 14.63 kg / kg of FO
Actual mass of air supplied = 20.5 Kg/Kg of FO
Actual mass of air supplied = (1 + Excess air) * (Theoretical air)
(1 + Excess air) = 20.5 / 14.63
(1 + Excess air) = 1.4012

Excess air = 0.4012
Excess air supplied , % = 40.12
S-6 3
In a dryer, 100 m /hr of hot thermic fluid is circulated at 270C. The thermic fluid
heater fired by coal, operates at a range of 15C. Estimate the coal requirement if
the thermal efficiency of the heater is 65% and GCV of the coal is 4200 kCal/hr.
Consider specific heat & density of the thermic fluid to be 0.55 kCal/kgC & 820
3
kg/m respectively.
Ans Absorbed heat in thermic fluid = m * Cp * del T
Absorbed heat in thermic fluid = (100 * 820) * 0.55 * 15

Absorbed heat in thermic fluid = 676500 Kcal/hr
8
_______________________
Paper 2 Set B Key
Thermal efficiency of the heater = absorbed duty / heat duty

Mass of coal required = absorbed duty / (efficiency * calorific value of coal)
Mass of coal required = 676500 / (0.65 * 4200)

Mass of coal required = 247.8 kg/hr
S-7 A heat exchanger is to be designed to condense a vapour at the rate of 9 kg/sec

o
which is available at its saturation temperature of 80 C. The latent heat of
o
condensation of vapour is 550 kJ/kg. The cooling water at 20 C and a flow rate of
62 kg/sec is used to remove the heat. Determine the LMTD of the heat exchanger.
Heat of condensation = heat gained by the liquid

Mv x hfgv = Mc x Cpc x (Tout Tin)
9 x 550 = 62 x 4.2 x (Tout 20)
o
Tout = 39 C
LMTD = (80 20) (80 39)

Ln (60/41)
o
= 49.89 C
S-8 List five energy saving measures in an oil fired reheating furnace
Ans
9
_______________________
Paper 2 Set B Key
------- End of Section - II ---------
10
_______________________
Paper 2 Set B Key

L-1 Make an illustrative sketch of the followings
simple back pressure turbine

double extraction back pressure turbine
double extraction condensing turbine
gas turbine combined cycle
ANS
a) b) c)
d)
11
_______________________
Paper 2 Set B Key
L-2 In a counter flow heat exchanger, water is being chilled by sodium chloride brine.
The rate of flow of the brine is 2.7 kg/s and that of the water is 1.58 kg/s. Estimate
the temperature to which the water is cooled if the brine enters at 6 C and
leaves at 10 C, and if the water enters the exchanger at 38 C. Calculate the area
of the heat exchanger surface if the overall heat transfer co-efficient is 100
2
J/m sC. Consider the specific heat of brine and water is 3.38 & 4.18 kJ/kgC
respectively.
ANS Heat gain by brine = heat lost by water
2.7 * 3.38 * (10-(-6)) = 1.58 * 4.18 * (38 T)
T = 15.89 C
i) Water leaves the exchanger at 15.89 C
ii) LMTD of counter flow pattern
T (3810) (13.2 (6)

LMTD
(3810
ln
(13.2 (6)
= 24.81 C
Q = m*Cp* Del T = U * A * LMTD

2.7 * 3.38 * (10 (-6)) * 1000 = 100 * A * 24.81
A = 58.85 m2
2
Area of the heat exchanger surface is 58.85 m

general requirements of refractory material for furnace application
causes of boiler tube leakages
thermocompressor
heat pipe
ANS a) Requirements of refractory material
Abilitytowithstandhightemperatures.
Abilitytowithstandsuddenchangesoftemperatures.
Abilitytowithstandactionofmoltenmetalslag,glass,hotgases,etc.
Abilitytowithstandloadatserviceconditions.
Abilitytowithstandloadandabrasiveforces.
12
_______________________
Paper 2 Set B Key
Lowcoefficientofthermalexpansion.
Shouldbeabletoconserveheat.
Shouldnotcontaminatethematerialwithwhichitcomesintocontact.
Tube failures can be attributed to design, manufacturing, operational, maintenance and

ageing related aspects. The tube failures mechanisms can be classified as Mechanical,
chemical, metallurgical & in adequate quality compliance.
Mechanical causes
Mechanical damage of tubes takes place due to fly ash erosion, steam impingement
from soot blowers, falling clinker and fuel particles. The Mechanical damage increases
the stress level leading to tube failure.
Chemical causes
Water side and fire side corrosion failure of tubes occurs due to phenomenon like caustic
gouging, hydrogen embrittlement, pitting, and stress corrosion cracking while fire side
corrosion is often due to high as well as low temperature effects
Metallurgical causes
In high temp components like superheaters, reheaters creep damage occurs due to
overheating wherein the tube material loses its strength and failure occurs by stress
rupture. Weld joint failures by cracking and fatigue failures by vibration, thermal and
corrosion phenomenon are other reasons for metallurgical related tube failures.
Quality assurance gaps
Tube failures are also known to occur due to

inadequate quality assurance procedures during
design/manufacturing of boiler tubes. Due care
during material procurement, adoption of healthy
fabrication practices, good operation and
maintenance practices in tube manufacturing would
help to minimize tube leakages and achieve high
availability.
c) Thermocompressor
In many of the steam utilization equipment where

condensate comes out at high pressure, a major
portion of it flashes into low pressure steam which
goes wasted. Using a thermocompressor (Figure
3.7) it becomes feasible to compress this low
pressure steam by high pressure steam and reuse it
as a medium pressure steam in the process. The
major energy in steam is in its latent heat value and
thus thermocompressing would give a large
improvement in waste heat recovery. Figure 3.7 Thermocompressor
13
_______________________
Paper 2 Set B Key
Thermocompressors are designed to accurately mix lower-pressure steam with higher-

pressure steam. The higher-pressure motive steam entrains the lower pressure steam
and increases its pressure. The motive steam is introduced through the nozzle of the
thermocompressor. As the nozzle opens, the high velocity motive steam draws the lower-
pressure steam into the thermocompressor body. An exchange of momentum occurs as
the steam flows are mixed and the mixed flow is accelerated to high velocity with a
uniform profile in the mixing chamber of the thermocompressor. As the mixed flow enters
the diffuser section, the diffuser flow area gradually increases to allow the velocity of the
mixed flow to be reduced. As the velocity is reduced, the steam pressure increases. At
the end of the diffuser, the discharge steam pressure is higher than the lower-pressure
suction flow entering the thermocompressor. A figure of thermocompressor is shown in
Figure 3.7. A typical application is in evaporators where the boiling steam is
recompressed and used as heating steam.
d) Heat Pipe
A heat pipe can transfer up to 100 times more thermal energy than copper, the best
known conductor. In other words, heat pipe is a thermal energy absorbing and
transferring system and have no moving parts and hence require minimum maintenance.
interior surface of the container tube and sealed under vacuum. Thermal energy applied
to the external surface of the heat pipe is in equilibrium with its own vapour as the
container tube is sealed under vacuum. Thermal energy applied to the external surface
of the heat pipe causes the working fluid near the surface to evaporate instantaneously.
Vapour thus formed absorbs the latent heat of vapourisation and this part of the heat
pipe becomes an evaporator region. The vapour then travels to the other end the pipe
where the thermal energy is removed causing the vapour to condense into liquid again,
thereby giving up the latent heat of the condensation. This part of the heat pipe works as
the condenser region. The condensed liquid then flows back to the evaporated
14
_______________________
Paper 2 Set B Key
region. A figure of Heat pipe is shown in Figure
L-4 An oil fired boiler is generating 30 T/hr Steam and operates for 8000 hrs/year. The
TDS in boiler feed water was reduced from 550 ppm to 200 ppm. The maximum
permissible limit of TDS in the boiler is 3000 ppm and make up water is 10%.
Temperature of the blow down water is 170C and boiler feed water temperature is
40C. GCV of fuel is 10000 kCal/kg and efficiency of the boiler is 80%.
Calculate the savings in fuel oil per annum due to reduction in the blow down
ANS Blow down % = Feed water TDS * % make up water * 100 / (maximum permissible
TDS in boiler water Feed water TDS)



Heat savings = 459 * 1 * (170 40)

= 7.46 * 8000 hr = 59.68 MT / annum
L-5a) Draw the schematics of a heat pump system and state two examples of heat
pump applications.
b) An oil fired boiler has the following operating parameters
Steam generation : 5 T/hr
Steam pressure : 8 kg/cm
2

15
_______________________
Paper 2 Set B Key
Steam enthalpy : 660 kCal/kg

Steam Saturation temperature : 170 C
GCV of fuel oil : 9550 kCal/kg
Consumption of fuel oil : 320 kg/hr
Calculate the boiler efficiency if the dryness fraction is 0.8.
ANS a) Refer Book 3, Page No. 229-230

b) Steam generated = 5 T/hr
Dry steam = 4 T/hr

Wet steam = 1 T/hr
Total heat of the steam = 4000 * (660-50) + 1000*1*(170 50)
Total heat of the steam = 2.56 * 106 Kcal/hr
Boiler Efficiency = Heat of steam / (mass of fuel * calorific value)
6
Boiler Efficiency = 2.56 * 10 / (320 * 9550) * 100
Answer:
Boiler Efficiency = 83.76 %
L-6 In a crude distillation unit of a refinery, 50 MetricTonne/hr of crude is heated using

saturated steam in a heat exchanger from 30C to 85C. Plant is operating for
8000 hrs/annum. Consider specific heat of the crude as 0.631 kCal/kgC. The plant
has two steam headers operating at 3 bar and 8 bar respectively, passing nearby
the heat exchanger. Cost of steam is same for both 3 bar and 8 bar @ Rs.4.50/kg
As an Energy Manager, which of the following options will you recommend to the
unit based on the annual cost of steam?
a) Utilising 3 bar steam
b) Utilising 8 bar steam
Given: Data from steam table:
Steam Enthalpy kCal/kg

Pressure, Water Evaporation Steam
bar
3.0 133 517 650
8.0 171 489 660
ANS Heat gain in crude = m * Cp * T
Heat gain in crude = 50 * 1000 * 0.631 * (85 30)
Heat gain in crude = 1735250 kCal/hr
Heat gain in crude = heat loss in steam
16
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Paper 2 Set B Key
Heat loss in steam = mass of the steam * latent heat of steam

Option A:

Mass of the steam = 3356.38 kg / hr

Cost of steam expenditure = 3356.38 * 8000 * 4.5
Option B:

Mass of the steam = 3548.56 kg / hr

Cost of steam expenditure = 3548.56 * 8000 * 4.5
Answer:
Option A is recommended as it is found to be economical (Steam @ 3 bar pressure)

since the expenditure per annum is less when compared to Option B.

17
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13th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS - September 2012
Date: 15.9.2012 Timings:14:00-17:00Hrs Duration:3 Hrs Max.Marks:150

Steam mains are run with a slope primarily to
a) avoid water hammer b) increase the velocity of steam

c) avoid condensation of steam d) reduce radiation and convection losses
2. Which of the following is not true of condensate recovery?
a) reduces water charges b) reduces fuel costs
c) increases boiler output d) increases boiler blow down
If 10% air is entrained in a steam system at 3 kg/cm 2 g then the saturation temperature of steam will
be
less than the saturation temperature at 3 kg/cm 2 g

more than the saturation temperature at 3 kg/cm2 g
equal to the saturation temperature at 3 kg/cm2 g
equal to the saturation temperature at 3.3 kg/cm2 g
4. The mineral matter in coal after combustion mostly becomes

a) carbon dioxide b) carbon monoxide c) nitrous oxide d) ash
5. Conditioning of coal with water in certain boilers is done to

a) increase unburnt losses b) increase GCV
c) minimize losses of fine coal particles d) increase convection heat transfer

6. Which of the following is false?
a) LPG vapour is twice as light as air b) LPG is a mixture of propane and butane
c) LPG is a gas at normal atmospheric pressure d) LPG is required to be odorized
7.
,
Of the following fuels which will have the highest carbon content?
a) furnace oil b) coal c) natural gas d) paddy husk
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100 kg of a fuel contains 2% sulphur. For complete combustion of sulphur it will require
_________kg of oxygen
a) 2 b) 4 c) 50 d) 200
In the direct method of efficiency evaluation of boilers which of the following is not required?
a) enthalpy of steam b) calorific value of fuel

in flue gas d) mass flow rate of steam
c) O2
Select the incorrect statement with respect to steam
evaporation is a constant temperature process

higher the pressure higher is the steam saturation temperature
higher the pressure higher is the latent heat
latent heat at critical point is zero
The amount of flash steam generated from the condensate mainly depends on _____
a) sensible heat of high pressure condensate b) sensible heat of flash steam

c) latent heat of flash steam d) all of the above
12. Tuyeres is a terminology associated with

a) induction furnace b) pusher type furnace c) arc furnace d) cupola
In determining the economic thickness of steam pipe insulation which of the following is not required?
a) cost of fuel b) boiler efficiency c) steam pressure d) heat content of fuel
The softening temperature of a refractory is indicated by
a) Pyrometric cone equivalent (PCE) b) refractoriness under load (RUL)

c) creep d) cold crushing strength
Which of the following is not a property of ceramic fibre ?

Low combustion temperature in FBC boilers results in the reduced formation of
a) NOx b) SOx c) CO d) CO2
An axial compressor is used in conjunction with which of the following
a) gas turbine b) back pressure steam turbine

c) condensing steam turbine d) all of the above
Power is to be generated from a cement kiln exhaust gas. The applicable type of cogeneration is
called
a) topping cycle b) trigeneration c) bottoming cycle d) none of the above
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a) specific heat of hot fluid b) specific heat of cold fluid

c) inlet temperature of hot fluid d) LMTD
An element in fuel oil responsible for corrosion in exhaust system of a boiler is
a) carbon b) hydrogen c) sulphur d) chlorine

21.
The presence of calcium and magnesium bicarbonates in feedwater to a boiler would form:
Turn down ratio of a burner is the ratio of
maximum to minimum fuel input without affecting optimum excess air levels
minimum to maximum fuel input without affecting optimum excess air levels
maximum to average fuel input
average to minimum fuel input
Comparatively, lowest excess air is required in a

The velocity of steam in steam pipe is directly proportional to

The emissivity of ceramic coatings used in furnace
decreases with increase in furnace temperature

Increases with increase in furnace temperature
remains constant
Scale losses in reheating furnaces will

27.
Instrument used for measuring billet temperature in a reheating furnace is ___.
a) thermograph b) infrared pyrometer
c) Pt/Pt-Rh thermocouple with indicator d) chrome alumel thermocouple with indicator
Glass mineral wool can be applied for temperature range application upto
a) 950 oC b) 500 oC c) 1200 oC o

d) 750 C
Heat transfer in a reheating furnace is achieved by
a) Conduction b) Convection c) Radiation d) All of the above
The storage heat losses in a batch type furnace can be best reduced by
a) insulating brick b) ceramic fibre c) cold face insulation d) fire brick

The cogeneration system which has high overall system efficiency is

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32. The Brayton cycle is a characteristic of
a) steam turbine b) petrol engine c) gas turbine d) none of the above

Recuperator as a waste heat recovery system is used mainly in a
a) boiler b) reheating furnace

The device used for recovering waste heat from the textile drier exhaust
a) heat wheel b) recuperator c) economizer d) regenerator

Density of liquid fuels are measured at a reference temperature of
a) 0C b) 15C c) 25C d) 30C
Which of the following contributes to erosive effect on burner tips during combustion?
a) ash content b) water content c) sulphur content d) volatile matter
In the context of cogeneration turbine, the thermodynamic process taking place is
a) expansion b) condensation c) contraction d) both (a) & (c)
Reduction of steam pressure will increase
a) sensible heat b) enthalpy of steam

c) saturation temperature d) specific volume
Ten meter lift of condensate in a distribution pipe work will result in
a) 0.1 bar back pressure b) 1 bar back pressure

c) 10 bar back pressure d) none of the above
____________ is predominantly used as a medium for soot blowing in boilers .
a) compressed air b) steam

c) high pressure water d) all of the above
The recommended TDS level for package fire tube boilers is
a) 10,000 ppm b) 5,000 ppm c) 2,000 ppm d) 3,000 ppm
Ideal furnace for melting & alloying is
a) induction furnace b) cupola furnace

c) rotary hearth d) recirculating bogie furnace
Commonly used flux medium in a cupola furnace
a) calcium carbide b) fluorspar

c) calcium carbonate d) sodium carbonate
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44. Dolomite is a ________ type of refractory

45. The unit of specific gravity in SI system is

a) kg/ m3 b) m3/kg c) gm/cc d) none of the above
46. Insulation used for temperatures more than 350C is

a) polyurethane b) polystyrene c) calcium silicate d) wood
47. Time dependent property that determines the deformation of a refractory is

a) creep b) refractoriness under load
c) porosity d) crushing strength
48. Capillary wick is a part of

a) heat pump b) heat wheel c) heat pipe d) heat recovery steam generator
49. The working fluid for thermo compressor is

a) low pressure steam b) high pressure steam
c) compressed air d) waste heat from chimney

50. Fly ash in a FBC boiler is in the range of
a) 20% b) 30% c) 40% d) none of the above

Each question carries 5 marks
S-1 In a paper industry, 35,000 kg/hr of soda liquor with specific heat of 0.38 kCal/kgC
is heated using saturated steam at 8 bar in a heat exchanger from 65C to 115C.
Calculate the LMTD of the exchanger & the amount of steam required for heating
using the following data:
Steam Steam Enthalpy kcal/kg

Pressure Temperature
(bar) C Water Evaporation Steam
8.0 170 170 490 660
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Ans a) Heat gain by soda liquor = 35000 x 0.38 x (115-65)

= 665000 Kcal/hr
Heat lost by saturated steam = 665000 Kcal/hr
Steam required for heating = 665000 / 490
= 1357 Kg/hr
Amount of steam required for heating is 1.36 Ton/hr
b)LMTD calculation = (170-115)-(170-65)
Ln (170-115)
(170-65)
= (55-105)/ln(55/105)
= 77.3C
S-2 A process requires 5.5 tonnes/hr of dry saturated steam at 7 kg/cm 2g having specific
volume of 0.28 m3/kg. For the flow velocity not to exceed 25 m/s, determine the pipe
diameter.
Ans Volumetric flow rate = 5500 x 0.28 = 1540 m3/hr

= 1540/3600
= 0.43 m3/s
Cross sectional area = volumetic flow rate / velocity
2
3.14 x D /4 = 0.43 / 25
= 0.017
D2 = 0.0217
Diameter, D = 0.149 m (or) 150 mm
S-3 a) 230 kg/hr of hot condensate from a heat exchanger is coming out at 6 bar(g) with a
sensible heat of 166 kCal/kg. Using a flash vessel, the condensate is flashed to 1
bar(g) with a sensible heat of 120 kCal/kg and latent heat of 526 kCal/kg. Find out
the flash steam generation in kg/hr.
o o
b) The flash steam produced above is used to heat water from 30 C to 80 C by direct
injection. Calculate the quantity of hot water in that can be obtained per hour.
Ans a) Flash steam available % =( S1 - S2 ) / L2

Flash Steam generated = ( 166 120) x 230
526
= 20.11 Kg/hr.
b) Quantity of hot water generated
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m x cp x (80-30) = 20.11 x (120+526)

m = 260 kg/hr
S-4 The evaporation ratio of a coal fired boiler is 4.50. A quantity of 600 kCal/kg of heat
is added to the feed water in the boiler to produce the steam.
a) If the GCV of coal is 3800 kCal/kg, find out the efficiency.
b) Find out the total enthalpy of the steam as per the details of the data given below
Saturation temperature = 143oC
Sensible heat = 143.7 kCal/kg
Latent heat = 509.96 kCal/kg
Specific volume = 0.47 m3/kg
Dryness fraction of steam = 96%
Ans
a) Boiler efficiency (%) = Evaporation ratio x enthalpy added x 100
GCV of coal
Boiler efficiency = 4.5 x 600/3800
= 71 %
b) Total enthalpy of steam = 143.7 + (0.96 x 509.96 )
= 633.26 kCal/kg
S-5 a. Steam should be used in the process at the lowest acceptable pressure . Explain
the significance of the terms lowest and acceptable
b. Explain briefly about turbine heat rate. How is it related to turbine efficiency ?
Ans a.
lowest : Lower the pressure higher is the latent heat which is primarily used in the
process. Hence the lowest pressure would be desirable.
acceptable: However the lower the steam pressure lower will be the steam
temperature. Since the temperature is the driving force for heat transfer, rate of heat
transfer reduces and increases process time. Therefore there is a limit to the reduction
in steam pressure.
b.
Heat rate is the heat input to turbine, needed to produce 1 kWh of electricity
Turbine efficiency is the ratio useful heat and power output, to the heat input to the
turbine in Kcal or KJ, expressed as a percentage. Performance of steam turbine is

also expressed as heat rate, which is the quantity of heat in kCal or KJ required to
generate 1 kWh of electrical power output.
Turbine heat rate is expressed in kJ/kWh. The inverse relation between heat rate and
efficiency is applicable only to a power plant, since all the input energy is deployed
for power generation alone.
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S-6 Write short notes on factors affecting wall losses in batch type reheating furnaces?
Ans a) Emissivity of walls : Emissivity of fire brick refractory should be high

Emissivity of most of the refractory bricks decreases with increase in
temperature. High emissivity coatings whose emissivity increases with
temperature can be used to increase emissivity and decrease wall losses.
b) Conductivity of refractories: The refractory and insulating bricks should have
low thermal conductivity. Chosing low thermal conductivity bricks will

reduce wall losses. Conductivity raises with rise in temperature. Batch type
furnaces can use ceramic fibre to reduce storage losses.
c) Wall thickness of batch furnaces: Heat losses can be reduced by increasing the
wall thickness, or through the application of insulating bricks. Outside wall

temperature and heat losses for a composite wall of a certain thickness of
firebrick and insulation brick are much lower due to lesser conductivity of
may be worked out to reduce the heat storage.
S-7 Explain any two proven methods of testing steam traps?
ANS There are two proven methods of testing of steam traps: - Sound method and
Temperature method.
1.Sound Method : Mechanisms within steam traps and the flow of steam and
condensate through steam traps generate sonic (audible to the human ear) and
supersonic sounds. Proper listening equipment, coupled with the knowledge of
normal and abnormal sounds, can yield reliable assessments of steam trap working
condition. Listening devices range from a screwdriver or simple mechanic's
stethoscope that allow listening to sonic sounds.
2.Temperature Method: Saturated steam and condensate exist at the same
temperature. So it's not possible to distinguish between the two based on temperature.
Still, temperature measurement provides important information for evaluation
purposes.
A cold trap (i.e., one that is significantly cooler than the expected saturated steam
temperature) indicates that the trap is flooded with condensate, assuming the trap is in
service. On the other hand, the temperature downstream of the trap will be nearly
constant if significant steam is getting past the trap. At the low-end, spitting on the
trap and watching the sizzle provides a general indication of temperature.
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Finally, non-contact (i.e., infrared) temperature measuring devices provide the

precision of thermometers and thermocouples without requiring physical contact.
Non-contact temperature measurement makes it easier to evaluate traps that are
relatively difficult or dangerous to access closely.
S-8 A vessel has to be cooled from 90C to 55C. The mass of the vessel is 2 tonnes. The
specific heat of vessel material is 0.18 kCal/kg C. The vessel is cooled with water
which is available at 28C. The maximum allowed increase in water temperature is
5C. Calculate the quantity of water required for vessel cooling.
Ans Mass of vessel (m) = 2000 kg
Specific heat (Cp) = 0.18 kCal/kg C

Initial vessel temperature (T1) = 90C
Desired vessel temperature (T2) = 55C
Total heat that has to be removed from the vessel = m x Cp x (T1 - T2)
= 2000 x 0.18 x (90-55)

= 12600 kCal
Quantity of water required = M kg
Specific heat of water = 1 kCal/kg C

Inlet cooling water temperature (T3) = 28C
Maximum cooling water outlet temperature (T4) = 33C
Heat removed by water, 12600 = M x 1 x (33 - 28)
Quantity of water required , M = 12600/5 = 2520 kg
------- End of Section - II ---------

L-1 Paddy husk is being used as a fuel in a water tube boiler. The ultimate analysis of fuel
is given below. Calculate the theoretical quantity of air required for complete
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combustion and also compute the quantity of CO 2, H2O and SO2 generated per 100
kg of fuel. The ultimate analysis of paddy husk is given below.
Ultimate analysis of paddy husk %

Moisture 10.8
Mineral Matter 16.7
Carbon 34.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5
GCV (kCal/kg) 3570
ANS
Considering a sample of 100 kg of paddy husk. The chemical reactions are:
Oxygen required for complete combustion of carbon:
C+ O2 CO2
(34.0) C + (34 x 2.67) O2 124.78 CO2
90.78
Oxygen required for complete combustion of hydrogen:
H2 + O2 H2O
(5) H2 + (5 x 8) O2 45 H2O
40
Oxygen required for complete combustion of sulphur:
S + O2 SO2
(0.1) S + (0.1 x 1) O2 0.2 SO2
0.1
Total Oxygen required = 90.78 + 40 + 0.1 = 130.88
Oxygen already present in 100 kg fuel (given) = 32.5 kg
Additional Oxygen Required = 130.88 -32.5 = 98.38

Therefore quantity of dry air reqd. = (98.38) / 0.23 = 427 kg
CO2 generated per 100 kg of fuel = 124.78 kg
H2O generated per 100 kg of fuel = 45 kg

SO2 generated per 100 kg of fuel = 0.2 kg
L-2 3
In a crude distillation unit of a refinery, furnace is operated to heat 500 m /hr of crude
oil from 255C to 360C by firing 3.4 tons/hr of fuel oil having GCV of 9850 kcal/kg.
As an energy conservation measure, the management has installed an air preheater
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(APH) to reduce the flue gas heat loss. The APH is designed to pre-heat 57 tonnes/hr
of combustion air to 195C.
Calculate the efficiency of the furnace before & after the installation of APH.
Consider the following data:
Specific heat of crude oil = 0.6 kcal/kgC

Specific heat of air = 0.24 kcal/kgC
Specific gravity of Crude oil = 0.85
Ambient temperature = 28C.
ANS Before the installation of APH

Heat gain by the crude = 500 x 1000 x 0.85 x 0.6 x (360-255)
= 26775000 Kcal/hr
Heat input to the furnace = 3.4 x1000x 9850
= 33490000 kcal/hr
Efficiency of the furnace = 26775000 / 33490000
= 80 %
After the installation of APH

= 26775000 Kcal/hr
Heat gain by Air-preheater = 57 x 1000 x 0.24 x (195-28)
= 2284560 Kcal/hr
Heat reduction in input to the furnace = Heat gain by Air-preheater
New Heat input to the furnace= 33490000 2284560
= 31,205,440
Efficiency of furnace after installation of APH = 26775000 / 31,205,440
= 85.8 %
L3 The management of a foundry is considering retrofitting the existing heat treatment

furnace with hot face insulation of 75 mm ceramic fibre. (Note: Hot face insulation is
known as veneering: ie over the existing refractory lining, ceramic fibre modules are
applied to reduce the heat loss during operation and heat storage loss in refractory
structure).
Furnace Operating data:
Heat Treatment furnace : (Bogey Type) Batch Operation
Furnace Capacity : 5 Ton (per batch)

Fuel type : Furnace Oil
Surface Area of 2
(1.4 x 4.5) x 2 = 12.6 m
Side walls :
2
Back Wall : 0.95 x 1.4 = 1.33 m
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2
Roof : 0.95 x 4.5 = 4.3 m
Refractory Type : Fire Bricks
Wall Thickness
Side walls : 18 inches

Arch : 13.5 inches
Number of cold starts per month: 5 Nos.
Number of batches per month : 15 Nos.
Fuel Cost : Rs 48/ kg
GCV of furnace oil : 10200 kCal/kg
2
Heat Storage (kCal /m ) for batch operation and cold start from walls and roof area
are given below.
For batch operation Cold Start
Existing(with 75 mm Existing(with 75 mm
only fire bricks) Veneering+ only fire Veneering+ fire
fire bricks bricks) bricks
Wall 79480 45350 116697 23,964
Roof 74770 31,401 97,236 16,438
For batch operation furnace is heated from 300oC to 850oC

o o
For cold start up furnace is heated from ambient 30 C to 850 C
Calculate the following due to veneering
Total heat loss reduction per month from wall and roof during batch operation.
Total heat loss reduction per month from wall and roof during cold starts.
Ans
Heat loss calculation for batch operation
Heat reduction from Wall per m2 = 79480-45350 =34130 Kcal
Heat reduction from total side wall & back wall = 34130 x13.93 =475430.90 Kcal
2 = 74770- 31401 =43369 Kcal
Heat reduction from roof per m
Heat reduction from total roof area = 43369 x 4.3 = 186486.7 Kcal
Total heat reduction per batch from wall& roof = 475430. 90 + 186486.7
= 661917.60
Number of batches per month = 15 Nos
Total heat reduction per month from wall& roof = 661917.6 x15
= 9928764 Kcals/month
Heat loss calculation for Cold Start
2 = 116697.5- 23,964.50 = 92733 Kcal

Heat reduction from Wall per m
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Heat reduction from total side wall & back wall = 92733 x13.93 = 1291770.69 Kcal
2 = 97,236 - 16,438.00 = 80798 Kcal
Heat reduction from roof per m
Total heat reduction per batch from wall& roof =1291770.69 + 347431.4
=1639202
Number of cold starts per month =5 Nos.
Total heat reduction per month from wall& roof = 8196010
Total heat reduction per month from operation and cold start =1,81,24,774kCal/month
L-4 a) Find out the efficiency of the furnace oil fired boiler by direct method in a agro
product manufacturing plant with the data given below:
Type of boiler : Furnace oil fired
Quantity of steam (dry) generated : 5 Ton per hour (TPH)
Steam pressure / temp : 10 kg/cm2(g)/ 180 oC
Quantity of oil consumed : 0.350 TPH
o
GCV of Furnace oil : 10400 kCal/kg
2
Enthalpy of saturated steam at 10 kg/cm : 665 kCal/kg
Enthalpy of feed water : 75 kCal/kg
b) The above furnace oil fired boiler was converted to coconut shell firing.
Determine the boiler efficiency by direct method after conversion.

GCV of coconut shell fuel : 4565 kCal/kg
Quantity of coconut shell consumed for the same steam demand and
pressure. : 850 kg/hr
c) The cost of fuel and operating hour of boiler are given below.
Operating hour/ year = 5000 hr

Cost of furnace oil per ton = Rs 40000/ton
Cost of coconut per ton = Rs 5000/ton
Find out the annual cost saving due to the fuel substitution fuel in the
above boiler?
ANS a)Boiler efficiency with furnace oil firing :
Boiler Efficiency ( ) = 5000 x (665-75) x 100 / (350 x 10400)
Boiler efficiency = 81% (on GCV basis)
b)Boiler efficiency with coconut shell fuel firing :
Boiler Efficiency ( ) = 5000 x (665-75) x 100/ (850 x 4565)

c) Annual cost saving
Annual furnace oil cost = 5000Hr x 0.35 x Rs 40000
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= Rs.7.0 crore
Annual coconut shell Cost = 5000 hrs x 0.85x Rs.5000
= Rs. 2.125 crore

Annual cost saving = 7.0- 2.125= Rs 4.875 Crore
L5 Explain briefly any two of the following

a) Heat Wheel
b) Topping and bottoming cycles for cogeneration with examples

c) Economic thickness of insulation
Ans a) Heat wheel
Widely used in low to medium temperature waste heat recovery systems.

A disk rotates between two side-by-side ducts: one a cold gas duct, the
other a hot gas duct.
As the disk slowly rotates, sensible heat (moisture that contains latent
heat) is transferred to the disk by the hot air and, as the disk rotates,
from the disk to the cold air.
In a topping cycle, the fuel supplied is used to first produce power and
then thermal energy, which is the by-product of the cycle and is used to
satisfy process heat or other thermal requirements ex. steam turbine,
Diesel engine, Gas turbine etc.
In a bottoming cycle, the primary fuel produces high temperature
thermal energy and the heat rejected from the process is used to
generate power through a recovery boiler and a turbine generator Power
production from waste heat of cement plant, sponge iron plant etc
As the insulation thickness increases heat loss cost reduces, At the same
time insulation cost increases. Hence there is an optimum limit to
thickness. The economic thickness of insulation is the thickness at which
the combined cost is least.
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L6 List five energy conservation measures in ANY TWO of the following:

a) Furnaces
b) Steam distribution systems
c) Boilers
Ans a) Furnaces

Correct heat distribution
Reducing heat losses from furnace openings
Waste heat recovery from the flue gases
Use of Ceramic Coatings
Steam Distribution systems

Proper Air Venting
Condensate Recovery
Reducing the Work to be done by Steam
Boilers
Reduce Stack Temperature

Combustion Air Preheating
Ensure complete Combustion
Control excess air
Ensure boiler Loading for Efficiency
Boiler Replacement for efficiency
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FOR
ENERGY MANAGERS & ENERGY AUDITORS - September 2012

Date: 15.9.2012Timings:14:00-17:00Hrs Duration:3 Hrs Max.Marks:150

1. Which of the following is not true of condensate recovery?
a) reduces water charges b) reduces fuel costs

c) increases boiler output d) increases boiler blow down
2. Which of the following is not a property of ceramic fibre ?

3. Which of the following is false?

a) LPG vapour is twice as light as air b) LPG is a mixture of propane and butane
c) LPG is a gas at normal atmospheric pressure d) LPG is required to be odorized

Which of the following in fuel contributes to erosive effect on burner tips during
combustion?
a) ash content b) water content c) sulphur content d) volatile matter
5. Tuyeres is a terminology associated with
a) induction furnace b) pusher type furnace c) arc furnace d) cupola
Turn down ratio of a burner is the ratio of
maximum to minimum fuel input without affecting optimum excess air levels
minimum to maximum fuel input without affecting optimum excess air levels
maximum to average fuel input
average to minimum fuel input
Time dependent property that determines the deformation of a refractory is
a) creep b) refractoriness under load c) porosity d) crushing strength
8. The working fluid for thermo compressor is

a) low pressure steam b) high pressure steam
c) compressed air d) waste heat from chimney
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9. The velocity of steam in steam pipe is directly proportional to


10. The unit of specific gravity in SI system is
a) kg/ m3 b) m3/kg c) gm/cc d) none of the above
11. The storage heat losses in a batch type furnace can be best reduced by
a) insulating brick b) ceramic fibre c) cold face insulation d) fire brick
12. The softening temperature of a refractory is indicated by

a) Pyrometric cone equivalent (PCE) b) refractoriness under load (RUL)
c) creep d) cold crushing strength

13. The recommended TDS level for package fire tube boilers is
a) 10,000 ppm b) 5,000 ppm c) 2,000 ppm d) 3,000 ppm
The presence of calcium and magnesium bicarbonates in feedwater to a boiler would

form

15. The mineral matter in coal after combustion mostly becomes
a) carbon dioxide b) carbon monoxide c) nitrous oxide d) ash
The emissivity of ceramic coatings used in furnace
decreases with increase in furnace temperature

Increases with increase in furnace temperature
remains constant
a) specific heat of hot fluid b) specific heat of cold fluid

c) inlet temperature of hot fluid d) LMTD
18. The device used for recovering waste heat from the textile drier exhaust is
a) heat wheel b) recuperator c) economizer d) regenerator
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20. The Brayton cycle is a characteristic of

a) steam turbine b) petrol engine c) gas turbine d) none of the above
21. The amount of flash steam generated from the condensate depends on _____
a) sensible heat of high pressure condensate b) sensible heat of flash steam
c) latent heat of flash steam d) all of the above

22. Ten meter lift of condensate in a distribution pipe work will result in
a) 0.1 bar back pressure b) 1 bar back pressure
c) 10 bar back pressure d) none of the above
23. Steam mains are run with a slope primarily to

a) avoid water hammer b) increase the velocity of steam
c) avoid condensation of steam d) reduce radiation and convection losses

24. Select the incorrect statement with respect to steam
a) evaporation is a constant temperature process
b) higher the pressure higher is the steam saturation temperature

c) higher the pressure higher is the latent heat
d) latent heat at critical point is zero

26. Reduction of steam pressure will increase
a) sensible heat b) enthalpy of steam c) saturation temperature d) specific volume
27. Recuperator as a waste heat recovery system is used mainly in a

a) boiler b) reheating furnace c) compressor d) gas turbine
Power is to be generated from a cement kiln exhaust gas. The applicable type of
a) topping cycle b) trigeneration c) bottoming cycle d) none of the above

29. Of the following fuels, which will have the highest carbon content?
a) furnace oil b) coal c) natural gas d) paddy husk

30. Low combustion temperature in FBC boilers results in the reduced formation of
a) NOx b) SOx c) CO d) CO2
31. Insulation used for temperatures more than 350C is

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a) polyurethane b) polystyrene c) calcium silicate d) wood
32. Instrument used for measuring billet temperature in a reheating furnace is ___.
a) thermograph b) infrared pyrometer

c) Pt/Pt-Rh thermocouple with indicator d) chrome alumel thermocouple with
indicator
In the direct method of efficiency evaluation of boilers which of the following is not
required?
a) enthalpy of steam b) calorific value of fuel

c) O2 in flue gas d) mass flow rate of steam
34. In the context of cogeneration turbine, the thermodynamic process taking place is
a) expansion b) condensation c) contraction d) both (a) & (c)
In determining the economic thickness of steam pipe insulation which of the following is
not required?
a) cost of fuel b) boiler efficiency c) steam pressure d) heat content of fuel
If 10% air is entrained in a steam system at 3 kg/cm 2 g then the saturation temperature
of steam will be
less than the saturation temperature at 3 kg/cm 2 g

2
more than the saturation temperature at 3 kg/cm g
2
equal to the saturation temperature at 3 kg/cm g
2
equal to the saturation temperature at 3.3 kg/cm g
Ideal furnace for melting & alloying is
a) induction furnace b) cupola furnace c) rotary hearth d) recirculating bogie
furnace
38. Heat transfer in a reheating furnace is achieved by
a) conduction b) convection c) radiation d) all of the above

39. Glass mineral wool can be applied for temperature range application upto
a) 950 oC b) 500 oC c) 1200 oC d) 750 oC
40. Fly ash in a FBC boiler is in the range of

a) 20% b) 30% c) 40% d) none of the above
41. Dolomite is a ________ type of refractory

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42. Density of liquid fuels are measured at a reference temperature of

a) 0C b) 15C c) 25C d) 30C
43. Conditioning of coal with water in certain boilers is done to

a) increase unburnt losses b) increase GCV
c) minimize losses of fine coal particles d) increase convection heat transfer

44. Comparatively, lowest excess air is required in a

45. Commonly used flux medium in a cupola furnace
a) calcium carbide b) fluorspar c) calcium carbonate d) sodium carbonate
46. Capillary wick is a part of

a) heat pump b) heat wheel c) heat pipe d) heat recovery steam
generator
47. An element in fuel oil responsible for corrosion in exhaust system of a boiler is
a) carbon b) hydrogen c) sulphur d) chlorine
48. An axial compressor is used in conjunction with

a) gas turbine b) back pressure steam turbine
c) condensing steam turbine d) all of the above

100 kg of a fuel contains 2% sulphur. For complete combustion of sulphur it will require
_________kg of oxygen
a) 2 b) 4 c) 50 d) 200
50. ____________ is predominantly used as a medium for soot blowing in boilers .
a) compressed air b) steam c) high pressure water d) all of the above

S-1 a. Steam should be used in the process at the lowest acceptable pressure . Explain
the significance of the terms lowest and acceptable
b. Explain briefly about turbine heat rate. How is it related to turbine efficiency ?
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Ans a.
lowest : Lower the pressure higher is the latent heat which is primarily used in the
process. Hence the lowest pressure would be desirable.
acceptable: However the lower the steam pressure lower will be the steam
temperature. Since the temperature is the driving force for heat transfer, rate of heat
transfer reduces and increases process time. Therefore there is a limit to the reduction
in steam pressure.
b.
Heat rate is the heat input to turbine, needed to produce 1 kWh of electricity
Turbine efficiency is the ratio useful heat and power output, to the heat input to the
turbine in Kcal or KJ, expressed as a percentage. Performance of steam turbine is

also expressed as heat rate, which is the quantity of heat in kCal or KJ required to
generate 1 kWh of electrical power output.
Turbine heat rate is expressed in kJ/kWh. The inverse relation between heat rate and
efficiency is applicable only to a power plant, since all the input energy is deployed
for power generation alone.
S-2 A process requires 6.5 tons/hr of dry saturated steam at 7 kg/cm 2g having specific
volume of 0.28 m3/kg. For the flow velocity not to exceed 25 m/s, determine the pipe
diameter.
3
Ans Volumetric flow rate = 6500 x 0.28 = 1820 m /hr
= 1820/3600
3
= 0.505 m /s
Cross sectional area = volumetic flow rate / velocity
3.14 x D2/4 = 0.505 / 25

= 0.0202
D2 = 0.0257
Diameter, D = 0.160 m (or) 160 mm
S-3 A vessel has to be cooled from 90C to 45C. The mass of the vessel is 2 tonnes. The
specific heat of vessel material is 0.18 kCal/kg C. The vessel is cooled with water
which is available at 28C. The maximum allowed increase in water temperature is
6C. Calculate the quantity of water required for vessel cooling.
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Ans Mass of vessel (m) = 2000 kg

Specific heat (Cp) = 0.18 kCal/kg C
Initial vessel temperature (T1) = 90C
Desired vessel temperature (T2) = 45C
Total heat that has to be removed from the vessel = m x Cp x (T1 - T2)
= 2000 x 0.18 x (90-45)

= 16200 kCal
Quantity of water required = M kg
Specific heat of water = 1 kCal/kg C

Inlet cooling water temperature (T3) = 28C
Maximum cooling water outlet temperature (T4) = 34C
Heat removed by water, 16200 = M x 1 x (34 - 28)
Quantity of water required , M = 12600/6 = 2700 kg
S-4 a) 350 kg/hr of hot condensate from a heat exchanger is coming out at 6 bar(g) with a
sensible heat of 166 kCal/kg. Using a flash vessel, the condensate is flashed to 1
bar(g) with a sensible heat of 120 kCal/kg and latent heat of 526 kCal/kg. Find out
the flash steam generation in kg/hr.
o o
b) The flash steam produced above is used to heat water from 30 C to 80 C by direct
injection. Calculate the quantity of hot water in that can be obtained per hour.
Ans a) Flash steam available % =( S1 - S2 ) / L2

Flash Steam generated = ( 166 120) x 350
526
= 30.6 Kg/hr.
b) Quantity of hot water generated
m x cp x (80-30) = 30.6 x (120+526)
m = 395 kg/hr
S-5 Explain any two proven methods of testing steam traps?
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ANS There are two proven methods of testing of steam traps: - Sound method and
Temperature method.
1.Sound Method : Mechanisms within steam traps and the flow of steam and
condensate through steam traps generate sonic (audible to the human ear) and
supersonic sounds. Proper listening equipment, coupled with the knowledge of
normal and abnormal sounds, can yield reliable assessments of steam trap working
condition. Listening devices range from a screwdriver or simple mechanic's
stethoscope that allow listening to sonic sounds.
2.Temperature Method: Saturated steam and condensate exist at the same
temperature. So it's not possible to distinguish between the two based on temperature.
Still, temperature measurement provides important information for evaluation
purposes.
A cold trap (i.e., one that is significantly cooler than the expected saturated steam
temperature) indicates that the trap is flooded with condensate, assuming the trap is in
service. On the other hand, the temperature downstream of the trap will be nearly
constant if significant steam is getting past the trap. At the low-end, spitting on the
trap and watching the sizzle provides a general indication of temperature.
Finally, non-contact (i.e., infrared) temperature measuring devices provide the
precision of thermometers and thermocouples without requiring physical contact.

Non-contact temperature measurement makes it easier to evaluate traps that are
relatively difficult or dangerous to access closely.
S-6 In a paper industry, 35,000 kg/hr of soda liquor with specific heat of 0.38 kCal/kgC
is heated using saturated steam at 8 bar in a heat exchanger from 60C to 120C.
Calculate the LMTD of the exchanger & the amount of steam required for heating
using the following data:

Pressure Temperature
(bar) C Water Evaporation Steam
8.0 170 170 490 660
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Ans a) Heat gain by soda liquor = 35000 x 0.38 x (120-60)

= 798000 Kcal/hr
Heat lost by saturated steam = 798000 Kcal/hr
Steam required for heating = 798000 / 490
= 1628 Kg/hr
Amount of steam required for heating is 1.63 Ton/hr
b)LMTD calculation = (170-120)-(170-60)
Ln (170-120)
(170-60)
= (50-110)/ln(50/110)
= 76.1C
S-7 Write short notes on factors affecting wall losses in batch type reheating furnaces?
Ans a) Emissivity of walls : Emissivity of fire brick refractory should be high

Emissivity of most of the refractory bricks decreases with increase in
temperature. High emissivity coatings whose emissivity increases with
temperature can be used to increase emissivity and decrease wall losses.
b) Conductivity of refractories: The refractory and insulating bricks should have
low thermal conductivity. Chosing low thermal conductivity bricks will

reduce wall losses. Conductivity raises with rise in temperature. Batch type
furnaces can use ceramic fibre to reduce storage losses.
c) Wall thickness of Wall thickness of batch furnaces: Heat losses can be
reduced by increasing the wall thickness, or through the application of

insulating bricks. Outside wall temperature and heat losses for a composite
wall of a certain thickness of firebrick and insulation brick are much lower
due to lesser conductivity of may be worked out to reduce the heat storage.
S-8 The evaporation ratio of a coal fired boiler is 4.50. A quantity of 600 kCal/kg of heat
is added to the feed water in the boiler to produce the steam.
If the GCV of coal is 3800 kCal/kg, find out the boiler efficiency.
Find out the total enthalpy of the steam as per the details of the data given below
Saturation temperature = 143oC
Sensible heat = 143.7 kCal/kg
Latent heat = 509.96 kCal/kg
Specific volume = 0.47 m3/kg
Dryness fraction of steam = 92%
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Ans
a) Boiler efficiency (%) = Evaporation ratio x enthalpy added x
100 GCV of coal
Boiler efficiency = 4.5 x 600/3800

= 71 %
Total enthalpy of steam = 143.7 + (0.92 x 509.96 )

612.86 kCal/kg
------- End of Section - II ---------

L-1 a) Find out the efficiency of the furnace oil fired boiler by direct method in a agro
product manufacturing plant with the data given below:
Quantity of steam (dry) generated : 5 Ton per hour (TPH)
Steam pressure / temp : 10 kg/cm2(g)/ 180 oC
Feed water temperature : 75 oC
2
Enthalpy of saturated steam at 10 kg/cm : 665 kCal/kg
b) The above furnace oil fired boiler was replaced by a new coconut shell
fired boiler. Determine the boiler efficiency of the new coconut shell fired
boiler by direct method
GCV of coconut shell fuel : 4565 kCal/kg
Quantity of coconut shell consumed for the same steam demand and
pressure. : 850 kg/hr
c) The cost of fuel and operating hour of boiler are given below.
Operating hour/ year = 7000 hr

Cost of furnace oil per ton = Rs 40000/ton
Cost of coconut per ton = Rs 5000/ton
Find out the annual cost saving due to boiler replacement and fuel
substitution?
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ANS a)Boiler efficiency with furnace oil firing :

Boiler Efficiency ( ) = 5000 x (665-75) x 100 / (350 x 10400)
b)Boiler efficiency with coconut shell fuel firing :
Boiler Efficiency ( ) = 5000 x (665-75) / (850 x 4565)

c) Annual cost saving
Annual furnace oil cost =7000Hr x 0.35 x Rs 40000
= Rs.9.8 crore
Annual coconut shell Cost =7000 hrs x 0.85x Rs.5000
= Rs. 2.975 crore

Annual cost saving =9.8- 2.975= Rs 6.825 Crore
L2 Explain briefly any two of the following

a) Heat Wheel
b) Topping and bottoming cycles for cogeneration with

examples
Ans a) Heat wheel

Widely used in low to medium temperature waste heat recovery systems.
A disk rotates between two side-by-side ducts: one a cold gas duct, the
other a hot gas duct.
As the disk slowly rotates, sensible heat (moisture that contains latent
heat) is transferred to
the disk by the hot air and, as the disk rotates, from the disk to the cold air.
In a topping cycle, the fuel supplied is used to first produce power and
then thermal energy,
which is the by-product of the cycle and is used to satisfy process heat or
other thermal
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requirements ex. steam turbine, Diesel engine, Gas turbine etc.

In a bottoming cycle, the primary fuel produces high temperature thermal
energy and the
heat rejected from the process is used to generate power through a
recovery boiler and a
turbine generator Power production from waste heat of cement plant,
sponge iron plant etc
c) Economic thickness of
insulation
As the insulation thickness increases heat loss cost reduces, At the same
time insulation cost
increases. Hence there is an optimum limit to thickness. The economic

thickness of insulation
is the thickness at which the combined cost is least.
3
L-3 In a crude distillation unit of a refinery, furnace is operated to heat 500 m /hr of crude
oil from 255C to 360C by firing 3.4 tons/hr of fuel oil having GCV of 9850 kcal/kg.
As an energy conservation measure, the management has installed an air preheater
(APH) to reduce the flue gas heat loss. The APH is designed to pre-heat 57 tonnes/hr
of combustion air to 195C.
Calculate the efficiency of the furnace before & after the installation of APH.
Consider the following data:
Specific heat of crude oil = 0.6 kcal/kgC

Specific heat of air = 0.24 kcal/kgC
Specific gravity of Crude oil = 0.85
Ambient temperature = 28C.
ANS Before the installation of APH

= 26775000 Kcal/hr
Heat input to the furnace = 3.4 x1000x 9850
= 33490000 kcal/hr
Efficiency of the furnace = 26775000 / 33490000
= 80 % 5 marks
After the installation of APH

= 26775000 Kcal/hr
Heat gain by Air-preheater = 57 x 1000 x 0.24 x (195-28)
= 2284560 Kcal/hr
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Heat reduction in input to the furnace = Heat gain by Air-preheater
New Heat input to the furnace= 33490000

2284560 = 31,205,440
Efficiency of furnace after installation of APH = 26775000 /
31,205,440 = 85.8 %
List five energy conservation measures in ANY TWO of the following:
L4
Furnaces
Steam distribution systems
Boilers
a) Furnaces
Ans
Correct heat distribution
Reducing heat losses from furnace openings
Waste heat recovery from the flue gases
Use of Ceramic Coatings
Steam Distribution systems

Proper Air Venting
Condensate Recovery
Boilers
Reduce Stack Temperature

Combustion Air Preheating
Ensure complete Combustion
Control excess air
Ensure boiler Loading for Efficiency
Boiler Replacement for efficiency
L-5
Paddy husk is being used as a fuel in a water tube boiler. The ultimate analysis of fuel is
given below. Calculate the theoretical quantity of air required for complete
combustion and also compute the quantity of CO 2, H2O and SO2 generated per 1000
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kg of fuel. The ultimate analysis of paddy husk is given below.
Ultimate analysis of paddy husk %

Moisture 10.8
Mineral Matter 16.7
Carbon 34.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5
GCV (kCal/kg) 3570
ANS
Considering a sample of 100 kg of paddy husk. The chemical reactions are:
Oxygen required for complete combustion of carbon:
C+ O2 CO2
(34.0) C + (34 x 2.67) O2 124.78 CO2
90.78
Oxygen required for complete combustion of hydrogen:
H2 + O2 H2O
(5) H2 + (5 x 8) O2 45 H2O
40
Oxygen required for complete combustion of sulphur:
S + O2 SO2
(0.1) S + (0.1 x 1) O2 0.2 SO2
0.1
Total Oxygen required = 90.78 + 40 + 0.1 = 130.88
Total oxygen required for 1000 kg of fuel = 130.88 x 10 = 1308.8 kg

(If calculation is done for 1 kg or 100 kg or 1000 kg full marks may be given)
Oxygen already present in 1000 kg fuel (given) = 325 kg

Additional Oxygen Required = 1308.8 -325 =983.8
Therefore quantity of dry air reqd. = (983.38) / 0.23 =4270
CO2 generated per 1000 kg of fuel = 1247.8 kg
H2O generated per 1000 kg of fuel = 450 kg

SO2 generated per 1000 kg of fuel = 2 kg
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L6 The management of a foundry is considering retrofitting the existing heat treatment

furnace with hot face insulation of 75 mm ceramic fibre. (Note: Hot face insulation is
known as veneering: ie over the existing refractory lining, ceramic fibre modules are
applied to reduce the heat storage in refractory structure).
Operating data:
Heat Treatment furnace : (Bogey Type) Batch Operation
Furnace Capacity : 5 Ton (per batch)

Fuel type : Furnace Oil
Area (1.4 x 4.5) x 2 = 12.6 m2
Side walls :
Back Wall : 0.95 x 1.4 = 1.33 m2
Roof : 0.95 x 4.5 = 4.3 m2
Refractory Type : Fire Bricks
Wall Thickness
Side walls : 18 inches
Arch : 13.5 inches
Number of cold starts per month: 10 Nos.
Number of batches per month : 20 Nos.
Fuel Cost : Rs 48/ kg
GCV of furnace oil : 10200 kCal/kg
2
Heat Storage (kCal /m ) for batch operation and cold start from walls and roof area
are given below.
For batch operation Cold Start
Existing(with 75 mm Existing(with 75 mm
only fire bricks) Veneering+ only fire Veneering+ fire
fire bricks bricks) bricks
Wall 79480 45350 116697 23,964
Roof 74770 31,401 97,236 16,438

o o
For batch operation furnace is heated from 300 C to 850 C
For cold start up furnace is heated from ambient 30 oC to 850oC
Calculate the following due to veneering
Total heat loss reduction per month from wall and roof during batch operation.
Total heat loss reduction per month from wall and roof during cold starts.
Ans
Heat loss calculation for batch operation
Heat reduction from Wall per m2 = 79480-45350 =34130 Kcal
Heat reduction from total side wall & back wall = 34130 x13.93 =475430.90 Kcal
_________________________ 15
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Heat reduction from roof per m2 = 74770- 31401 =43369 Kcal

Total heat reduction per batch from wall& roof = 475430. 90 + 186486.7
= 661917.60
Number of batches per month = 20 Nos.
Total heat reduction per month from wall& roof = 661917.6 x 20
= 13238352 Kcals/month
Heat loss calculation for Cold Start
2 = 116697 - 23,964 = 92733 Kcal

Heat reduction from Wall per m
Heat reduction from total side wall & back wall = 92733 x13.93 = 1291770.69 Kcal
Heat reduction from roof per m2 = 97,236 - 16,438 = 80798 Kcal
Heat reduction from total roof area = 80798.5 x 4.3 = 347431.4 Kcal
Total heat reduction per batch from wall& roof =1291770.69 + 347431
=1639202.09
Number of cold starts per month =10Nos.
Total heat reduction per month from wall& roof = 16392020.9
_________________________ 16

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Paper 2 Set A

FOR
ENERGY MANAGERS & ENERGY AUDITORS August, 2014
Date:23-8-2014 Timings:14:00-17:00 Duration: 3 HRS Max. Marks: 150

Please hatch the appropriate oval in the OMR answer sheet with black pen or HB pencil.
1. If the terminal temperature differences at the hot and cold end of a heat exchanger
is same, then the LMTD is
a) 100 oC b) 0 oC c) 50 oC d) none of the above
a) coconut shell b) natural gas c) oil d) rice husk
3. Which of these is not true of critical point of steam/water mixture?

a) the temperature at critical point is 374.15oC

a) LPG b) methane c) hydrogen d) diesel

operation in a
c) orifice type trap d) none of the above
6. Which of the following will be ideal for heat transfer in a heat exchanger?
7. What is the predominant mode of heat transfer in reheating furnaces?

generated
_________________________ 1
Paper 2 Set A
a) 5-10% b) 20-30% c) 30-40% d) 40-45%

9. In an oil fired steam boiler the Air to fuel ratio by mass is 15:1 & evaporation ratio is
14:1. The flue gas to fuel ratio will be
a) 29:1 b) 16:1 c) 1:1 d) 15:1
10. The cogeneration system which has high overall system efficiency is one which
uses
11. Regenerator is used mainly along with a
a) boiler b) high temperature furnace
12. The device used to upgrade a lower pressure steam to a higher pressure steam is
called
a) heat pump b) thermo compressor c) heat pipe d) heat wheel


14. Which agro-residue has the lowest gross calorific value?
a) deoiled bran b)paddy husk c)sawdust d) coconut shell

a) LDO b) Furnace oil c) LSHS d) Kerosene

a) low thermal conductivity b) high heat capacity
c) light weight d) thermal shock resistance

17. For stoichiometric combustion of 1 kg of carbon, the required amount of air will be
about
a) 31 kg b) 21 kg c) 11.6 kg d) 2.67 kg
18. For coal fired system, the flame length is influenced by

a) moisture b) volatile matter c) ash content d) fixed carbon
.
19. Which of the following in fuel contributes to erosive effect on burner tips?
a) ash b) water c) sulphur d) volatile matter
_________________________ 2
Paper 2 Set A
20. The largest heat loss in the heat balance of a coal fired boiler is due to

21. Water treatment for steam boilers is generally required to
a) remove hydrogen b) prevent scale formation
22. The stoichiometric air to natural gas ratio by volume for complete combustion is
a) 14-15 b) 7-8 c) 9.5-10.5 d) none of the above

24. For transporting the steam to the long distance, the best quality of steam is
25. In a steam system, the purpose of air venting is because air

a) is a good conductor b) acts as insulator c) is inert d) is diluent
26. The inverted bucket trap operates on the principle of _______ difference between
water and steam
27. Furnace wall heat loss does not depend on ______

28. The insulation material suitable for low temperature application to prevent heat
gain is
29. In FBC boiler, the combustion is carried out at a temperature

a) closer to steam temperature. b) adiabatic combustion temperature
c) below ash fusion temperature d) above ash fusion temperature
30. The material used to control SOx in the FBC boiler is

31. In an industry, exhaust gas from the furnace is used for power generation by
installing waste heat recovery steam boiler and a steam turbine. This type of co-
generation is termed as
a) combined cycle b) Braton cycle c) topping cycle d) bottoming cycle
32. F&A( from and at) rating of the boiler is the amount of steam generated from
_________________________ 3
Paper 2 Set A
a) water at 0 oC to saturated steam at 100 oC
b)water at feed water temperature to saturated steam at 100 oC

c)water at 100 oC to saturated steam at 100 oC
d)water at ambient temperature to saturated steam at 100 oC
33. Pinch analysis of heat exchangers depicts plot of
a) temperature vs entropy b) temperature vs area
c) temperature vs specific heat d) temperature vs enthalpy

a) specific heat of hot fluid b) inlet temperature of hot fluid
c) inlet temperature of cold fluid d) LMTD
35. Parameter assumed to remain constant during LMTD calculation of a heat

exchanger is
a) temperature drop b) heat transfer area
c) specific heat of fluids d) all the above

36. How much kg of SO2 is produced in complete combustion of 32 kg of sulphur?
a) 16 b) 32 c) 64 d) 128
37. Micro turbine can be used to replace _______ for energy savings
a)gas turbines b) diesel generator c) HRSG d) PRV
38. When steam pressure reduces, which of the following increases ?

a ) sensible heat b) enthalpy of steam

39. If excess air is 20% in a boiler, the excess oxygen in flue gas would be
a) 3.5% b) 4% c) 2% d) 1.5%
40. Which of the following requires the lowest stoichiometric oxygen demand (kg/kg of
fuel)?
a) hydrogen b) carbon c) sulphur d) methane
41. Temperature control in fuel oil storage tank is intended to control

a) viscosity b) density c) specific heat d) caloric value

a) thermal conductivity b) heat capacity
c) resistance to slag penetration d) all of the above

43. In a CFBC boiler,the capture and recycling of bed material is accomplished by
a) bag filter b) settling chamber c) cyclone d) scrubber system
_________________________ 4
Paper 2 Set A
44. Bomb calorimeter is used to measure

a) atmospheric pressure b) pour point of liquid Fuels
c) calorific value of fuels d) viscosity of fuel
46. In a steam turbine power plant, vacuum is generated at

a) turbine inlet b) condenser c) deaerator d) all of the above

differences
c) heat transfer between a liquid and gas
d) corrosive gases
48. In a condenser, which part of the heat of the steam is rejected?
a) super heat b) latent heat
c) sensible heat d) latent heat and super heat
49. The highest energy loss occurs in which of the following thermal power plant
equipment ?
a) boiler b) steam turbine c) generator d) condenser
50. Which of the following gives a rough estimate of calorific value of coal ?
a) moisture content b) volatile matter c) fixed carbon d) ash content
-------- End of Section - I ---------
Answer all eight questions

Each question carries five marks
S1 An economizer was installed in the furnace-oil fired boiler. The following are the data
monitored after commissioning the economiser.
Air to fuel ratio = 20
Evaporation ratio of the boiler = 12
Specific heat of flue gas = 0.25 kcal/kgOC.
Condensate recovery in the plant = Nil.
Calculate the rise in temperature of feedwater in an economizer, which brings down the flue
gas temperature from 280 OC to 180 OC.

_________________________ 5
Paper 2 Set A
Ans
For 1 kg of fuel, steam generated = 12 kg
For 1 kg of fuel, required combustion air = 20 kg
For 1 kg of fuel, flue gas generated = 20 +1= 21 kg
In economizer heat given by flue gas = heat received by water
21 x 0.25 x (280-180) = 12 x 1 x T
Rise in temperature of water T = 43.75 C
S2 Hot condensate from a heat exchanger is coming out at 9 bar with a sensible heat of 176.4
kcal/kg. The condensate is flashed to 3 bar with a sensible heat of 133.4 kcal/kg and latent
heat of 517 kcal/kg. The flash steam generated is 50 kg/hr.
Find out the flow rate of hot condensate in kg/hr from the heat exchanger..
Ans =S1- S2 / L2
% Flash steam available = (176.4-133.4) / 517
=8.3 %
Flow rate of hot condensate = 50/.083
= 602 kg/hr.
S3 The measured CO2 in flue gas of oil fired boiler is 10 % against the theoretical CO 2 content
of 14.5 %, Air to fuel ratio for combustion in the boiler is found to be 20. Calculate the
theoretical air required for combustion.
% Excess air = (Theoretical CO2 / Actual CO2 ) 1
Ans
(14.5 / 10) 1
45 %
Theoretical air required for combustion = 20 / 1.45
= 13.8 kg of air / kg of fuel
S4 A gas turbine generator is operating with naphtha as a fuel. The following are the data
collected during the gas turbine generator operation:
Fuel (Naphtha) consumption = 350 kg/hr
GCV of naphtha fuel = 10550 kcal/kg

Overall efficiency of gas turbine generator = 35 %
Cost of naphtha fuel = Rs 45000 / ton
Find out the cost of generating one unit of electricity.
Ans = 10550 * 350

Heat input to the turbine
= 3692500 kcal/hr
Gas Turbine Output = [(3692500x0.35) / 860]

= 1503 kWh
Cost of generating 1503 units of electricity = 350 kg/hr x Rs 45.0
_________________________ 6
Paper 2 Set A
= Rs. 15750
Cost of one unit of electricity generated = 15750 / 1503
= Rs 10.5 per kWh
S5 A paint drier requires 75.4 m3/min of air at 93C, which is heated in a steam-coil unit with 4
bar saturated steam. The density of air is 1.2 kg/m3 and specific heat of air is 0.24
kcal/kgC. Inlet air temperature to drier is 32C.

pressure temperature
bar C Water Evaporation Steam
4.0 143 143 510 653
How many kg of steam at 4 bar does this steam coil unit require per hour?
Ans Air flow rate (vol) = 75.4 m3/min x 60

= 4524 m3/hr
Air flow rate (mass) = 4524 x 1.2
= 5428.8 kg/hr
Sensible heat of air = m x Cp x T
= 5428.8 x 0.24 x (93-32)
= 79477 kcal/hr
Latent heat of Steam = 510 kcal/kg
Steam required = 79477 / 510
Steam required = 156 kg/hr
S6 List three functions of steam traps. What type of trap is generally used for main
steam lines?
Ans i) Page no 80 & 81

To discharge condensate as soon as it is formed
Not to allow steam to escape
To be capable of discharging air and other incondensable gases
ii) Thermodynamic steam trap is used in the main line
S7 Explain with sketch the working principle of a regenerator used for high temperature
furnace
Ref page no 222

Ans
_________________________ 7
Paper 2 Set A
S8 Explain briefly the bottoming cycle cogeneration system and mention any two of its
application in industry
Ans i) Ref page no 191
_________________________ 8
Paper 2 Set A
ii) steel, cement, ceramic, glass industry
-------- End of Section - II ---------
Answer all SIX questions

L1 A counter-flow double pipe heat exchanger using hot process liquid is used to heat water,
which flows at 10.5m3/hr. The process liquid enters the heat exchanger at 180C and leaves
at 130C. The inlet and exit temperature of water are 30C and 90C respectively. Specific
heat of water is 4.18 kJ/kgC.
Calculate the heat transfer area, if overall heat transfer coefficient is 814 W/m2C..
What would be the percentage increase in area, if the fluid flows were parallel?
Ans Water flow rate = 10.5 x 1000 = 10500 kg/hr
Heat content in water = m x Cp x T
= 10500 x 4.18 x (90 30)

= 2633400 KJ/hr
= 2633400 / 3600
= 731.5 kW
For Counter current flow:
T1 = 180 90 = 90C
T2 = 130 30 = 100C
LMTD of counter flow = (100-90)/ ln(100/90) = 95C
_________________________ 9
Paper 2 Set A
Overall heat transfer coeff. = 814 W/m2C
Area of heat exchanger for counter flow = 731.5 x 1000 / (814x 95 )
= 9.5 m2
For Parallel flow:
T1 = 180 30 = 150C
T2 = 130 90 = 40C
LMTD of parallel flow = (150-40)/ ln(150/40) = 83C
Area of heat exchanger for parallel flow = 731.5 x 1000 / (814 x 83 )
= 10.8 m2
Increase in the area for parallel flow = [(10.8 9.5) / 9.5] x 100
= 14 %
L2 In a chlor-alkali plant, 100 TPD caustic solution at 30% concentration is dried to 55%
concentration in a single effect evaporator, where the ratio of steam input to moisture
removal is 1.0 kg/kg. It is proposed to be replaced by a triple effect evaporator at an
investment cost of Rs. 5 crore, for which the ratio of steam input to moisture removal is 0.45
kg/kg. Steam for the evaporator is generated from an oil fired boiler at an evaporation ratio
of 14 which operates for 300 days in a year.
Calculate payback period if the cost of Fuel Oil is Rs.50,000 per ton.
Ans
% salt concentration at inlet = 30%
% salt concentration at outlet = 55%
Input quantity of caustic solution to drier = 100 TPD
Amount of salt at drier inlet = 100x 0.3 = 30 TPD
Flow rate of salt solution at drier outlet = 30 / 0.55 = 54.5 TPD
Amount of water removed = 100 54.5

= 45.5 TPD
Ratio of steam / moisture for single effect = 1.0
Amount of steam required for single effect = 45.5 TPD
Ratio of steam / moisture for triple effect = 0.45

Amount of steam required for triple effect = 45.5 x 0.45
= 20.475 TPD
Amount of steam saved by triple effect = 45.5 20.45
= 25 TPD
Evaporation ratio = 14
Amount of fuel savings = 25 / 14 = 1.79 TPD
_________________________ 10
Paper 2 Set A
FO savings per year = 1.79 x 300
= 537 Tons/year
Cost of FO saved = 537 x 50,000
= Rs. 2.69 Crores per year
Investment on triple effect evaporator = Rs. 5 Crores
Payback period = 5 / 2.69
= 1.86 years (or) 22 months
L3 a) List the advantages of CFBC boilers over AFBC boilers.

b) What are the advantages of plate heat exchanger over shell and tube heat exchanger?
Ans a)
List the advantages of CFBC boilers over AFBC boilers.
i. Higher processing temperature because of high gas velocity through the system.
ii. Lower combustion temperature of about 870 oC can be achieved constantly, which
results in minimal NOx formation.
iii. The combustion air is supplied at 1.5 to 2 psig rather than 3 to 5 psig as required by
bubbling bed combustors.
iv. Higher combustion efficiency.
v. Better turndown ratio.
vi. Erosion of heat transfer surface in the combustion chamber is reduced, since the
surface is parallel to the flow. In AFBC system, the surface is generally
perpendicular to the flow.
b)
i. The heat recovery efficiency is higher for plate heat exchanger when compared with
shell and tube heat exchanger
ii. Plate heat exchanger is compact in size.
iii. If the temperature difference is small between cold and hot stream, then plate heat
exchanger is used more effectively when compared with shell and tube heat
exchanger
iv. Heat exchange surface is easily increased or decreased by addition or removal of
plates.
L4 List five energy saving measures in each of the following

a) Oil fired industrial reheating furnace.
b) Steam systems
_________________________ 11
Paper 2 Set A
b) Steam Systems
1) Avoiding Steam Leakages
2) Providing Dry Steam for Process

3) Utilising Steam at the Lowest Acceptable Pressure for the Process
4) Proper Utilization of Directly Injected Steam
5) Minimising Heat Transfer Barriers
6) Proper Air Venting
7) Condensate Recovery
8) Insulation of Steam Pipelines and Hot Process Equipments
9) Flash Steam Recovery
10) Pipe Redundancy
11) Reducing the Work to be done by Steam
12) Monitoring Steam Traps
L5 A boiler utilizes Coconut shell as fuel and the ultimate analysis (by weight %) of the fuel is
given below:
COMPONENT Ultimate ANALYSIS

%
Carbon 45
Hydrogen 5
Nitrogen 0.6
Oxygen 32
Sulfur 0.08
Mineral matter 4
Moisture 13.32
The CO2 content of the exit flue gas measured is 10%.
For 100 kg of coconut shell fuel fired calculate the following
(a) Theoretical amount of air required for combustion

(b) Theoretical CO2 content in flue gas.
(c) % excess air supplied
Ans a)
Total oxygen required =45x2.67+ 5 x 8+.08 x 1 = 160.23kg
Oxygen present in the fuel =32 kg
_________________________ 12

Paper 2 Set A
Net oxygen required =160.23 - 32 = 128.23 kg

Air required =128.23/0.23 = 557.52kg
Theoretical amount of air required for combustion =557.52 kg/100 kg of fuel.
b)
Nitrogen in the air =557.52 - 128.23 = 429.29kg
Nitrogen in the fuel =0.6kg
Moles of Nitrogen = 429.89 / 28 = 15.35
Amount of carbon dioxide in flue gas = 45 x 44/12 = 165 kg
Moles of Carbon dioxide =165 / 44 = 3.75
Moles of sulphur = 0.08 x 2/64 =0.0025
b)Theoretical CO2 content in flue gas = 3.75 / (3.75+15.35+.0025) =19.7%
c) % Excess air supplied = 100x(19.7/10) -1 = 97%
L-6 The schematic of a back pressure steam turbine cogeneration system of process plant
operating round the clock with operating data is depicted below.
If the steam requirement of the process is to be increased to 44TPH which can be met by
the existing boiler through the back pressure turbine,
find out the reduction in cost of electrical energy drawn from the grid per day due to
additional power generation ,assuming the same steam to power recovery as in the
existing case and at a grid electricity cost of Rs.7/kWh, Aux power remains the same
also find out the additional coal requirement per day?
_________________________ 13
Paper 2 Set A
Ans Present steam to power recovery ratio =40,000 kg/hr / 3,200 kWh
= 12.5 kg/kWh
Additional steam generation = 4TPH
Additional power generation potential = 4000 kg/hr /12.5 kg/kWh

=320 kW
Daily saving due to additional power generation =320 kW x24 hr x Rs.7
= Rs 53,760
Additional coal requirement per hour = 4000 x(780-135) / (0.8 x 4300)
= 750 kg/hr
b)Additional coal requirement per day =750 kg/hr x 24
= 18,000 kg/day = 18 Ton/day
_________________________ 14
Paper 2 Set B

FOR
ENERGY MANAGERS & ENERGY AUDITORS August, 2014
Date:23-8-2014 Timings:14:00-17:00 Duration: 3 HRS Max. Marks: 150

Please hatch the appropriate oval in the OMR answer sheet with black pen or HB pencil.
1. If the terminal temperature differences at the hot and cold end of a heat exchanger
is same, then the LMTD is
a) 100 oC b) 0 oC c) 50 oC d) none of the above


a) thermal conductivity b) heat capacity
c) resistance to slag penetration d) all of the above
4. Bomb calorimeter is used to measure

a) atmospheric pressure b) pour point of liquid Fuels
c) calorific value of fuels d) viscosity of fuel
5. F&A( from and at) rating of the boiler is the amount of steam generated from
a) water at 0 oC to saturated steam at 100 oC
b)water at feed water temperature to saturated steam at 100 oC

c)water at 100 oC to saturated steam at 100 oC
d)water at ambient temperature to saturated steam at 100 oC
6. For coal fired system, the flame length is influenced by
a) moisture b) volatile matter c) ash content d) fixed carbon
.
7. For stoichiometric combustion of 1 kg of carbon, the required amount of air will be
about
a) 31 kg b) 21 kg c) 11.6 kg d) 2.67 kg
_________________________ 1
Paper 2 Set B
8. For transporting the steam to the long distance, the best quality of steam is
9. Furnace wall heat loss does not depend on ______


differences
c) heat transfer between a liquid and gas
d) corrosive gases
11. How much kg of SO2 is produced in complete combustion of 32 kg of sulphur?
a) 16 b) 32 c) 64 d) 128
12. If excess air is 20% in a boiler, the excess oxygen in flue gas would be
a) 3.5% b) 4% c) 2% d) 1.5%
13. In a CFBC boiler,the capture and recycling of bed material is accomplished by

a) bag filter b) settling chamber c) cyclone d) scrubber system
14. In a condenser, which part of the heat of the steam is rejected?

a) super heat b) latent heat
c) sensible heat d) latent heat and super heat
generated
a) 5-10% b) 20-30% c) 30-40% d) 40-45%
16. In a steam system, the purpose of air venting is because air

a) is a good conductor b) acts as insulator c) is inert d) is diluent
17. In a steam turbine power plant, vacuum is generated at

a) turbine inlet b) condenser c) deaerator d) all of the above
18. In an industry, exhaust gas from the furnace is used for power generation by
installing waste heat recovery steam boiler and a steam turbine. This type of co-
generation is termed as
a) combined cycle b) Braton cycle c) topping cycle d) bottoming cycle
_________________________ 2
Paper 2 Set B
19. In an oil fired steam boiler the Air to fuel ratio by mass is 15:1 & evaporation ratio
is 14:1. The flue gas to fuel ratio will be
a) 29:1 b) 16:1 c) 1:1 d) 15:1
20. In FBC boiler, the combustion is carried out at a temperature

a) closer to steam temperature. b) adiabatic combustion temperature
c) below ash fusion temperature d) above ash fusion temperature
21. Micro turbine can be used to replace _______ for energy savings
a)gas turbines b) diesel generator c) HRSG d) PRV
22. Parameter assumed to remain constant during LMTD calculation of a heat

exchanger is
c) specific heat of fluids d) all the above

24. Pinch analysis of heat exchangers depicts plot of

a) temperature vs entropy b) temperature vs area
c) temperature vs specific heat d) temperature vs enthalpy
25. Regenerator is used mainly along with a

a) boiler b) high temperature furnace
26. Temperature control in fuel oil storage tank is intended to control

a) viscosity b) density c) specific heat d) caloric value
27. The stoichiometric air to natural gas ratio by volume for complete combustion is
a) 14-15 b) 7-8 c) 9.5-10.5 d) none of the above
28. The cogeneration system which has high overall system efficiency is one which
uses
29. The device used to upgrade a lower pressure steam to a higher pressure steam is
called
a) heat pump b) thermo compressor c) heat pipe d) heat wheel
operation in a
_________________________ 3

Paper 2 Set B

c) orifice type trap d) none of the above
a) specific heat of hot fluid b) inlet temperature of hot fluid
c) inlet temperature of cold fluid d) LMTD

a) LDO b) Furnace oil c) LSHS d) Kerosene
33. The highest energy loss occurs in which of the following thermal power plant
equipment ?
a) boiler b) steam turbine c) generator d) condenser
34. The insulation material suitable for low temperature application to prevent heat
gain is
35. The inverted bucket trap operates on the principle of _______ difference between
water and steam
36. The largest heat loss in the heat balance of a coal fired boiler is due to

38. Water treatment for steam boilers is generally required to

a) remove hydrogen b) prevent scale formation
39. What is the predominant mode of heat transfer in reheating furnaces?

40. When steam pressure reduces, which of the following increases ?

a ) sensible heat b) enthalpy of steam

41. Which agro-residue has the lowest gross calorific value?
a) deoiled bran b)paddy husk c)sawdust d) coconut shell
a) coconut shell b) natural gas c) oil d) rice husk
_________________________ 4
Paper 2 Set B
43. Which of the following gives a rough estimate of calorific value of coal ?
a) moisture content b) volatile matter c) fixed carbon d) ash content
44. Which of the following in fuel contributes to erosive effect on burner tips?
a) ash b) water c) sulphur d) volatile matter

a) low thermal conductivity b) high heat capacity
c) light weight d) thermal shock resistance

46. Which of the following requires the lowest stoichiometric oxygen demand (kg/kg of
fuel)?
47. Which of the following will be ideal for heat transfer in a heat exchanger?


a) LPG b) methane c) hydrogen d) diesel
50. Which of these is not true of critical point of steam/water mixture?

a) the temperature at critical point is 374.15oC
-------- End of Section - I ---------

S1 Hot condensate from a heat exchanger is coming out at 9 bar with a sensible heat of 176.4
kcal/kg. The condensate is flashed to 3 bar with a sensible heat of 133.4 kcal/kg and latent
heat of 517 kcal/kg. The flash steam generated is 40 kg/hr.
_________________________ 5
Paper 2 Set B
Find out the flow rate of hot condensate in kg/hr from the heat exchanger.
Ans =S1- S2 / L2
% Flash steam available = (176.4-133.4) / 517
=8.3 %
Flow rate of hot condensate = 40/.083
= 482 kg/hr.
An economizer was installed in the furnace-oil fired boiler. The following are the data
S2
monitored after commissioning the economiser.
Air to fuel ratio = 19

Evaporation ratio of the boiler = 12
Specific heat of flue gas = 0.25 kcal/kgOC.
Condensate recovery in the plant = Nil.
Calculate the rise in temperature of feedwater in an economizer, which brings down the flue
gas temperature from 280 OC to 180 OC.
For 1 kg of fuel, steam generated = 12 kg
For 1 kg of fuel, required combustion air = 19 kg
For 1 kg of fuel, flue gas generated = 19 +1= 20 kg
In economizer heat given by flue gas = heat received by water
20 x 0.25 x (280-180) = 12 x 1 x T
Rise in temperature of water T = 41.7 C

A gas turbine generator is operating with naphtha as a fuel. The following are the data
S3
collected during the gas turbine generator operation:
Fuel (Naphtha) consumption = 350 kg/hr

GCV of naphtha fuel = 10550 kcal/kg
Overall efficiency of gas turbine generator = 35 %
Cost of naphtha fuel = Rs 50000 / ton
Find out the cost of generating one unit of electricity.
Heat input to the turbine = 10550 * 350

Ans
= 3692500 kcal/hr
Gas Turbine Output = [(3692500x0.35) / 860]

= 1503 kWh
Cost of generating 1503 units of electricity = 350 kg/hr x Rs 50
= Rs. 17,500
Cost of one unit of electricity generated = 17500 / 1503
= Rs 11.64 per kWh
_________________________ 6
Paper 2 Set B
S4 The measured CO2 in flue gas of oil fired boiler is 11 % against the theoretical CO 2
content of 14.5 %, Air to fuel ratio for combustion in the boiler is found to be 20.
Calculate the theoretical air required for combustion.
% Excess air = (Theoretical CO2 / Actual CO2 ) 1

= (14.5 / 11) 1
= 31.8 %
Theoretical air required for combustion = 20 / 1.318
= 15.2 kg of air / kg of fuel
S5 Explain with sketch the working principle of a regenerator used for high temperature
furnace
Ans Ref page 222
S6 Explain briefly the bottoming cycle cogeneration system and mention any two of its
application in industry
Ans i) Ref page no 191
_________________________ 7
Paper 2 Set B
ii) steel, cement, ceramic, glass industry
S7 List three functions of steam traps. What type of trap is generally used for main
steam lines?
Ans i) Page no 80 & 81

To discharge condensate as soon as it is formed
Not to allow steam to escape
To be capable of discharging air and other incondensable gases
ii) Thermodynamic steam trap is used in the main line
_________________________ 8
Paper 2 Set B
S8 A paint drier requires 75.4 m3/min of air at 93C, which is heated in a steam-coil unit with 4
bar saturated steam. The density of air is 1.2 kg/m3 and specific heat of air is 0.24
kcal/kgC. Inlet air temperature to drier is 32C.

pressure temperature
bar C Water Evaporation Steam
4.0 143 143 510 653
How many kg of steam at 4 bar does this steam coil unit require per hour?
Ans Air flow rate (vol) = 75.4 m3/min x 60

= 4524 m3/hr
Air flow rate (mass) = 4524 x 1.2
= 5428.8 kg/hr
Sensible heat of air = m x Cp x T
= 5428.8 x 0.24 x (93-32)
= 79478 kcal/hr
Latent heat of Steam = 510 kcal/kg
Steam required = 79478 / 510
Steam required = 156 kg/hr
-------- End of Section - II ---------

L 1 In a chlor-alkali plant, 100 TPD caustic solution at 30% concentration is dried to 55%
concentration in a single effect evaporator, where the ratio of steam input to moisture
removal is 1.0 kg/kg. It is proposed to be replaced by a triple effect evaporator at an
investment cost of Rs. 5 crore, for which the ratio of steam input to moisture removal is 0.45
kg/kg. Steam for the evaporator is generated from an oil fired boiler at an evaporation ratio
of 14 which operates for 330 days in a year.
Calculate payback period if the cost of Fuel Oil is Rs.60,000 per ton.
_________________________ 9
Paper 2 Set B
Ans
% salt concentration at inlet = 30%
% salt concentration at outlet = 55%
Input quantity of caustic solution to drier = 100 TPD
Amount of salt at drier inlet = 100x 0.3 = 30 TPD
Flow rate of salt solution at drier outlet = 30 / 0.55 = 54.5 TPD
Amount of water removed = 100 54.5

= 45.5 TPD
Ratio of steam / moisture for single effect = 1.0
Amount of steam required for single effect = 45.5 TPD
Ratio of steam / moisture for triple effect = 0.45

Amount of steam required for triple effect = 45.5 x 0.45
= 20.475 TPD
Amount of steam saved by triple effect = 45.5 20.45
= 25 TPD
Evaporation ratio = 14
Amount of fuel savings = 25 / 14 = 1.79 TPD
FO savings per year = 1.79 x 330

= 590.7 Tons/year
Cost of FO saved = 590.7 x 60,000
= Rs. 3.54 Crores per year
Investment on triple effect evaporator = Rs. 5 Crores

= 1.41 years (or) 17 months
L2 A counter-flow double pipe heat exchanger using hot process liquid is used to heat water,
which flows at 10.5m3/hr. The process liquid enters the heat exchanger at 180C and leaves
at 130C. The inlet and exit temperature of water are 30C and 90C respectively. Specific
heat of water is 4.18 kJ/kgC.
Calculate the heat transfer area, if overall heat transfer coefficient is 760W/m2C.
What would be the percentage increase in area, if the fluid flows were parallel?
Ans Water flow rate = 10.5 x 1000 = 10500 kg/hr

Heat content in water = m x Cp x T
= 10500 x 4.18 x (90 30)

= 2633400 KJ/hr
= 2633400 / 3600
= 731.5 kW
For Counter current flow:
_________________________ 10
Paper 2 Set B
T1 = 180 90 = 90C

T2 = 130 30 = 100C
LMTD of counter flow = (100-90)/ ln(100/90) = 95C
Area of heat exchanger for counter flow = 731.5 x 1000 / (760 x 95 )
= 10.13 m2
For Parallel flow:
T1 = 180 30 = 150C
T2 = 130 90 = 40C
LMTD of parallel flow = (150-40)/ ln(150/40) = 83C
Area of heat exchanger for parallel flow = 731.5 x 1000 / (760 x 83 )
= 11.59 m2
Increase in the area for parallel flow = [(11.59 10.13) / 10.13] x 100
= 14.4 %
L 3 A boiler utilizes Coconut shell as fuel and the ultimate analysis (by weight %) of the fuel is
given below:
Component Weight %
Carbon 45
Hydrogen 5
Nitrogen 0.6
Oxygen 32
Sulfur 0.08
Mineral matter 4
Moisture 13.32
The CO2 content of the exit flue gas measured is 8 %.
For 100 kg of coconut shell fuel fired calculate the following

% excess air supplied
Ans
a)
Total oxygen required =45x2.67+ 5 x 8+.08 x 1 = 160.23kg
Oxygen present in the fuel =32 kg
Net oxygen required =160.23 - 32 = 128.23 kg
_________________________ 11
Paper 2 Set B
Air required =128.23/0.23 = 557.52kg

Theoretical amount of air required for combustion =557.52 kg/100 kg of fuel.
b)
Nitrogen in the air =557.52 - 128.23 = 429.29kg

Nitrogen in the fuel =0.6kg
Moles of Nitrogen = 429.89 / 28 = 15.35
Amount of carbon dioxide in flue gas = 45 x 44/12 = 165 kg
Moles of Carbon dioxide =165 / 44 = 3.75
Moles of sulphur = 0.08 x 2/64 =0.0025
b)Theoretical CO2 content in flue gas = 3.75 / (3.75+15.35+.0025) =19.7%
c) % Excess air supplied = 100x(19.7/8) -1 = 146 %
L4 a) List the advantages of CFBC boilers over AFBC boilers.

b) What are the advantages of plate heat exchanger over shell and tube heat exchanger?
Ans a)
List the advantages of CFBC boilers over AFBC boilers.
i. Higher processing temperature because of high gas velocity through the system.
ii. Lower combustion temperature of about 870 oC can be achieved constantly, which
results in minimal NOx formation.
iii. The combustion air is supplied at 1.5 to 2 psig rather than 3 to 5 psig as required by
bubbling bed combustors.
iv. Higher combustion efficiency.
v. Better turndown ratio.
vi. Erosion of heat transfer surface in the combustion chamber is reduced, since the
surface is parallel to the flow. In AFBC system, the surface is generally
b) perpendicular to the flow.
i. The heat recovery efficiency is higher for plate heat exchanger when compared with
shell and tube heat exchanger
ii. Plate heat exchanger is compact in size.
iii. If the temperature difference is small between cold and hot stream, then plate heat
exchanger is used more effectively when compared with shell and tube heat
exchanger
iv. Heat exchange surface is easily increased or decreased by addition or removal of
plates.
L5 List five energy saving measures in each of the following

a) Oil fired industrial reheating furnace.
b) Steam systems
_________________________ 12

Paper 2 Set B
Steam Systems

Proper Air Venting
Condensate Recovery
Pipe Redundancy
_________________________ 13
Paper 2 Set B
L-6 The schematic of a back pressure steam turbine cogeneration system of process plant
operating round the clock with operating data is depicted below.
If the steam requirement of the process is to be increased to 44TPH which can be met by
the existing boiler through the back pressure turbine,
find out the reduction in cost of electrical energy drawn from the grid per day due to
additional power generation ,assuming the same steam to power recovery as in the
existing case and at a grid electricity cost of Rs.6/kWh, Aux power remains the same
also find out the additional coal requirement per day?

Ans =40,000 kg/hr / 3,200 kWh
Present steam to power recovery ratio
= 12.5 kg/kWh
Additional steam generation = 4TPH
Additional power generation potential = 4000 kg/hr /12.5 kg/kWh

=320 kW
Daily saving due to additional power generation =320 kW x24 hr x Rs.6
= Rs 46,080
Additional coal requirement per hour = 4000 x(780-135) / (0.8 x 4300)
= 750 kg/hr
b)Additional coal requirement per day =750 kg/hr x 24
= 18,000 kg/day = 18 Ton/day
_________________________ 14
REGULAR Paper 2 Set A
Regn No: __________________
Name : __________________
th
FOR
ENERGY MANAGERS & ENERGY AUDITORS September, 2015

Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB pencil
1. Which one of the following is not true with respect to the role of nitrogen in the combustion
of any fuel
a) produces oxides of nitrogen
b) reduces the volume of combustion by-products

c) dilutes the flue gases
d) carries useful heat in flue gases
2. Which one of the following fuel has the highest hydrogen content and lowest sulphur
content
a) coal b) fuel oil c) natural gas d) LSHS
3. Which of the following yields a low CO2 reading

a) soot deposits on boiler tubes b) flue gas bypass in air pre-heater
c) proper air-fuel mixture d) air ingress in flue gas duct

4. Which of the following salt causes temporary hardness in water
a) calcium sulphate b) calcium bicarbonate
c) calcium chloride d) calcium nitrate

_________________________ 1

combustion
6. Which of the following is not required for determining economic thickness of steam line
a) cost of fuel b) boiler efficiency c) enthalpy of steam d) calorific value of fuel
7. Which of the following has the lowest stoichiometric oxygen demand (kg/kg of fuel)
8. Which of the following depends on physical properties of fluids as well as geometry of the
heat exchanger
a) overall heat transfer coefficient b) fouling coefficient
c) LMTD (Log Mean Temperature Difference) d) effectiveness

9. Which of the following contribute to spontaneous combustion of coal
a) low Volatile matter b) low fixed carbon c) less ash d) none of the above
10. Which of the following can be used as desiccant in boiler preservation

a) silica gel b) activated carbon c) un-slaked lime d) all of the above
11. Which of the following boiler water treatment ensures complete removal of salts
a) demineralization b) softening c) de-aeration d) all of the above
12. Which of the following boiler utilizes the combination of suspension firing and great firing
a) traveling grate stoker boiler b) packaged boiler
c) spreader stoker boiler d) pulverized fuel boiler

13. Which of the component is common to supercritical boiler and sub critical boiler for power
generation
a) economizer b) water walls c) re-heaters d) all of the above
14. Which fuel among the following needs temperature control during storage
a) coal b) furnace oil c) diesel oil d) kerosene
15. What happens when the float in a float trap develops a puncture
a) loss of condensate b) loss of live steam c) fails to open d) fails to close
16. Transfer of heat without a conveying medium is possible with


a) number of bends in pipe b) 5th power of the diameter of pipe
c) length of pipe d) specific volume of steam

18. The unit of overall heat transfer coefficient is
a) W/m2 K b) W2/m2 K c) W2 /m3 K d) W/m3 K
_________________________ 2

19. The thermal resistance of an insulation


d) has no relation with thermal conductivity
20. The stoichiometric amount of air required to burn 1 kg of methane is
a) 69.57 b) 4 c) 17.39 d) 16
21. The parameter assumed to remain constant during LMTD calculation of a Heat exchanger
is
c) specific heat of fluids d) none of the above

a) limestone b) alumina c) silica d) fly ash
23. The heat loss in a furnace depends on

a) emissivity of walls b) conductivity of refractory
c) wall thickness d) all of the above

24. The chemical used to prevent oxidation in boiler feedwater is
a) sodium sulphite b) sodium phosphate
c) calcium phosphate d) magnesium phosphate

25. The best time for intermittent blow down in a boiler
a) High load under full pressure b) low load under full pressure
c) high load under partial pressure d) low load under partial pressure
26. The amount of CO2 produced in complete combustion of 18 Kg of carbon
a) 50 b) 44 c) 66 d) 792


28. Removal of condensate from main steam line is done to prevent
a) steam locking b) air locking c) water hammer d) all of the above
29. Presence of _____ in flue gas confirms incomplete combustion in furnace

a) CO b) NOx c) SOx d) all of the above
30. Portable fyrite is used for the measurement of

a) CO2 content in flue gas b) O2 content in flue gas
c) stack temperature d) both (a) & (b)

31. On an inverted bucket trap, what happens to the bucket as the trap fills with water
a) it rises b) it inclines c) it sinks d) it remains stationary
_________________________ 3

32. NOx formation in FBC boilers is minimised because of

a) higher velocity of flue gas in combustion chamber
b) higher pressure of the air supplied

c) lower temperatures in the bed and combustion chamber
d) higher contact of solid particles in the flue gas
33. In which zone of cupola furnace does the conversion of CO 2 to CO take place?
a) combustion zone b) melting zone c) reduction zone d) preheating zone
34. In a fire-tube boiler, soot forms on

a) outside tube surface b) inside tube surface
c) waterside surface d) water wall surface

35. If the volatile matter in coal is low, which of the following equipment is the best waste heat
recovery option in a boiler
a) economiser b) air preheater c) deaerator d) heat pipe
36. Hydrometer is used for the measurement of

a) viscosity b) density c) water content d) humidity

38. Furnace wall heat loss depends on
c) thermal conductivity of wall brick d) all of the above

39. For flash steam calculation, flash steam quantity available depends upon

40. Enthalpy of evaporation of any vapour at its critical point will be
a) more than zero b) zero c) less than zero d) unpredictable
41. Corrosion in chimney, air pre-heater and economizer is mainly influenced by

a) sulphur content in fuel b) ash content in fuel
c) moisture content in fuel d) all of the above

42. Condensate at pressure of 4 kg/cm2 and 160oC temperature when exposed to atmosphere
will
a) become super heated b) partly convert to flash steam
c) remain as condensate d) fully convert to flash steam

43. Coal size of 75% below 75 micron is required for use in
a) spreader stoker boiler b) chain grate stoker boiler
c) fluidized bed boiler d) pulverized fuel boiler

44. Ceramic coating is used in furnaces because it enhances
_________________________ 4


45. As the pressure of water increases from 1kg/cm 2 to 8 kg/cm2, the values of enthalpy of
steam and enthalpy of evaporation respectively

a) volume stability b) heat capacity
c) Resistance to slag penetration d) all of the above

47. A small quantity of leakage of stored Liquid LPG evaporates to produce about ____ times
of volume of gas.
a) 100 b) 150 c) 250 d) 350
48. A high carbon monoxide reading indicates

a) moisture in the fuel b) high furnace temperature
c) high excess air d) none of the above

49. 2 m lift of condensate in steam pipe will result in back pressure of
a) 0.02 bar b) 0.2 bar c) 2 bar d) 20 bar
50. _____ gives an estimate of heating value of coal

a) ash content b) moisture content c) fixed carbon d) volatile matter
-------- End of Section

S-1 Determine the Energy Utilization Factor (EUF) from the following back pressure cogeneration
plant diagram and data given.
Back Pr.Steam
P =4 kg/cm2
T =165 C Process
Q =12MT/hr Plant Condensate
H =650kcal/kg
P= 4 kg/cm2
o
T= 165 C
Inlet Steam
P = 42 kg/cm2
T = 410 C
Q = 12 MT/hr BPT Power
H = 760kcal/kg Alternator 0.7 MW
Back Pr Turbine
Cogeneration Plant
_________________________ 5
Solution:
Input heat to turbine = 12,000 x 760 = 91,20,000 Kcal/hr .(1 mark)

Useful heat to process Plant = 12,000 x 650-165 = 5820,000 Kcal/hr .(1 mark)
Useful Electrical output in alternator = 700x860= 602000 Kcal/hr .(1 mark)
Energy Utilization Factor (EUF) = [(602000+5820,000) /91,20,000] x 100
= 70.42% .(2 marks)
S-2 For combustion of 500 kg/hr of natural gas containing 100% methane, calculate the
percentage of CO2 in the flue gas while 15% excess air is supplied.
Ans:

CH4 + 2 O2 CO2 + 2H2O
1 mole of Methane requires 2 moles of Oxygen.
16 Kg of Methane requires 64 Kg of Oxygen.
16 Kg of Methane produces 44 Kg of CO2.
500 Kg/hr of Methane requires 2000 Kg/hr of Oxygen.
500 Kg/hr of Methane produce 1375 Kg/hr of CO2.

. (1 mark)
Theoretical air required for combustion = 2000 / 0.23 = 8696 Kg/hr
. (1 mark)
Considering 15% excess air,
Actual air supplied for combustion is = 8696 * 1.15
= 10,000.4 Kg/hr of air

. (1 mark)
Flue gas generation with 15% excess air= 500 + 10,000.4
= 10,500.4 Kg/hr
. (1 mark)
% CO2 in the flue gas = (1375 / 10,500.4)x 100
= 13.1 %
. (1 mark)
_________________________ 6
S-3 In a sugar mill, a process requires 5000 kg/hr of dry saturated steam at 7 kg/cm2 (g). For the
flow velocity not to exceed 28 m/s, determine the pipe diameter size for distribution of steam.
Specific volume at 7 kg/cm2 = 0.24 m3/kg.
Ans:
The velocity of steam maximum = 28 m/s
Specific volume at 7 kg/cm2 = 0.24 m3/kg

Mass flow rate = 5000 kg/hr
= 5000/3600 = 1.389 kg/sec
Volumetric flow = 1.389 x 0.24 = 0.333 m3/sec
Therefore, using: . (1 mark)
Volumetric flow rate(m3/s) = Velocity (m/s) x Cross sectional area (m2)

. (1 mark)
D U 4 Volumetric flowrate
Flow velocity
D U 4 0.333
28
D U 0.123 m or123 mm
. (3 marks)
Since the steam velocity must not exceed 28 m/s, the pipe size must be at least 123 mm; the
nearest commercially available size, 150 mm, would be selected.
S-4 Paddy husk is being used as a combustion fuel in a water tube boiler. The ultimate analysis
of fuel is given below. Calculate theoretical amount of air required per 100 kg of husk for the
combustion from the following data.
Ultimate Analysis of Typical Agro Residues %

Moisture 10.8
Mineral Matter 16.7
Carbon 34.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5
_________________________ 7

Ans:
Considering a sample of 100 kg of paddy husk.
Component in % (wt) in Equation Specific Actual

fuel fuel stoichiometric stoichiometric
oxygen required oxygen required
Carbon 34 C + O2 = CO2 2.67 90.78

12 + 32 = 44 (32/12) (34 x 2.67)
Hydrogen 5 H2 + 0.5 O2 = H2O 8.0 40.0

2 + 16 = 18 (16/2) (5 x 8)
Sulphur 0.1 S + O2 = SO2 1.0 0.1

32 + 32 = 64 (32/32) (0.1 x 1)
Oxygen 32.5 (-)32.5
Nitrogen 0.9 -
Moisture 10.8 -
Mineral matter 16.7 -
Total 100 98.38
.. (4 marks)
Total Oxygen required = 98.38 kg oxygen / 100 kg fuel
Therefore theoretical quantity of dry air reqd. = 98.38 / 0.23 =427.7 kg air / 100 kg fuel
(air contains 23% oxygen by wt.)
.. (1 mark)
S-5 (a) Why should LPG cylinders not be stored in basements or cellars?
(b) Why should the stack temperature of furnace oil fired boilers not be maintained below
160-170C?
Ans:
LPG is a predominant mixture of propane and butane. Both propane and butane are denser than
air. Consequently, the vapour flows along the ground into drains and sinks to the lowest level
of the surroundings and gets ignited at a considerable distance from the source of leakage.
Escape of even small quantities of LPG can give rise to large volume of vapour mixture and
can cause considerable hazard. Hence there should be adequate
_________________________ 8
ground level ventilation where LPG cylinders are stored. For this reason LPG cylinders
should not be stored in cellars or basements, which have no ventilation at ground levels.
.(2.5 marks)
(b) For fuels containing sulphur, low temperatures (below 160-170C) of stack can lead to
sulphur dew point corrosion. The main disadvantage of sulphur is the risk of corrosion by
sulphuric acid formed during and after combustion, and condensing on cool parts of the
chimney or stack, air preheater and economiser.
.(2.5 marks)
S-6 Calculate the electricity consumption in an induction melting furnace from the following melt
cycle data
Specific heat of MS : 0.68 kJ/kg 0C

MS melting temperature : 1450 0C
Inlet MS charge temperature : 35 0C
Efficiency of furnace : 70%
Ans:
Theoretical energy required for melting = 1250 (0.68 x (1450 35) + 270)/3600
= 427.8 kWh
. (3 marks)
Actual energy input to the furnace = 427.8 / 0.7
Electricity consumption = 611.2 kWh
. (2 marks)
S-7 Feed water is provided to a boiler from the feed water tank at 60oC, temperature of
condensate water returning to the tank is 80oC, and temperature of makeup water is 27oC.
What is the amount of condensate recovered?
Solution:
_________________________ 9

27x + (1 x) 80 =60
Therefore x = 0.37
(37 percent makeup water or only 63 per cent of condensate is recovered).

.(5 marks)
S-8 Milk is flowing in a pipe cooler at a rate of 0.95 kg/sec. Initial temperature of the milk is 55 C
and it is cooled to 18 C using a stirred water bath with the constant temperature of 10C
around the pipe. Specific heat of milk is 3.86 KJ/kgC. Calculate the heat transfer rate
(kcal/hr) and also LMTD of the exchanger.
Ans:
Heat transfer in cooling milk = 0.95 * 3.86 * (55 18)
= 135.7 KJ/sec
=135.7 /4.18
= 32.46 kcal/sec
=(32.46*3600)= 116856 kCal/hr
. (2.5 marks)
LMTD: DT1 = 55 10 = 45 C
DT2 = 18 10 = 8 C
LMTD of the heat exchanger = (45 8) / ln (45 / 8)
LMTD of the heat exchanger = 21.4 C
. (2.5 marks)
-------- End of Section - II ---------
(i) Answer all SIX questions
(ii) Each question carries Ten marks
L-1 a) Find out the efficiency of the furnace oil fired boiler by the direct method in an agro product
manufacturing plant given the following data:
Quantity of steam (dry) generated : 5 TPH

Steam pressure / temp : 10 kg/cm2(g)/ 180 0C
_________________________ 10


Feed water temperature : 75 0C
Enthalpy of saturated steam at 10 kg/cm2 pressure : 665 kCal/kg
Cost of furnace oil : Rs 32/kg
Annual operating hours : 7200 hrs /year
b) The oil fired boiler was converted to coconut shell firing maintaining the same
steam and feed water parameters.

i) Determine the fuel consumption per hour
ii) Return on investment for the conversion scheme.
Fuel fired in the boiler : coconut shell fuel
GCV of coconut shell : 4200 kCal/kg

Efficiency with coconut shell firing : 76%
Cost of coconut shell : Rs 12/kg
Annual interest on capital : Rs 6 lakhs /yr
Investment towards boiler conversion : Rs 50 lakhs
Solution:
a) Efficiency of furnace oil fired boiler (Direct method)
Boiler Efficiency () = 5000 x (665-75) / (350 x 10400)
= 81% (on GCV basis) . (2.5 marks)

b) i) Coconut shell fuel consumption after conversion:
Fuel consumption = 5000 x (665-75) / (0.76 x 4200)
= 924.2 kg/hr . (2.5 marks)

ii) ROI for the conversion scheme:
Annual fuel cost of furnace oil fired boiler = 350 x 7200 x 32 = Rs 8,06,40,000 /year
.. (1 mark)
Annual fuel cost of coconut shell fired boiler = 924.2 x 7200 x 12
= Rs 7,98,50,880/year
Annual net monetary savings after conversion .. (1 mark)
= [(8,06,40,000 - 7,98,50,880) 6,00,000] x 100
50,00,000
= 3.8 % . (3 marks)
_________________________ 11
L-2 A liquid waste stream has a flow rate of 3.5 kg/s and a temperature of 70 o C with a specific
heat capacity of 4190 J/kgK. Heat recovered from the hot waste stream is used to pre-heat
boiler make-up water. The flow rate of the make-up water is 2 kg/s, its temperature is 10oC
and its specific heat capacity is 4190 J/kg/K. The overall heat transfer coefficient of the heat
exchanger is 800 W/m2K. If a make-up water exit temperature of 50oC is required, and
assuming that there is no heat losses from the exchanger, determine
1) The heat transfer rate
2) The exit temperature of the effluent and

3) The area of the heat exchanger required
Solution :
Heat gained by makeup water = Qc= mc cc T = 2 x 4190 x (50-10)

335200 W = 335.2 kW
..(2 marks)
mh ch (th1 th2) = mc cc (tc1 tc2)
x 4190 x (70 - th2) = 2 x 4190 x (50 -10) t h2

= 47.14 o C
..(3 marks)
iii) Now because the water outlet temperature is above the outlet temperature of the effluent a
counter-flow heat exchanger is required.
LMTD = t1 t2
ln (t1/ t2)
((70-50)-(47.14-10) ln
(70-50)/(47.14-10)
LMTD = 27.69oC
..(2.5 marks)
Q = UA (LMTD)
A = 335200 800
x 27.69
Area = 15.13 m2
..(2.5 marks)
_________________________ 12
L-3 Write short notes on any two of the following: (5 marks each)
a) Plate heat exchanger (page 242 of book-2)
b) Multiple effect evaporator (page 247-248 of book-2)
c) Gas turbine cogeneration system (page 192 of book-2)
L-4 a) In a typical fertiliser manufacturing plant, the quantity of 133200 Ton of Ammonia is
produced annually, using naphtha as fuel as well as raw material (feed) and electricity
from captive power plant.
Naphtha Electricity
as fuel
Naphtha Ammonia Ammonia

as feed production
raw Production
plant
The quantity of annual raw material consumption and its heating values are given in table.
Raw material Quantity Heating Value
consumption
1.Naphtha - feed 66800 Ton 10650 kCal / kg

2.Naphtha - fuel 31200 Ton 10650 kCal / kg
3.Electricity 1180 x Lakh kWh 2500 kCal/kWh
Calculate the specific energy consumption of ammonia production in Gcal / Ton.
Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing
Answer :
a) Specific Energy Consumption(SEC) of Ammonia
Raw material Quantity Heating Value Gcal

consumption
1 mark
1.Naphtha - feed 66800 Ton 10650 kCal / kg 711420
2.Naphtha - fuel 31200 Ton 10650 kCal / kg 332280 1 mark
3.Electricity 1180 x Lakh kWh 2500 kCal/kWh 295000 1 mark
1338700
Ammonia 133200 Ton
production 2marks
Specific Energy Consumption(SEC) of Ammonia production 10.05 Gcal
= per Ton
_________________________ 13

b) Schematic diagram of (i) Back Pressure Turbine and (ii) Extraction Condensing Turbine
Cogeneration systems
(2.5 marks for each schematic)
L-5 As a part of energy conservation measure, APH (Air Pre-heater) is installed in a fired heater.
The APH is designed to pre-heat 240 m3/min of combustion air to 250C. Flue gas enters the
APH at 375C. Calculate the flue gas leaving the stack and also determine the improvement
in furnace efficiency after the installation of APH with the following data
Density of air : 1.15 kg/m3
Specific heat of air : 0.23 Kcal/kgC
Specific heat of flue gas : 0.26 Kcal/kgC
Calorific value of fuel : 9850 Kcal/kg
Air to fuel ratio : 18
Efficiency of furnace : 73 %
Ambient temperature : 30C
Solution:
Amount of Air flow = 240 * 60 * 1.15
= 16560 Kg/hr
. (1mark)
Amount of fuel = 16560 / 18
= 920 Kg/hr
. (1mark)
Amount of flue gas = 16560 + 920
= 17480 Kg/hr
. (1mark)
Heat absorbed by combustion air = 16560 * 0.23 * (250 30)
= 837936 Kcal/hr
. (1.5 marks)
_________________________ 14

Temperature difference in flue gas = 837936 / (17480 * 0.26)

= 184 C
. (1.5 mark)
Flue gas leaves the stack at temp = 375 184 = 191 C
. (1 mark)
Efficiency of APH = Heat absorbed by air / Heat input * 100
= 837936 * 100 / (920* 9850)
= 9.2 %
..(2 marks)
Overall efficiency after APH = 73 + 9.2 % = 82.2 %
.. (1 mark)
L-5 A process industry is equipped with a steam power plant generating 1,00,000 units/day and a
separate low-pressure boiler generating at an average steam production of 8.3 Tons of
steam/hour at enthalpy of 630 kcal/kg for process heating. The feed water temperature to the
boiler is 70oC. The efficiencies of the steam power plant and boiler are 29% and 75%
respectively. Coal is used in both cases and calorific value of coal is 3800 kcal/kg.
The management proposes to commission a cogeneration plant retaining the coal as fuel.
The expected energy utilization factor of the cogeneration plant is 75%.

Calculate coal savings with the new cogeneration plant.
SOLUTION:
Heat input for separate production of = (100000 x 860) / (24 x 0.29) + (8.3 x (630-70)
power and useful heat x 1000))/0.75
= 12356321 + 6197333
= 18553654 kcal/hr
..(4 marks)
Heat input with cogeneration plant = [(100000 x 860) /24 + (8.3 x (630-70) x
1000)] / 0.75
= (3583333 + 4648000) / 0.75
= 10975111 kcal/hr
..(4 marks)
Coal savings = (18553654 10975111) / 3800
= 1995 kg/h
...(2 marks)
_________________________ 15
REGULAR Paper 2 Set B
Regn No: __________________
Name : __________________
th
FOR

1. Which one of the following is not true with respect to the role of nitrogen in the combustion
of any fuel

content
combustion
4. Which of the following depends on physical properties of fluids as well as geometry of the
heat exchanger
_________________________ 1


6. Which of the following boiler utilizes the combination of suspension firing and great firing

7. Which of the component is common to supercritical boiler and sub critical boiler for power
generation




12. The parameter assumed to remain constant during LMTD calculation of a Heat exchanger
is




_________________________ 2




20. Condensate at pressure of 4 kg/cm2 and 160 oC temperature when exposed to
atmosphere will




24. A small quantity of leakage of stored Liquid LPG evaporates to produce about ____
times of volume of gas.
a) 100 b) 150 c) 250 d) 350
25. Which of the following yields a low CO2 reading

a) soot deposits on boiler tubes b) flue gas bypass in air pre-heater
c) proper air-fuel mixture d) air ingress in flue gas duct


29. Which of the following contribute to spontaneous combustion of coal
_________________________ 3

a) low Volatile matter b) low fixed carbon c) less ash d) none of the above
a) demineralization b) softening c) de-aeration d) all of the above
32. What happens when the float in a float trap develops a puncture
a) loss of condensate b)loss of live steam c) fails to open d) fails to close

a) 69.57 b) 4 c) 17.39 d) 16


35. The chemical used to prevent oxidation in boiler feedwater is
a) sodium sulphite b) sodium phosphate
c) calcium phosphate d) magnesium phosphate

36. The best time for intermittent blow down in a boiler
a) High load under full pressure b) low load under full pressure
c) high load under partial pressure d) low load under partial pressure
a) 50 b) 44 c) 66 d) 792




a) it rises b) it inclines c) it sinks d) it remains stationary
43. In a fire-tube boiler, soot forms on

a) outside tube surface b) inside tube surface
c) waterside surface d) water wall surface

_________________________ 4

44. If the volatile matter in coal is low, which of the following equipment is the best waste heat
recovery option in a boiler
a) economiser b) air preheater c) deaerator d) heat pipe




48. A high carbon monoxide reading indicates
a) moisture in the fuel b) high furnace temperature
c) high excess air d) none of the above


-------- End of Section - I ---------

cycle data,
Ans: Theoretical energy required for melting = 1250 (0.68 x (1650 35) + 270)/3600
= 475.1 kWh
. (3 marks)
_________________________ 5


Electricity consumption = 730.9 kWh
. (2 marks)
S-2 (a) Why should LPG cylinders not be stored in basements or cellars? (2.5 marks)
160-170C ? (2.5 marks)
Ans:
LPG is a predominant mixture of propane and butane. Both propane and butane are denser than
air. Consequently, the vapour flows along the ground into drains and sinks to the lowest level
of the surroundings and gets ignited at a considerable distance from the source of leakage.
Escape of even small quantities of LPG can give rise to large volume of vapour mixture and
can cause considerable hazard. Hence there should be adequate ground level ventilation
where LPG cylinders are stored. For this reason LPG cylinders should not be stored in cellars
or basements, which have no ventilation at ground levels.
.(2.5 marks)
For fuels containing sulphur, low temperatures (below 160-170C) of stack can lead to
sulphur dew point corrosion. The main disadvantage of sulphur is the risk of corrosion by
sulphuric acid formed during and after combustion, and condensing in cool parts of the
chimney or stack, air preheater and economiser.
.(2.5 marks)
S-3 Feed water is provided to a boiler from the feed water tank at 60oC, temperature of
condensate water returning to the tank is 88oC, and temperature of makeup water is 27oC.
What is the amount of condensate recovered ?
Solution:
27x + (1 x) 88 =60

Therefore x = 0.36
(36 percent makeup water or only 64% of condensate is recovered).
.(5 marks)
_________________________ 6
S-4 Milk is flowing in a pipe cooler at a rate of 0.85 kg/sec. Initial temperature of the milk is 60C
and it is cooled to 22 C using a stirred water bath with a constant temperature of 10C
around the pipe. Specific heat of milk is 3.86 KJ/kgC. Calculate the heat transfer rate
(kcal/hr) and also LMTD of the exchanger.
Ans:
Heat transfer in cooling milk = 0.85 * 3.86 * (60 22)
= 124.678 KJ/sec
= 124.678 / 4.18
= 29.83 Kcal /sec
= (29.83*3600)= 107378.122 kCal/hr
. (2.5 marks)
LMTD:
DT1 = 60 10 = 50 C
DT2 = 22 10 = 12 C
LMT D of the heat exchanger = (50 12) / ln (50 / 12)
= 26.6 C
. (2.5 marks)
combustion from the following data.
Ultimate Analysis of Typical Agro Residues %

Moisture 11.8
Mineral Matter 17.7
Carbon 32.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5
Ans
_________________________ 7


Carbon 32 C + O2 = CO2 2.67 85.44

12 + 32 = 44 (32/12) (32x2.67)
Hydrogen 5 H2 + 0.5 02 = H2O 8.0 40.0

2 + 16 = 18 (16/2) (5x8)
Sulphur 0.1 S + O2 = SO2 1.0 0.1

32 + 32 = 64 (32/32) (0.1x1)
Oxygen 32.5 (-)32.5
Nitrogen 0.9 -
Moisture 11.8 -
Total 100 93.04
. (4 marks)
Therefore theoretical quantity of dry air reqd. = 93.04 / 0.23 = 404.5 kg air / 100 kg fuel
(air contains 23% oxygen by wt.)
..(1 mark)
Back Pr.Steam
P =4 kg/cm2
T =170 C Process
Q =11MT/hr
Plant Condensate
H =650kcal/kg
At P = 4 kg/cm2
T =170 C
Inlet Steam
P = 42 kg/cm2
T = 410 C
Q = 11 MT/hr Power
Back Pr Turbine Cogeneration

Plant
_________________________ 8
Solution
Input heat to turbine = 11,000 x 760 = 8360000 Kcal/hr .(1 mark)

Useful heat to process Plant = 11,000 x 650-170 = 5280000 Kcal/hr .(1 mark)
Useful Electrical output in alternator = 700x860= 602000 Kcal/hr .(1 mark)
Energy Utilization Factor (EUF) = (602000+5280000) /8360000
= 70.36% .(2 marks)
S-7 For combustion of 500 kg/hr of Natural Gas containing 100% Methane, Calculate the
Ans:

CH4 + 2 O2 CO2 + 2H2O

500 Kg/hr of Methane requires 1375 Kg/hr of CO2.
. (1 mark)
. (1 mark)

= 10435 Kg/hr of air
. (1 mark)
Flue gas generation with 20% excess air = 500 + 10435
= 10935 Kg/hr
. (1 mark)
% CO2 in the flue gas = 1375 / 10935
= 12.6 %
. (1 mark)
_________________________ 9


Ans.

= 5000/3600 = 1.389 kg/sec
Volumetric flow = 1.389 x 0.24 = 0.333 m3/sec
. (1 mark)
Volumetric flow rate(m3/s) = Velocity (m/s) x cross sectional area (m2)

D2 U 4 Volumetric flowrate . (1 mark)
Therefore, Flow velocity
D U 4Volumetric flowrate
Flow velocity
D U 40.333
25
D U 0.130 m or 130 mm
. (3 marks)
-------- End of Section - II ---------

_________________________ 10





Solution:
= 81.8% (on GCV basis)

b) i) Coconut shell fuel consumption after conversion: . (2.5 marks)
= 924.2 kg/hr . (2.5 marks)

ii) ROI for the conversion scheme:
.. (1 mark)
= Rs 7,98,50,880/year
.. (1 mark)
Annual net monetary savings after conversion
= [(8,06,40,000 - 7,98,50,880) 6,00,000] x 100

50,00,000
= 3.8 %
_________________________ 11

.. (3 marks)
L-3 a) In a typical fertiliser manufacturing plant, the quantity of 133200 Ton of Ammonia is
produced using naphtha as fuel as well as raw material (feed) and electricity from
captive power plant.
Naphtha Electricity
as fuel
Naphtha Ammonia Ammonia

as feed production
raw Production
plant
The quantity of raw material consumption and its heating values are given in table.
Raw material Quantity Heating Value
consumption
1.Naphtha - feed 56800 Ton 10650 kCal / kg

2.Naphtha - fuel 28200 Ton 10650 kCal / kg
3.Electricity 1080 x Lakh kWh 3200 kCal/kWh
Calculate the specific energy consumption of ammonia production in Gcal / Ton.
Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing
Answer
a) Specific Energy Consumption(SEC) of Ammonia
Raw material Quantity Heating Value Gcal

consumption
1 mark
1.Naphtha - feed 56800 Ton 10650 kCal / kg 604920
2.Naphtha - fuel 28200 Ton 10650 kCal / kg 300330 1 mark
3.Electricity 1080 x Lakh 3200 kCal/kWh 345600 1 mark
_________________________ 12

kWh
1250850
Ammonia 133200 Ton
production 2 marks
Specific Energy Consumption(SEC) of Ammonia 9.39 Gcal per
production = Ton
Answer
b) schematic diagram of (i)Back Pressure Turbine and (ii)Extraction Condensing

Turbine Cogeneration systems
(2.5 marks for each schematic)
APH at 375C. Calculate the flue gas leaving the stack and also determine the improvement
in furnace efficiency after the installation of APH with the following data
_________________________ 13

Solution:
= 16560 Kg/hr
. (1mark)
= 974.12 Kg/hr
. (1mark)
Amount of flue gas = 16560 + 974.12
= 17534.1 Kg/hr
. (1mark)
= 837936 Kcal/hr
. (1.5 mark)
Temperature difference in flue gas = 837936 / (17534.1 * 0.26)
= 183.8 C
. (1.5 mark)
Flue gas leaves the stack at temp = 375 183.8 = 191.2 C
. (1 mark)
Efficiency of APH = Heat absorbed by air / Heat input * 100
= 837936 * 100 / (974.12* 9850)

= 8.73 %
. (2 marks)
.. (1 mark)
o
L-5 A liquid waste stream has a flow rate of 3.5 kg/s and a temperature of 75 C with a specific
heat capacity of 4190 J/kgK. Heat recovered from the hot waste stream is used to pre-heat
boiler make-up water. The flow rate of the make-up water is 2.8 kg/s, its temperature is 12oC
and its specific heat capacity is 4190 J/kg/K. The overall heat transfer coefficient of the heat
exchanger is 800 W/m2K. If a make-up water exit temperature of 50oC is required, and
assuming that there are no heat loss from the heat losses from the exchanger, determine

Solution :
i) Heat gained by makeup water = Qc= mc cc T = 2.8 x 4190 x (50-12)
= 445816 W = 445.82 kW
ii) mh ch (th1 th2) = mc cc (tc1 tc2) . (2 marks)
3.5 x 4190 x (75 - th2) = 2.8 x 4190 x (50 -12)
th2 = 44.6 o C
..(3 marks)
_________________________ 14

counter-flow heat exchanger is required
LMTD = t1 t2
ln ( t1/ t2)
= (75-50)-(44.6-12)
ln (75-50)/(44.6-12)
= 25-32.4
ln(25/32.4)
LMTD = 28.54oC ..(2.5 marks)
Q = UA (LMTD)
= 445816
800 x 28.54
Area =19.5 m2 ..(2.5 marks)
L-6 A process industry is equipped with a steam power plant generating 1,25,000 units/day and a
separate low-pressure boiler generating at an average steam production of 9.5 Tons of
steam/hour at enthalpy of 630 kcal/kg for process heating. The feed water temperature to the
boiler is 62oC.The efficiencies of the steam power plant and boiler are 27% and 78%
respectively. Coal is used in both cases and calorific value of coal is 4000 kcal/kg.
The management proposes to commission a cogeneration plant retaining the coal as fuel.
The expected energy utilization factor of the cogeneration plant is 75%.

Calculate coal savings with the new cogeneration plant.
SOLUTION:
Heat input for separate production of = (125000 x 860) / (24 x 0.27) + (9.5 x (630-62)
power and useful heat x 1000))/0.78
= 16589506 + 6917949
= 23507455 kcal/hr
. (4 marks)
_________________________ 15

Heat input with cogeneration plant = [(125000 x 860) /24 + (9.5 x (630-62) x
1000)] / 0.75
= (4479167 + 5396000) / 0.75
= 13166889 kcal/hr
..(4 marks)
Coal savings = (23507455 13166889) / 4000
= 2585 kg/h
..(2 marks)
_________________________ 16
SUPPLIMENTARY Paper 2 Set A

FOR



3. A small quantity of leakage of stored Liquid LPG evaporates to produce about ------
a) 100 b) 150 c) 250 d) 350





o
8. Condensate at pressure of 4 kg/cm2 and 160 C temperature when exposed to
atmosphere will
_________________________ 1


9. Corrosion in chimney, air pre-heater, economizer is mainly influenced by

10. Economiser in a boiler exchanges heat between
a) flue gas & combustion air b) steam & feed water
c) steam & combustion air d) feed water & flue gas


c) thermal conductivity of wall brick d) All of the above


16. In which of following, heat loss due to moisture formation on complete combustion will
be maximum
a) LSHS b) furnace oil c) natural gas d) coal



_________________________ 2




23. Secondary air requirement for a coal fired boiler is influenced by
a) fixed carbon b) mineral matter c) volatile matter d) sulphur

a) 50 b) 44 c) 66 d) 792
operation in a
c) float trap d) inverted bucket trap


27. The inverted bucket operates on the principle of _______ difference between water and
steam

29. The parameter assumed to remain constant during LMTD calculation of a Heat
exchanger is

30. The presence of calcium and magnesium bicarbonates in water to steam boiler would
form
a) acidic solution b) basic solution c) neutral solution d) none of the above

a) 69.57 b) 4 c) 17.39 d) 16
32. The TDS level in boiler water for boiler blow down, is measured through

_________________________ 3




37. Which among the following operates at vacuum

a) heat wheels b) heat pump c) heat pipe d) all of the above
39. Which of the component is common to supercritical boiler and sub critical boiler for
power generation
40. Which of the following boiler utilizes the combination of suspension firing and great
firing

a) demineralizationb) softening c) de-aeration d) all of the above

43. Which of the following depends on physical properties of fluids as well as geometry of
the heat exchanger

45. Which of the following increases, when steam is discharged to atmosphere

a) sensible heat b) enthalpy of steam

_________________________ 4


combustion


content
50. Which one of the following is not true with respect to the role of nitrogen in the
combustion of any fuel

-------- End of Section - I ---------

(i) Answer all eight questions
(ii) Each question carries five marks
combustion from the following data
Ultimate Analysis of Paddy Husk %

Moisture 10.8
Mineral Matter 16.7
Carbon 34.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5
_________________________ 5
Ans:

Carbon 34 C + O2 = CO2 2.67 90.78
12 + 32 = 44 (32/12) (34x2.67)
Hydrogen 5 H2 + 0.5 O2 = H2O 8.0 40.0
2 + 16 = 18 (16/2) (5x8)
Sulphur 0.1 S + O2 = SO2 1.0 0.1
32 + 32 = 64 (32/32) (0.1x1)
Oxygen 32.5 (-)32.5
Nitrogen 0.9 -
Moisture 10.8 -
Total 100 98.38
(4 marks)
Therefore theoretical quantity of dry air reqd. = 98.38 / 0.23 =427.7 kg air / 100 kg fuel
(air contains 23% oxygen by wt.) (1 mark)
Ans.

= 5000/3600= 1.389 kg/sec
Volumetric flow = 1.389 x 0.24 =0.333 m3/sec (1 mark)
Therefore, using:
Volumetric flow rate (m3/s) = Velocity (m/s) x Cross sectional area (m2)
(1 mark)
_________________________ 6
Flow velocity
D U 4 0.333
28
D U 0.123 m or123 mm

(3 marks)
S-3 For combustion of 500 kg/hr of natural gas containing 100% methane, calculate the
Ans:

CH4 + 2 O2 CO2 + 2H2O


500 Kg/hr of Methane produce 1375 Kg/hr of CO2.

(2 marks)

= 999.25 Kg/hr of air
(1 mark)
Flue gas generation with 15% excess air = 500 + 999.25
= 10499.25 Kg/hr
(1 mark)
% CO2 in the flue gas = (1375 / 10499.25)x 100

= 13.1 %
(1 mark)
_________________________ 7
Back Pr.Steam
P =4 kg/cm2
T =165 C Process
Q =12MT/hr
H =650kcal/kg Plant Condensate
P= 4 kg/cm2
T= 165oC
Inlet Steam
P = 42 kg/cm2
T = 410 C
Back Pr Turbine
Cogeneration Plant
Solution:
Input heat to turbine = 12,000 x 760 = 91,20,000 Kcal/hr
(1 mark)
Useful heat to process Plant = 12,000 x 650-165 = 5820,000 Kcal/hr
(1 mark)
Useful Electrical output in alternator = 700x860= 602000 Kcal/hr
(1 mark)
Energy Utilization Factor (EUF) = [(602000+5820,000) /91,20,000] x 100
= 70.42%
(2 marks)
S-5 A steam pipe of 100mm diameter is insulated with mineral wool. As a part of energy saving
measures, the insulation is upgraded with efficient calcium silicate insulation. Calculate the
percentage reduction in heat loss as a result of implementation of the above measure given
the following data
Surface temperature with mineral wool : 95C

Surface temperature with calcium silicate : 45C
Ans:
Heat loss through non-insulated pipe = [10 + (Ts Ta) / 20] * (Ts Ta) ]
Ts = Surface temperature
Ta = Ambient temperature
_________________________ 8
=[10 + (95 25) / 20] * (95 25) ]

= 945 kcal/hr-m2 (2 marks)
Heat loss through insulated pipe = [10 + (45 25) / 20] * (45 25) ]
= 220 kcal/hr-m2 (2 marks)
% Reduction in heat loss = (945 220) / 945
= 76.7 % (1 mark)
S-6 In a heat exchanger, steam is used to heat 3.0 KL/hr of furnace oil from 30oC to 100oC. The
specific heat of furnace oil is 0.22 kcal/ kg/oC and the density of furnace oil is 0.95 gm/cc.
How much steam per hour is needed if steam at 4 kg/cm2 with latent heat of 510 kcal/ kg is
used. If steam cost is Rs. 4.0/kg and electrical energy cost is Rs.6.0/kWh, which type of
heating would be more economical in this particular case? (assume no losses in electrical
and steam heating process)

= (3 x 1000 x 0.95) x 0.22 x (100-30)
= 43890 kcal/hr (1.5 mark)
a) Amount of steam required = 43890/510
= 86 kg/hr
= Rs. 344/hr (1.5 mark)
b) Amount of electricity required = 43890/860
= 51 kWh
= 51 x Rs. 6
= Rs.306/ hr
Electrical heating will be more economical (2 mark)
cycle data

_________________________ 9

Ans:
= 427.8 kWh/hr or 427.8 kw

(3 marks)
(1 mark)
Electricity consumption = 611.2 kWh/hr or 611.2 kw
(1 mark)
160-170C ? (2.5 marks)
Ans:
(a) LPG is a predominant mixture of propane and butane. Both propane and butane are
denser than air. Consequently, the vapour flows along the ground into drains and sinks
to the lowest level of the surroundings and gets ignited at a considerable distance from
the source of leakage. Escape of even small quantities of LPG can give rise to large
volume of vapour mixture and can cause considerable hazard. Hence there should be
adequate ground level ventilation where LPG cylinders are stored. For this reason LPG
cylinders should not be stored in cellars or basements, which have no ventilation at
ground levels.
(2.5 marks)
(b) For fuels containing sulphur, low temperatures (below 160-170C) of stack can lead to
sulphur dew point corrosion. The main disadvantage of sulphur is the risk of corrosion
by sulphuric acid formed during and after combustion, and condensing in cool parts of
the chimney or stack, air preheater and economiser.
(2.5 marks)
-------- End of Section - II ---------

L-1 Oil fired Boiler is generating 100 TPH of steam at 85% efficiency, operating 330 days in a year.
Management has installed a water treatment plant at Rs 2 Crore investment for reducing the
TDS in boiler feed from 450 ppm to 150 ppm. The maximum permissible limit of TDS in the
boiler is 3000 ppm and make up water is 10%. Temperature of blowdown water is 175C and
_________________________ 10
boiler feed water temperature is 45C. Calorific value of Fuel oil is 10200 Kcal/kg.
Calculate the payback period if the cost of fuel is Rs.32000 per ton.
Ans:
Blow down % = Feed water TDS * % make up water x 100

(maximum permissible TDS in boiler water Feed water TDS)



(4 marks)
Specific heat of water is 1 kcal/kgC
Heat savings = m * Cp * (T1 T2) = 1238 * 1 * (175 45)


= 18.6 * 24 * 330 / 1000
= 147.1 MT / annum
Fuel Oil cost savings = 147.1 * 32000

= Rs. 47.07 lakh
(4 marks)
Investment on water treatment plant = Rs. 2 Crore
_________________________ 11

Payback period = 4.2 years (or) 51 months
(2 marks)




Solution:

(2.5 marks)
= 924.2 kg/hr (2.5 marks)
_________________________ 12

ii) ROI for the conversion scheme

(1 mark)
= Rs 7,98,50,880/year
(1 mark)
Annual net monetary savings after conversion
= [(8,06,40,000 - 7,98,50,880) 6,00,000] x 100
50,00,000
= 3.8 %
(3 marks)
o
L-4 A liquid waste stream has a flow rate of 3.5 kg/s and a temperature of 70 C with a specific heat
capacity of 4190 J/kgK. Heat recovered from the hot waste stream is used to pre-heat boiler
make-up water. The flow rate of the make-up water is 2 kg/s, its temperature is 10oC and its
specific heat capacity is 4190 J/kg/K. The overall heat transfer coefficient of the heat exchanger
is 800 W/m2K. If a make-up water exit temperature of 50oC is required, and assuming that there
is no heat losses from the exchanger, determine

Solution:
i) Heat gained by makeup water = Qc= mc cc deltaT = 2 x 4190 x (50-10)
= 335200 W = 335.2 kW
(2 marks)
x 4190 x (70 - th2) = 2 x 4190 x (50 -10) th2
= 47.14 o C
(3 marks)
counter-flow heat exchanger is required.
LMTD = t1 t2
ln ( t1/ t2)
((70-50)-(47.14-10) ln
(70-50)/(47.14-10)
LMTD = 27.69oC
(2.5 marks)
Q = UA (LMTD)
= 335200 800 x
27.69
Area =15.13 m2
(2.5 marks)
_________________________ 13
L-5 a. State two examples of heat pump applications

b. In which situation are heat pumps most promising
c. Draw the schematics of a heat pump system
d. Briefly discuss each sub process stage of the heat pump system
heat pump applications
space heating system
use in plastic factory where chilled water is used to cool injection moulding machines, and
drying applications such as maintaining dry atmosphere in storage and drying compressed
air
(2 marks)
b) In a situation when both the cooling and heating capabilities of the cycle can be used in
combination
( 2 marks)
c) Schematic of a heat pump system:
(2 marks)
Step 1: In the evaporator the heat is extracted to boil the circulating working fluid
Step 2: The evaporated working fluid is compressed in a compressor rising working fluid
temperature and pressure
Step 3: The heat is delivered to the condenser
Step 4: The pressure of the working fluid is reduced in a throttling valve and condensate
returned to the compressor
(4 marks)
_________________________ 14
APH at 375C. Calculate the flue gas leaving the stack and also determine the improvement in
furnace efficiency after the installation of APH with the following data

Solution:
= 16560 Kg/hr
(1 mark)
= 920 Kg/hr
(1 mark)
Amount of flue gas = 16560 + 920
= 17480 Kg/hr
(1 mark)
= 837936 Kcal/hr
(1.5 mark)
Temperature difference in flue gas = 837936 / (17480 * 0.26)
= 184 C
(1.5 mark)
Flue gas leaves the stack at temp = 375 184 = 191 C
(1 mark)
Efficiency of APH = heat absorbed by air / Heat input * 100
= 837936 * 100 / (920* 9850)

= 9.2 %
(2 mark)
(1 mark)
_________________________ 15
SUPPLIMENTARY Paper 2 Set B
th
FOR



content
3. A small quantity of leakage of stored Liquid LPG evaporates to produce about ------
a) 100 b) 150 c) 250 d) 350
4. Secondary air requirement for a coal fired boiler is influenced by

a) fixed carbon b) mineral matter c) volatile matter d) sulphur
5. Which one of the following is not true with respect to the role of nitrogen in the
combustion of any fuel

6. In which of following, heat loss due to moisture formation on complete combustion will
be maximum
a) LSHS b) furnace oil c) natural gas d) coal
_________________________ 1

7.Which of the following requires the largest amount of oxygen/kg of substance for
combustion
Which of the following boiler utilizes the combination of suspension firing and great firing

9. Which of the component is common to supercritical boiler and sub critical boiler for
power generation
10. The TDS level in boiler water for boiler blow down, is measured through


13. Condensate at pressure of 4 kg/cm2 and 160 oC temperature when exposed to

atmosphere will


operation in a
c) float trap d) inverted bucket trap


_________________________ 2



20. The presence of calcium and magnesium bicarbonates in water to steam boiler would
form
a) acidic solution b) basic solution c) neutral solution d) none of the above


23. The inverted bucket operates on the principle of _______ difference between water and
steam




28. Which of the following depends on physical properties of fluids as well as geometry of
the heat exchanger

29. The parameter assumed to remain constant during LMTD calculation of a Heat
exchanger is

_________________________ 3




a) 50 b) 44 c) 66 d) 792






a) 69.57 b) 4 c) 17.39 d) 16



44. Which among the following operates at vacuum

a) heat wheels b) heat pump c) heat pipe d) all of the above
_________________________ 4

a) demineralizationb) softening c) de-aeration d) all of the above



48. Economiser in a boiler exchanges heat between
a) flue gas & combustion air b) steam & feed water
c) steam & combustion air d) feed water & flue gas

a) it risesb) it inclinesc) it sinks d) it remains stationary
-------- End of Section - I ---------

160-170C ? (2.5 marks)
Ans:
(a) LPG is a predominant mixture of propane and butane. Both propane and butane
are denser than air. Consequently, the vapour flows along the ground into drains and
sinks to the lowest level of the surroundings and gets ignited at a considerable
distance from the source of leakage. Escape of even small quantities of LPG can give
rise to large volume of vapour mixture and can cause considerable hazard. Hence
there should be adequate ground level ventilation where LPG cylinders are stored.
For this reason LPG cylinders should not be stored in cellars or basements, which
have no ventilation at ground levels.
(2.5 marks)
_________________________ 5
(b) For fuels containing sulphur, low temperatures (below 160-170C) of stack can
lead to sulphur dew point corrosion. The main disadvantage of sulphur is the risk of
corrosion by sulphuric acid formed during and after combustion, and condensing in
cool parts of the chimney or stack, air preheater and economiser.
( 2.5 marks)
S-2 A steam pipe of 100mm diameter is insulated with mineral wool. As a part of energy saving
measures, the insulation is upgraded with efficient Calcium silicate insulation. Calculate the
percentage reduction in heat loss as a result of implementation of the above measure given
the following data,
Surface temperature with mineral wool : 95C

Surface temperature with calcium silicate : 55C
Ans:
Heat loss thru non-insulated pipe = [10 + (Ts Ta) / 20] * (Ts Ta) ]
Ts = Surface temperature
Ta = Ambient temperature
Heat loss thru non-insulated pipe = [10 + (95 25) / 20] * (95 25) ]
= 945 kcal/hr-m2
(2 marks)
Heat los thru insulated pipe = [10 + (55 25) / 20] * (55 25) ]
= 345 kcal/hr-m2
(2 marks)
% Reduction in heat loss = (945 345) / 945
= 63.5 %
(1 mark)
cycle data,
Ans:
_________________________ 6

= 475.1 kWh/hr or 475.1 kw

(3 marks)

Electricity consumption = 730.9 Kwh/hr or 730.9 kw (2 marks)
combustion from the following data
Ultimate Analysis of Paddy Husk %
Moisture 11.8
Mineral Matter 17.7
Carbon 32.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5
Ans

Carbon 32 C + O2 = CO2 2.67 85.44

12 + 32 = 44 (32/12) (32x2.67)
Hydrogen 5 H2 + 0.5 02 = H2O 8.0 40.0

2 + 16 = 18 (16/2) (5x8)
Sulphur 0.1 S + O2 = SO2 1.0 0.1

32 + 32 = 64 (32/32) (0.1x1)
Oxygen 32.5 (-)32.5
Nitrogen 0.9 -
Moisture 11.8 -
Total 100 93.04
_________________________ 7

(4 marks)
Therefore theoretical quantity of dry air reqd. = 93.04 / 0.23 = 404.5 kg air / 100 kg fuel
(air contains 23% oxygen by wt.) (1 mark)
Back Pr.Steam
P =4 kg/cm2
T =170 C Process
Q =11MT/hr Plant Condensate
H =650kcal/kg
At P = 4 kg/cm2
T =170 C
Inlet Steam
P = 42 kg/cm2
T = 410 C
Back Pr Turbine Cogeneration
Plant
Solution
Input heat to turbine = 11,000 x 760 = 8360000 Kcal/hr (1 mark)
Useful heat to process Plant = 11,000 x 650-170 = 5280000 Kcal/hr (1 mark)
Useful Electrical output in alternator = 700x860= 602000 Kcal/hr (1 mark)
Energy Utilization Factor (EUF) = (602000+5280000) /8360000
= 70.36% (2 marks)
S-6 For combustion of 500 kg/hr of Natural Gas containing 100% Methane, Calculate the
_________________________ 8
Ans:

CH4 + 2 O2 CO2 + 2H2O

500 Kg/hr of Methane requires 1375 Kg/hr of CO2

Considering 20% excess air, (2 marks)

= 10434 Kg/hr of air
(1 mark)
Flue gas generation with 20% excess air = 500 + 10434
= 10934 Kg/hr
(1 mark)
% CO2 in the flue gas = 1375 / 10934
= 12.5 %
(1 mark)
S-7 In a heat exchanger, steam is used to heat 3.0 KL/hr of furnace oil from 30oC to 100oC. The
specific heat of furnace oil is 0.22 kCal/ kg/oC and the density of furnace oil is 0.95 gm/cc.
How much steam per hour is needed if steam at 4 kg/cm2 with latent heat of 510 kCal/ kg is
used. If steam cost is Rs. 4.0/kg and electrical energy cost is Rs.8.0/kWh, which type of
heating would be more economical in this particular case? (assume no losses in electrical
and steam heating process)

= (3 x 1000 x 0.95) x 0.22 x (100-30)
= 43890 kcal/hr (1.5 mark)
a) Amount of steam required = 43890/510

= 86 kg/hr
= Rs. 344/hr (1.5 marks)
b) Amount of electricity required = 43890/860
= 51 kWh
= 51 x Rs. 8
= Rs.486/ hr
Steam heating will be more economical (2 marks)
_________________________ 9

S-8 In a sugar mill, a process requires 5 000 kg/hr of dry saturated steam at 7 kg/cm2 (g). For the
Ans.

= 5000/3600 = 1.389 kg/sec
Volumetric flow = 1.389 x 0.24 = 0.333 m3/sec (1 mark)
Volumetric flow rate(m3/s) = Velocity (m/s) x cross sectional area (m2) (1 mark)
D2 U 4 Volumetric flowrate
Therefore, Flow velocity
Flow velocity
D U 4 0.333
25
D U 0.130 m or 130 mm
(3 marks)
-------- End of Section - II ---------
_________________________ 10

L-1 A liquid waste stream has a flow rate of 3.5 kg/s and a temperature of 75o C with a specific heat
capacity of 4190 J/kgK. Heat recovered from the hot waste stream is used to pre-heat boiler
make-up water. The flow rate of the make-up water is 2.8 kg/s, its temperature is 12oC and its
specific heat capacity is 4190 J/kg/K. The overall heat transfer coefficient of the heat exchanger
is 800 W/m2K. If a make-up water exit temperature of 50oC is required, and assuming that there
are no heat loss from the heat losses from the exchanger, determine

Solution
i) Heat gained by makeup water = Qc= mc cc T = 2.8 x 4190 x (50-12)
= 445816 W = 445.82 kW
(2 marks)
x 4190 x (75 - th2) = 2.8 x 4190 x (50 -12) t h2

= 44.6 o C
(3 marks)
counter-flow heat exchanger is required
LMTD = t1 t2
ln ( t1/ t2)
((75-50)-(44.6-12) ln
(75-50)/(44.6-12)
25-32.4
ln(25/32.4)
LMTD = 28.54oC
(2.5 marks)
_________________________ 11
Q = UA (LMTD)
= 445816
800 x 28.54
Area =19.5 m2 (2.5 marks)
L-2 Oil fired Boiler is generating 100 TPH of steam at 85% efficiency, operating 330 days in a year.
Management has installed a water treatment plant at Rs 2 Crore investment for reducing the
TDS in boiler feed from 450 ppm to 150 ppm. The maximum permissible limit of TDS in the
boiler is 3000 ppm and make up water is 10%. Temperature of blowdown water is 175C and
boiler feed water temperature is 45C. Calorific value of Fuel oil is 10200 Kcal/kg.
Calculate the payback period if the cost of fuel is Rs.34500 per ton.
Ans:
Blow down % = Feed water TDS * % make up water x 100
(maximum permissible TDS in boiler water Feed water TDS)



Reduction in blow down = 1238 kg/hr (4 marks)

Specific heat of water is 1 kcal/kgC
Heat savings = m * Cp * (T1 T2) = 1238 * 1 * (175 45)

= 18.6 * 24 * 330 / 1000

= 147.1 MT / annum
Fuel Oil cost savings = 147.1 * 345000
= Rs. 50.75 lakh ( 4 marks)

Investment on water treatment plant = Rs. 2 Crore
Payback period = 3.9 years (or) 47months

(2 marks)
_________________________ 12

APH at 375C. Calculate the flue gas leaving the stack and also determine the improvement in
furnace efficiency after the installation of APH with the following data

Solution:
= 16560 Kg/hr
(1 mark)
= 974.12 Kg/hr
(1 mark)
Amount of flue gas = 16560 + 974.12
= 17534.1 Kg/hr
(1 mark)
= 837936 Kcal/hr
(1.5 mark)
Temperature difference in flue gas = 837936 / (17534.1 * 0.26)
= 183.8 C
(1.5 mark)
Flue gas leaves the stack at temp = 375 183.8 = 191.2 C
(1 mark)
Efficiency of APH = heat absorbed by air / Heat input * 100
= 837936 * 100 / (974.12* 9850)

= 8.73 %
(2 marks)
(1 mark)
_________________________ 13





Solution:
Boiler efficiency = 81.8% (on GCV basis)

(2.5 marks)
= 924.2 kg/hr (2.5 marks)

ii) ROI for the conversion scheme
(1 mark)
= Rs 7,98,50,880/year
Annual net monetary savings after conversion (1 mark)
= [(8,06,40,000 - 7,98,50,880) 6,00,000] x 100
50,00,000
=3.8 % (3 marks)
_________________________ 14

L-6 a. State two examples of heat pump applications

b. In which situation are heat pumps most promising
c. Draw the schematics of a heat pump system
d. Briefly discuss each sub process stage of the heat pump system
heat pump applications
space heating system
use in plastic factory where chilled water is used to cool injection moulding machines, and
drying applications such as maintaining dry atmosphere in storage and drying compressed
air
(2 marks)
b) In a situation when both the cooling and heating capabilities of the cycle can be used in
combination
( 2 marks)
c) Schematic of a heat pump system:
(2 marks)
Step 1: In the evaporator the heat is extracted to boil the circulating working fluid
Step 2: The evaporated working fluid is compressed in a compressor rising working fluid
temperature and pressure
Step 3: The heat is delivered to the condenser
Step 4: The pressure of the working fluid is reduced in a throttling valve and condensate
returned to the compressor
(4 marks)
_________________________ 15

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Paper EM2 Energy Manager Set A

NATIONAL CERTIFICATION EXAMINATION 2004

PAPER EM2: Energy Efficiency in Thermal Utilities

Section I: OBJECTIVE TYPE Marks: 50 x 1 = 50

3. LPG consists of one of the following

4. Suitable atomizing viscosity of furnace oil for use in LAP/MAP burners is

c) 600 Red wood seconds-1 d) 400 Redwood Seconds-1

6. Element in fuel oil responsible for corrosion is

7. A system in which a package type boiler operates with a FD fan is called

11. Concentration of solids in boiler drum is controlled by

12. Major heat loss in an oil fired boiler is accounted by

c) un-burnt carbon loss d) blow down loss

c) 50 mm in 30 meteres d) 350 mm in 30 metres

c) absolute temperature d) fourth power of temperature

c) emissivity of external wall surfaces d) stock to be heated

c) emissivity d) factor for total radiation

20. Which of the following is not a property of ceramic fibre insulation.

c) high heat capacity d) thermal shock resistant

22. Low combustion temperature in FBC boilers results in reduced formation of

c) low radiation loss d) much smaller size

25. Ceramic recuperators can withstand gas side temperature up to

30. The average reduction of flue gas temperature by . results in an efficiency

c) lancashire boiler d) package and economic boiler

c) Brayton cycle d) bottoming cycle

c) 10,000 kilo calorie per kg d) 13,000 kilo calorie per kg

c) combined heat and power system d) Brayton cycle system

c) optimizing excess air d) addition of more burners

c) baking ovens d) glass melting furnaces

c) sensible heat loss in flue gas d) heat loss through openings

b) insulation of steam pipe lines

c) good conductor d) insulator

c) releases maximum heat during heat transfer at a fixed temperature

44. High emissivity coatings are most effective when applied on

c) refrigeration pipings d) none of the above

46. The efficiency of a typical FBC boiler would be around

47. In FBC boiler the combustion is carried out at a temperature

b) below ash fusion temperature of fuel used

50. The major limitation of metallic recuperator is

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

0 Answer all Ten questions

S-1. List some applications using ceramic fibre.

S-3. Explain what is meant by a combined cycle.

S-4. List at least five important parameters to be considered before installing a

S-5. What is a heat pipe? How does it work?

S-6. Explain the meaning of dryness fraction of steam.

S-9. Explain the importance of deaeration of boiler feed water.

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

(i) Answer all Five questions

L-2. Discuss four major energy conservation opportunities in a boiler system?

. End of Section III .

Duration: 3 HRS Max. Marks: 150

Section I: OBJECTIVE TYPE Marks: 50 x 1 = 50

Paper-2/Model Test Series-A Page 2 of 18

14. Whichtypeof Steamtrapoperatesontheprincipleofdifferenceintemperature

36. Thevelocityof fluidizedairinaAFBCboileris

Paper-2/Model Test Series-A Page 5 of 18

Paper-2/Model Test Series-A Page 6 of 18

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

(i) Answer all Ten questions

(ii) Each question carries Five marks

Paper-2/Model Test Series-A Page 7 of 18

S.No. Parameters Firetubeboilers Watertubeboilers

h. Cost&construction Higher Muchless

S-9. Explain the importance of deaeration of boiler feed water.