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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
177
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178
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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
_______________________ 1
Bureau of Energy Efficiency
Paper EM2 Energy Manager Set A
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
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
19. Which of the following influences energy savings when ceramic coating is applied on
furnace hot side
a) conductivity b) convective heat transfer coefficient
_______________________ 2
Bureau of Energy Efficiency
Paper EM2 Energy Manager Set A
23. A major advantage of PFBC boilers compared to conventional pulverised coal fired
boiler is
a) less ash removal b) low excess air
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
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
_______________________ 3
Bureau of Energy Efficiency
Paper EM2 Energy Manager Set A
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
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
_______________________ 4
Bureau of Energy Efficiency
Paper EM2 Energy Manager Set A
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
. End of Section I .
S-2. What are the important aspects to be considered for retrofitting a conventional
boiler to FBC technology?
_______________________ 5
Bureau of Energy Efficiency
Paper EM2 Energy Manager Set A
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-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 .
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-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.
_______________________ 6
Bureau of Energy Efficiency
nd
2 NATIONAL CERTIFICATION EXAMINATION - 2005
FOR
ENERGYMANAGERSANDENERGYAUDITORS
MODELTESTSERIESA
PAPER2:ENERGYEFFICIENCYINTHERMALUTILITIES
General instructions:
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
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
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
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
Paper-2/Model Test Series-A Page 3 of 18
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
Paper-2/Model Test Series-A Page 4 of 18
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
37. InacoalfiredAFBC,Clinkerformationoccurswhenbedtemperatureexceeds
o o o o
a)850 C b)950
C c)1000 C d)800 C
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%`
0 Adeviceusedtocompressalowpressuresteamtoahighpressuresteamiscalled
a)heatpumpb)heatpipec)thermocompressor d)economizer
Thefunctionofdraftinacombustionsystemistoexhausttheproductsofcombustionintothe
atmosphere.ThedraftcanbeclassifiedintotwotypesnamelyNaturalandMechanicalDraft.
NaturalDraft
Itisthedraftproducedbyachimneyalone.Itiscausedbythedifferenceinweightbetweenthe
columnofhotgasinsidethechimneyandcolumnofoutsideairofthesameheightandcross
section.
MechanicalDraft
Itisdraftartificiallyproducedbyfans.Threebasictypesofdraftsthatareapplied
BalancedDraft:Forceddraft(FD)fan(blower)pushesairintothefurnaceandaninduceddraft(I
D)fandrawsgasesintothechimneytherebyprovidingdrafttoremovethegasesfromtheboiler.
InducedDraft:Aninduceddraftfandrawsenoughdraftforflowintothefurnace,causingtheproductsof
combustiontodischargetoatmosphere
ForcedDraft:TheForceddraftsystemusesafantodelivertheairtothefurnace, forcingcombustion
productstoflowthroughtheunitandupthestack.
0 Whatarethecomparativeadvantagesanddisadvantagesoffiretubeandwatertubeboilers?
0 Howwaterhammerisproducedinapipingsystemandhowitcanbeeliminated?
Awaterhammerinasteamsystemiscausedbycondensatecollectionintheplantorpipeworkpickedup
bythefastmovingsteamandcarriedalongwithit.Whenthis
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
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:
Reductioninequipmentsizes:Wasteheatrecoveryreducesthefuelconsumption,which
leadstoreductioninthefluegasproduced.Thisresultsinreductioninequipmentsizes
ofallfluegashandlingequipmentssuchasfans,stacks,ducts,burners,etc.
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.
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.
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
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
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.
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
1000
Paper-2/Model Test Series-A Page 16 of 18
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
TheCO2inthefluegaseswillbeoftheorderof1415%atfullload.Hence,theFBCboilercan
operateatlowexcessaironly2025%.
1SimpleOperation,QuickStartUp
Highturbulenceofthebedfacilitatesquickstartupandshutdown.Fullautomationofstartupand
operationusingreliableequipmentispossible.
Date: 28.05.2004 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
2
Answer all 50 questions
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
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
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
13. To drain condensate from main steam line, the following type of trap is a suitable
trap.
a) float b) bimetallic
_________________________ 2
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
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
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
_________________________ 3
Bureau of Energy Efficiency
Paper 2 Set A
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
_________________________ 4
Bureau of Energy Efficiency
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
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
_________________________ 5
Bureau of Energy Efficiency
Paper 2 Set A
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.
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 thermal conductivity
1 creep at high temperature
2 capital costs
S-7 List advantages of fluidized bed combustion boiler over fixed grate boiler.
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-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.
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:
Operation data
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
(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.
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
(iii)
_________________________ 10
Bureau of Energy Efficiency
Paper 2 Set A
L-5 On the topic of waste heat recovery boilers, explain the following:
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
General instructions:
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
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%
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
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
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%?
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
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
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%
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
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?
5888 Whatarethetypesofsteamtrapsandbrieflyexplainabouttheirprincipleofoperation?
Therearethreebasictypesofsteamtrapintowhichallvariationsfall,
Whensteamisfirstadmittedtoapipeafteraperiodofshutdown,thepipeisfullofair.Further
amountsofairandothernoncondensablegaseswillenterwiththesteam,althoughtheproportions
ofthesegasesarenormallyverysmallcomparedwiththesteam.Whenthesteamcondenses,these
gaseswillaccumulateinpipes
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,
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
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
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.
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).
Whensteamfollowsthehotcondensateintothetrap,the
thermalelementfullyexpands,closingthetrap.Ifcondensate
entersthetrapduringsystemoperation,itcoolstheelement,
contractingitofftheseat,andquicklydischargingcondensate.
ThermostaticTrap
Thermostatictrapsaresmall,lightweight,andcompact.Onetrapoperatesoverextremelybroad
pressureandcapacityranges.Thermalelementscanbeselectedtooperatewithinarangeofsteam
temperatures.Insteamtracingapplicationsitmaybedesirabletoactuallybackuphotcondensatein
thelinestoextractitsthermalvalue.
3 Whatarevariousfurnacelosses?Describeatleastthreetypesoflosses.
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
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
(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
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.
ExtractionCondensingturbine:
Inthistype,steamenteringatHigh/MediumPressureisextractedatanintermediatepressure
intheturbineforprocessusewhiletheremainingsteamcontinuestoexpandandcondenses
inasurfacecondenserandworkisdonetillitreachesthecondensingpressure(vacuum).
Extractioncondensingturbine
Date: 28.05.2004 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
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
4. A heat pipe can transfer up to ____ times more thermal energy than copper
a) 10 b) 20 c) 50 d) 100
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
10. In glass industry waste heat is used for power generation. This type of cogeneration
is called
a) topping cycle b) bottom cycle
11. 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
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
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) inside the combustion zone b) bed tubes
c) outside of the combustion zone d) super heater tubes
22. De-aeration of boiler feed water is referred to as
a) removal of dissolved gases b) removal of silica from feed water
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%
29. Increase of steam pressure has which of the following effect on steam
a) steam temperature goes up and enthalpy of evaporation goes down
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
0 In which type of furnace operation is a low mass ceramic fiber insulation most
suitable to reduce specific fuel consumption
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
44. Which of the following fuel requires maximum air for stochiometric combustion?
a) Butane b) Propane c) Hydrogen d) Coal
46. Which fuel releases the most energy per kg on complete combustion
a) Carbon b) Sulphur c) Nitrogen d) Hydrogen
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
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?
C + O2 = CO2
12 + 32 = 44 (only for reference and further calculation)
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.
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.
S-4 Explain why group trapping is not recommended with steam traps.
S-6 How does high emissivity coating in a furnace chamber helps in reducing energy
consumption?
(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
(OR)
(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.
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:
Operation data
L-2 (i) Explain why dry saturated steam is preferred over wet or super heated steam for
industrial process heating
_________________________ 9
Bureau of Energy Efficiency
Paper 2 Set B
(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.
23 Where does the thermal conductivity of the wall or pipe structure enter in
this equation?
23 H = h x A x (Th Ta)
(iii) Thermal conductivity of the wall does enter this equation through Th
the hot surface temperature but not through h.
(OR)
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
(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
_________________________ 12
Bureau of Energy Efficiency
Paper 2
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
20. The TDS level by Softening process method for boiler water treatment may be
a) reduced
b) increased
c) Both a and b
d) None of the above
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
_________________________ 2
NPC-AIP 2006
Paper 2
NPC-AIP 2006
Paper 2
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
24 1,85,000 kcal/hr
25 8,00,000 kcal/hr
26 1,00,000 kcal/hr
_________________________ 4
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
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
d) None of the above
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
_________________________ 5
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
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.
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.
_________________________ 6
NPC-AIP 2006
Paper 2
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
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)
_________________________ 7
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.
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.
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.
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
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:
(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.
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
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
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.
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
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
_________________________ 12
NPC-AIP 2006
ModelQuestionPaper2006
NATIONALCERTIFICATIONEXAMINATION
FOR
ENERGYAUDITORSANDENERGYMANAGERS
PAPER2:ENERGYEFFICIENCYINTHERMALUTILITIES
Duration:3Hrs Max.Marks:150
GeneralInstructions:
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. 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
PAPER2:ENERGYEFFICIENCYINTHERMALUTILITIES
GeneralInstructions:
SectionI:ObjectiveTypeQuestions
23 Answerallquestionofthissection.
24 Eachquestioncarriesonemark.
25 Puta()tickmarkontheappropriateboxintheanswerbook.
0 ThecalorificvalueofDgradecoalsvariesbetween
23 2000to3000kcal/kg
24 3000to4000kcal/kg
25 4000to5000kcal/kg
26 5000to6000kcal/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
Date: 22.04.2006 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
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
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
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
_________________________ 2
Bureau of Energy Efficiency
Paper 2 Set A Solutions
19. Which of the following will be ideal for heat transfer in a heat exchanger
a) super heated steam b) saturated dry steam
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
24. The emissivity of conventional refractory ____ with the increase in temperature
a) increases b) decreases
_________________________ 3
Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
37. The low combustion temperature in FBC Boilers results in minimal formation of
d) CO
a) SOx b) NOx c) CO2
For standalone gas turbines without heat recovery system, the efficiency will be in the range
of
_________________________ 4
Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
ThequestionisrepeatofQuestionNo.3.Awardmarkiftheanswerisright.
_________________________ 5
Bureau of Energy Efficiency
Paper 2 Set A Solutions
S-1 What is meant by excess air in combustion systems and discuss the importance
of optimum excess air.
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-3 What are the disadvantages of direct method of boiler efficiency evaluation over
the indirect 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
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?
10300 - 581.08
9718.92
9719 Kcal / Kg
84
Boiler efficiency on NCV = ------ x 10300
9719
= 89.02 %
= 89%
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.
12
Evaporation Ratio = --- = 6
2
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-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.
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.
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?
The heat to power ratio of a facility should match the characteristic of the co-
generation system to be installed.
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.
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.
= [ 1 + ---- ] x 5.6
100
= 7.28 Kg of Air / Kg of coal
= ------------------------- x 100
GCV of fuel
Total mass of flue gas (m) = Mass of actual air supplied +
_________________________ 11
Bureau of Energy Efficiency
Paper 2 Set A Solutions
6.4584
6.46 %
= 5.78%
79.76%
15621.86 Kg / 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
Bureau of Energy Efficiency
Paper 2 Set A Solutions
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.
If inverted bucket traps are used for extremely small loads, it will have
continuous condensate discharge.
_________________________ 13
Bureau of Energy Efficiency
Paper 2 Set A Solutions
Flash Steam
If steam blows out continuously in a blue stream, it is leaking 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.
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.
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
will also be high and they will not get sufficient time condense before
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. 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
Condensate Recovery
For every 6 deg. C. rise in the feed water temperature, there will be
approximately 1% saving of fuel in the boiler.
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
Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
= 8167 KW
= x (721.75 - 186.69)
---------------------
860
= 44795.72 KW
= 44796 KW
44796
8167
= 5.48
_________________________ 16
Bureau of Energy Efficiency
Paper 2 Set A Solutions
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.
Upgradation (S2)
Pipe dimension = 100 mm x 100 m length
= 94,200 Kcal / hr
= 400 x 62.8
= 25,120 Kcal / hr
= 69,080 Kcal / hr
_________________________ 17
= 184 Tons
= 1.087 years
= 13 months
_________________________ 18
Bureau of Energy Efficiency
Paper 2 Set B Solutions
Date: 22.04.2006 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
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. 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
13. In a gas turbine, air compressor alone consumes about _____of the energy
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
_________________________ 2
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
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
_________________________ 3
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
34. The low combustion temperature in FBC Boilers results in minimal formation of
a) CO b) SOx c) NOx d) CO2
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
_________________________ 4
Bureau of Energy Efficiency
Paper 2 Set B Solutions
_________________________ 5
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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.
S-2 What is heat-to-power ratio of cogeneration system and state its importance?
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
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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.
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
S1 = is the sensible heat of higher pressure steam
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.
12
Evaporation Ratio = --- = 6
2
_________________________ 7
Bureau of Energy Efficiency
Paper 2 Set B Solutions
= 93.13 % = 93%
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?
10300 - 581.08
9718.92
9719 Kcal / Kg
_________________________ 8
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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?
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
S-10 What is meant by excess air in combustion systems and discuss the importance
of optimum excess air.
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.
_________________________ 10
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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.
Upgradation (S2)
Pipe dimension = 100 mm x 110 m length
Surface are after insulation (A2)= 3.14 x 0.2 x 110 = 69.1 Sq. M.
= 400 x 69.1
_________________________ 11
Bureau of Energy Efficiency
Paper 2 Set B Solutions
= 27640 Kcal / hr
= 75980 Kcal / hr
75980 x 8000
= 202.6 Tons
= 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
= 7989 KW
_________________________ 12
= 44796 KW
44796
systems.
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
_________________________ 13
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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.
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.
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
will also be high and they will not get sufficient time condense before
_________________________ 14
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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. 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
Condensate Recovery
For every 6 deg. C. rise in the feed water temperature, there will be
approximately 1% saving of fuel in the boiler.
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
Bureau of Energy Efficiency
Paper 2 Set B Solutions
So optimal loading will result in minimum losses and maximize the efficiency.
_________________________ 16
Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
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 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.
EA
Actual mass of Air supplied = [ 1 + ----- ] x Theoretical Air
100
30
= [1+]x5.6
100
= 7.28 Kg of Air / Kg of coal
= x 100
-------------------------
GCV of fuel
Total mass of flue gas (m) = Mass of actual air supplied +
_________________________ 17
Bureau of Energy Efficiency
Paper 2 Set B Solutions
6.30 %
= 5.64 %
80.06%
15183.73 Kg / hr
Date: 21.03.2007 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
With increase in excess air for combustion which of the following will result in flue 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
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
minimum fuel input d) maximum air input over minimum air input
makeup water.
15. For equal capacity, the boiler size is the smallest for
a) AFBC b) CFBC c) PFBC d) Pulverized coil fired boiler
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
BEE-2007 Paper-2:Set-A-Key 2
Paper 2 Set A- SOLUTION
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
furnace draft velocity d)stopping coal fines to fall through grate and being carried
away with furnace draft
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.
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.
above.
enthalpy is zero
saturated steam with high pressure d) wet steam with very high pressure
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
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
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
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
above
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
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
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%
BEE-2007 Paper-2:Set-A-Key 7
Paper 2 Set A- SOLUTION
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.
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
S.8 Howdoesathermocompressorwork?Explainbrieflywithasketch
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
BEE-2007 Paper-2:Set-A-Key 8
Paper 2 Set A- SOLUTION
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.
BEE-2007 Paper-2:Set-A-Key 9
Paper 2 Set A- SOLUTION
: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
After insulating with 50mm insulating material the surface temperature has reduced to
0
50 C
Substituting values S= 10+(50 30)/20 x(50-30)
2
=220 k.Cal/ hrm
BEE-2007 Paper-2:Set-A-Key 10
Paper 2 Set A- SOLUTION
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.
5
Power generation from Cogeneration 5000x(90/100)x8000 =360x10 kWh
plant
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.
a) Heat pipe
BEE-2007 Paper-2:Set-A-Key 12
Paper 2 Set A- SOLUTION
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
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.
BEE-2007 Paper-2:Set-A-Key 15
Paper 2 Set B SOLUTION
Name: ___________________
General instructions:
minimum fuel input d) maximum air input over minimum air input
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
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
Bureau of Energy Efficiency 3
Paper 2 Set B SOLUTION
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
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
a) condensing turbine b) back pressure turbine
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.
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.
29. Pick the wrong statement. The thermal efficiency of a furnace increases by
a)reducing surface heat loss b)preheating Combustion air.
32. Steam for process heating should always be generated and utilized at
a) same pressure b) lowest pressure and highest pressure respectively
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
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
c) increasing the furnace draft velocity d)stopping coal fines to fall through grate and being
carried away with furnace draft
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.
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
48. Which of the following will require minimum excess air for combustion
a) fluidized bed boiler b) spreader stoker 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
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
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
High negative pressures leads to air infiltration- affecting air-fuel ratio control,
problems of cold metal and non-uniform metal temperatures.
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.
Ans.
= Q(hg hf ) x 100 =
qGCV
5 * (666 60)
* 100
4200
=72.14%
Bureau of Energy Efficiency 9
Paper 2 Set B SOLUTION
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.
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
0.81* 584
= 4.6 %
10200
Bureau of Energy Efficiency 11
Paper 2 Set B SOLUTION
S-10 How does a thermo compressor work? Explain briefly with a sketch.
: 75%
: Rs.2500/tonne.
: 4000
0
kCal/kg :
150 C
0
: 50 C
0
: 30 C
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
Modified System :
After insulating with 50mm insulating material the surface temperature has reduced to
0
50 C
Substituting values S= 10+(50 30)/20 x(50-30)
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
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
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
Bureau of Energy Efficiency 14
Paper 2 Set B SOLUTION
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.
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.
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.
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
General instructions:
Please check that this question paper contains 7 printed pages
Please check that this question paper contains 64 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
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
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:
The presence of calcium and magnesium bicarbonates in boiler feed water would form:
Maximum Continuous Rating (MCR) of a boiler is the maximum evaporation rate that can be
sustained for
For flash steam calculation, flash steam quantity available depends upon
For the same size and rating, efficiency of continuous furnaces will be more than batch type of
furnaces mainly because of
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
The insulation material suitable for low temperature application to prevent heat gain is
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
In a heat pump
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
S-1 (a) State the stoichiometric combustion equation for Propane (C 3H8)
+ 160 = 132 + 72
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
Bureau of Energy Efficiency
Paper 2 Set A Answer Key
2
kCal/kg at 7 kg/cm g)
Ans
= 2000 x (660-60) x 100 = 80%
150 x 10000
= 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?
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
Bureau of Energy Efficiency
Paper 2 Set A Answer Key
S-7 Sketch the schematic of Back Pressure Turbine and Extraction Condensing
Turbine Cogeneration systems
Ans
_________________________ 7
Bureau of Energy Efficiency
Paper 2 Set A Answer Key
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
_________________________ 8
Bureau of Energy Efficiency
Paper 2 Set A Answer Key
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
C+O2 = CO2
2H2+O2 = 2H2O
S+O2 = SO2
= 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
Any other relevant point
_________________________ 10
Bureau of Energy Efficiency
Paper 2 Set A Answer Key
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.
The fuel contains very little sulfur and hence the sulfur dew point is
very low. Hence the temperature of 189 C. is acceptable.
L-4 (a) Explain why dry saturated steam is preferred over wet or superheated steam for
industrial process heating
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?
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.
Ans
Energy consumption per batch by furnace : 50 kWh
= 161250000 kCal/year
= 16710 kg/year
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
Sensible heat of steam at 2 kg/cm g : 120 kCal/kg
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:
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
General instructions:
Please check that this question paper contains 7 printed pages
Please check that this question paper contains 64 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
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
The inverted bucket trap operates on the principle of __________ difference between water
and steam
a) pressure b) density c) temperature d) velocity
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
For flash steam calculation, flash steam quantity available depends upon
a) 10 b) 100 c) 70 d) 50
9. The highest % of sulphur is present in
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
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
In flue gas, the theoretical CO 2 is 15.0% and the measured CO 2 is 12% by volume. The % excess
air is:
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 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
The presence of calcium and magnesium bicarbonates in boiler feed water would form:
27. Heat transfer rate for indirect heating application will be less if we heat with
a) saturated steam b) dry steam
_________________________ 3
Bureau of Energy Efficiency
Paper 2 Set B Answer Key
For the same size and rating, the efficiency of continuous furnaces will be more than batch type of
furnaces mainly because of
a) cooling water loss b) wall loss c) necessary opening loss d) flue gas loss
NOx formation in FBC boilers is eliminated because of
_________________________ 4
Bureau of Energy Efficiency
Paper 2 Set B Answer Key
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
Bureau of Energy Efficiency
Paper 2 Set B Answer Key
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)
+ 160 = 132 + 72
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
= 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%
_________________________ 7
Bureau of Energy Efficiency
Paper 2 Set B Answer Key
L-2 (a) Explain why dry saturated steam is preferred over wet or superheated steam for
industrial process heating
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
Bureau of Energy Efficiency
Paper 2 Set B Answer Key
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-3 A boiler utilizes bio-mass as fuel and the ultimate analysis (by weight %) of the fuel is
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:
Theoretical amount of air required for combustion
Theoretical CO2 content in flue gas.
Excess air supplied
C+O2 = CO2
2H2+O2 = 2H2O
S+O2 = SO2
_________________________ 9
Bureau of Energy Efficiency
Paper 2 Set B Answer Key
= 19.7 %
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?
Given are the data from steam tables :
2
Sensible heat of steam at 15 kg/cm g : 200 kCal/kg
2
Sensible heat of steam at 2 kg/cm g : 120 kCal/kg
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:
_________________________ 11
Bureau of Energy Efficiency
Paper 2 Set B Answer Key
th
6 NATIONAL CERTIFICATION EXAMINATION May, 2008
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 10.05.2008 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General 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
0 0 0 0
a) above 1000 C b) below 500 C c) 600-700 C d) 800-900 C
_______________________ 1
Bureau of Energy Efficiency
Paper 2 Set A Solution
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
13 Which data is not required to calculate the efficiency of boiler by indirect method
a) Flue gas temperature b) Ambient temperature
_______________________ 2
Bureau of Energy Efficiency
Paper 2 Set A Solution
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
29 What type of steam is used for electric power generation in thermal power plants
a) Dry saturated b) High pressure with superheat.
Air compressor alone consumes about _____ of the energy generated in a gas turbine
31 In a glass industry waste heat is used for power generation. This type of
cogeneration is called
a) topping cycle b) bottoming cycle
32 In circulating fluidized bed combustion boilers most of the heat transfer takes place
a) inside the combustion zone b) bed tubes
When 100 kg of fuel with 60% carbon is burnt with theoretical air, the mass of CO 2 released
will be
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
50 At the same temperature which of the following fuels will have maximum viscosity ?
a) LDO b) HSD c) Furnace oil d) LSHS
_______________________ 5
Bureau of Energy Efficiency
Paper 2 Set A Solution
2
Rate at which Heat is supplied for converting 10 TPH 60C water to 10 kg/cm
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
Bureau of Energy Efficiency
Paper 2 Set A Solution
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
Name two devices, which are used for improving the energy quality of
streams and explain the functioning of any one in brief.
_______________________ 7
Bureau of Energy Efficiency
Paper 2 Set A Solution
1 Mark
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;
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
Bureau of Energy Efficiency
Paper 2 Set A Solution
Thermocompressor
2 Marks
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
76.76%
3 Marks
_______________________ 9
Bureau of Energy Efficiency
Paper 2 Set A Solution
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.
Eventuallythetrappedpressureintheupperchamberfallsastheflashsteamcondenses.
Thediscisraisedbythenowhighercondensatepressureandthecyclerepeats
_______________________ 10
Bureau of Energy Efficiency
Paper 2 Set A Solution
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
Bureau of Energy Efficiency
Paper 2 Set A Solution
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
Ambient temperature : 30 C
_______________________ 12
Bureau of Energy Efficiency
Paper 2 Set A Solution
L-4 Draw simple schematic sketch to describe the following (No explanations
required)
2 Marks
2 Marks
_______________________ 13
Bureau of Energy Efficiency
Paper 2 Set A Solution
2 Marks
2 Marks
2 Marks
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
and flow rate of flash steam?
2
Sensible heat of steam at 2 kg/cm g : 133 kCal/kg
2
Latent heat of steam at 2 kg/cm g : 650 kCal/kg
b)
: 80 kgs/hr
5 Marks
Condensate Recovery
10 Marks (One mark for any of the 10 points in boiler and steam)
_______________________ 16
Bureau of Energy Efficiency
Paper 2 Set B Solution
th
6 NATIONAL CERTIFICATION EXAMINATION May, 2008
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 10.05.2008 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
1 What type of steam is used for electric power generation in thermal power plants
a) Dry saturated b) High pressure with superheat.
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
Air compressor alone consumes about _____ of the energy generated in a gas turbine
17 High percentage of carbon monoxide presence in the flue gas of boiler is an indicator
of
a) high excess air b) complete combustion
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
a) inside the combustion zone b) bed tubes
24 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
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
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
29 In which of the following equipment stored heat is used for preheating combustion air
a) Convective recuperator b) radiation recuperator
33 Which data is not required to calculate the efficiency of boiler by indirect method
a) Flue gas temperature b) Ambient temperature
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
_______________________ 4
Bureau of Energy Efficiency
Paper 2 Set B Solution
42 In a glass industry waste heat is used for power generation. This type of
cogeneration is called
a) topping cycle b) bottoming cycle
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
2
Rate at which Heat is supplied for converting 10 TPH 60C water to 10 kg/cm
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
Bureau of Energy Efficiency
Paper 2 Set B Solution
S-4 List the properties which are measured in proximate analysis and ultimate
analysis of solid fuels
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
Name two devices, which are used for improving the energy quality of streams
and explain the functioning of any one in brief.
_______________________ 7
Bureau of Energy Efficiency
Paper 2 Set B Solution
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;
(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
Bureau of Energy Efficiency
Paper 2 Set B Solution
Thermocompressor
2 Marks
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
75.4%
3 Marks
_______________________ 9
Bureau of Energy Efficiency
Paper 2 Set B Solution
3 Marks
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.
Eventuallythetrappedpressureintheupperchamberfallsastheflashsteamcondenses.
Thediscisraisedbythenowhighercondensatepressureandthecyclerepeats
_______________________ 10
Bureau of Energy Efficiency
Paper 2 Set B Solution
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
Bureau of Energy Efficiency
Paper 2 Set B Solution
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
Ambient temperature : 30 C
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
_______________________ 12
Bureau of Energy Efficiency
Paper 2 Set B Solution
Total heat loss in modified system =105x62.8 =6594 k.Cal/hr
L-4 Draw simple schematic sketch to describe the following (No explanations
required)
2 Marks
2 Marks
_______________________ 13
Bureau of Energy Efficiency
Paper 2 Set B Solution
2 Marks
2 Marks
2 Marks
_______________________ 14
Bureau of Energy Efficiency
Paper 2 Set B Solution
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
and flow rate of flash steam?
b)
:8 %
Flow rate of flash steam : 2000 x 8 %
: 160 kg/hr
5 Marks
Condensate Recovery
10 Marks (One mark for any of the 10 points in boiler and steam)
_______________________ 16
Bureau of Energy Efficiency
Paper 3 Set A Key
Date: 23.11.2008 Timings: 0930-1230 HRS Duration: 3 HRS Max. Marks: 150
_______________________ 1
Bureau of Energy Efficiency
Paper 3 Set A Key
_______________________ 2
Bureau of Energy Efficiency
Paper 3 Set A Key
_______________________ 3
Bureau of Energy Efficiency
Paper 3 Set A Key
_______________________ 4
Bureau of Energy Efficiency
Paper 3 Set A Key
_______________________ 5
Bureau of Energy Efficiency
Paper 3 Set A Key
_______________________ 6
Bureau of Energy Efficiency
Paper 3 Set A Key
_______________________ 7
Bureau of Energy Efficiency
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
Bureau of Energy Efficiency
Paper 3 Set A Key
300 = D1 D1
Q2 0.92
Q2 = 0.92 x 300
Q2 = 276 m3 /hr.
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.
S-5 Draw a sketch of a typical centrifugal fan characteristic curve along with system
resistance. (Note: No explanation is required)
_______________________ 9
Bureau of Energy Efficiency
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
= 11.52 Tonnes
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.
Install manometers across the filter and monitor the pressure drop as a guide to
replacement of element.
Consider the use of regenerative air dryers, which uses the heat of compressed
air to remove moisture.
_______________________ 10
Bureau of Energy Efficiency
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.
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.
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.
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.
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Bureau of Energy Efficiency
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 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.
On account of high pressure drop, ball or plug or gate valves are preferable over
globe valves in compressed air lines.
Answer:
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.
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Bureau of Energy Efficiency
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
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.
ANS:
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.
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Bureau of Energy Efficiency
Paper 3 Set A Key
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:
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Bureau of Energy Efficiency
Paper 3 Set A Key
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:
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Bureau of Energy Efficiency
Paper 3 Set A Key
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.
= 33.3%
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Bureau of Energy Efficiency
Paper 3 Set A Key
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.
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Bureau of Energy Efficiency
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.
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.
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Bureau of Energy Efficiency
Paper 2 Set B Key
th
7 NATIONAL CERTIFICATION EXAMINATION Nov. 2008
FOR
ENERGY MANAGERS & ENERGY AUDITORS
1
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Bureau of Energy Efficiency
Paper 2 Set B Key
2
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Bureau of Energy Efficiency
Paper 2 Set B Key
3
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Bureau of Energy Efficiency
Paper 2 Set B Key
4
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Bureau of Energy Efficiency
Paper 2 Set B Key
5
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Bureau of Energy Efficiency
Paper 2 Set B Key
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:
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:
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
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Bureau of Energy Efficiency
Paper 2 Set B Key
S-4 List five disadvantages if the steam pipe line is not insulated:
Answer:
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:
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
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Bureau of Energy Efficiency
Paper 2 Set B Key
Answer:
required with 10% excess air. Density of methane gas is 0.6 kg/m3
Answer:
With 10% excess air the Actual air required = (1+(10/100)) * 1303.125
= 1433.43 kg/hr
8
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Bureau of Energy Efficiency
Paper 2 Set B Key
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
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Paper 2 Set B Key
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
Answer:
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?
Answer:
a) Blow down (%) = Feed water TDS x % Makeup/ Permissible TDS in Boiler
11
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Bureau of Energy Efficiency
Paper 2 Set B Key
Answer :
Stack Temperature
Feed water preheating using economizer
Excess air control
Combustion air pre heating
Automatic Blowdown
Reduction of scaling and soot losses
Radiation and convection heat loss
Variable speed control for blowers and pumps
Proper boiler loading
Incomplete combustion and unburnt losses
12
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
Name: ___________________
th
9 NATIONAL CERTIFICATION EXAMINATION December, 2009
FOR
ENERGY MANAGERS AND ENERGY AUDITORS
Date: 19.12.2009 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
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
6 For same inlet conditions of the steam which of the following will generate the maximum power
a) condensing turbine b) back pressure turbine
8 In a glass industry waste heat is used for power generation. This type of cogeneration is called
a) topping cycle b) bottoming cycle
12 Good opportunity for energy savings from continuous blow down of boiler is by
a) recovery of flash steam for use in deaerator
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
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
17 Which data is not required to calculate the efficiency of boiler by indirect method?
a) flue gas temperature b) ambient temperature
3
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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%
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
4
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
43 Which of the following will be an ideal heating medium for heat transfer in a heat exchanger?
a) hot water b) super heated steam
45 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
47 The difference in temperature between steam and condensate is the principle of operation in a
a) temperature trap b) thermodynamic trap
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
. End of Section I .
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
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
S-2 What are the disadvantages of direct method of boiler efficiency evaluation over the
indirect method?
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)
S-4 A gas turbine was running with naphtha as a fuel. The following are the data collected
during the gas turbine operation:
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:
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)
7
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
16 Kg 64 44 36
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
6 mtr
(5 Marks)
(Burner 3 marks, chimney 2 marks)
S-8 Mention five important areas which reduces yield in a re-rolling mill.
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
= 3463 kg/hr
Annual operating hours = 7000
Annual coal consumption = 3463 * 7000 = 24241 MT
Annual cost of coal = 24241 * Rs 4000
9
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Paper 2 Set B Solutions
L-2 List 10 energy saving measures in a steam distribution and utilization system.
Ans
(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.
Ans.
Step 1:
Enthalpy drop across the turbine per kg of inlet steam (h1-h2)
(708-658)
50 kcal/kg
(2 Marks)
10
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Paper 2 Set B Solutions
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 electrical furnace : 70%
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
L-5 Explain briefly with the schematic the following heat recovery devices.
Heat Pipe
Metallic recuperator
Plate heat exchanger
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
Ans.
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.
(4 Marks)
b) Radiation Repuperator
(3 Marks)
c) Plate heat exchanger
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. 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?
b) hg =hf + X 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.
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
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Bureau of Energy Efficiency
Paper 2 Set B Key
Name: ___________________
th
8 NATIONAL CERTIFICATION EXAMINATION MAY, 2009
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 23.05.2009 Timings: 1400 to 1700 HRS Duration: 3 HRS Max. Marks: 150
General 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
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?
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
c) at and above ash fusion temperature d) below ash fusion temperature of fuel used
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
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Bureau of Energy
Efficiency
Paper 2 Set B Key
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
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
c) dry saturated steam with high pressure d) wet steam with very high pressure
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
3
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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
d) none of the above
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
a) 22.75 litres b) 2.275 litres c) 22.75 kilo litres d) 227.5 litres
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
a) fluidization factor b) slip velocity c) settling velocity d) none of the above
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
4
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Bureau of Energy
Efficiency
Paper 2 Set B Key
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
5
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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.
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
Feed water temperature = 30 C
Operating hours per year = 8000 hrs
Solution:
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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Bureau of Energy Efficiency
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
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Bureau of Energy Efficiency
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:
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.
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)
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.
9
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Bureau of Energy Efficiency
Paper 2 Set B Key
L-1 Calculate the steam generation requirement and fuel oil consumption for the co-
generation scheme depicted below
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 /
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:
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
11
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Bureau of Energy Efficiency
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
o
[5000 x 95 + 2000 x 28]/ 7000 = 76 C
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.
Calculate the Quantity of flash steam which can be recovered, and the annual fuel
oil savings on account of condensate recovery
Solution :
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
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
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Bureau of Energy Efficiency
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.
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
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Bureau of Energy Efficiency
Paper 2 Set A Key
Name: ___________________
th
8 NATIONAL CERTIFICATION EXAMINATION MAY, 2009
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 23.05.2009 Timings: 1400 to 1700 HRS Duration: 3 HRS Max. Marks: 150
General 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
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
c) dry saturated steam with high pressure d) wet steam with very high pressure
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 %
11 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
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
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Bureau of Energy Efficiency
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%
20 The difference between mean solid and mean gas velocity in FBC boiler is called
a) fluidization factor b) slip velocity c) settling velocity d) none of the above
21 The minimum capacity of any closed vessel which generates steam under pressure as covered
under Indian Boilers Regulation Act is
a) 22.75 litres b) 2.275 litres c) 22.75 kilo litres d) 227.5 litres
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
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
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Bureau of Energy
Efficiency
Paper 2 Set A Key
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
c) at and above ash fusion temperature d) below ash fusion temperature of fuel used
4
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Bureau of Energy Efficiency
Paper 2 Set A Key
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%
5
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Bureau of Energy Efficiency
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
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Bureau of Energy Efficiency
Paper 2 Set A Key
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 :
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.
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)
Solution:
Heat available for WHR boiler = 744 x 30 x 0.25 x (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 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
Boiler efficiency = 100 x Q (H-h) / (q x GCV)
= 4x (650-65) x 100
----------------------- = 58.5 %.
1 x 4000
8
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Bureau of Energy Efficiency
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
9
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Bureau of Energy Efficiency
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.
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.
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
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
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Bureau of Energy Efficiency
Paper 2 Set A Key
L-4 Calculate the steam generation requirement and fuel oil consumption for the co-
generation scheme depicted below
12
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Bureau of Energy Efficiency
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.
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).
13
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Bureau of Energy Efficiency
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
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:
th
10 NATIONAL CERTIFICATION EXAMINATION July, 2010
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 17.7.2010 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
1. Which of the following fuels needs minimum stoichiometric air for combustion?
a) coal b) natural gas c) LPG d) fuel oil
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
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%
15. Which of the following fuel requires the largest amount of excess air for complete combustion?
a) furnace oil b) LDO c) coal d) natural gas
18. The element that does not contribute to heating value during combustion process is
a) nitrogen b) sulphur c) hydrogen d) carbon
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
2
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
26. The waste heat boiler application is not suitable for which of the following?
a) gas turbine b) diesel engine c) furnaces d) dryers
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
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
3
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
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
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
47. 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
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
a) slightly superheated steam b) dry saturated steam
4
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
. End of Section I .
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)
1 Mark
Amount of steam required = 43890/510
5
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
= 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
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.
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
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.
S-7 Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing
Turbine Cogeneration systems (Note: no explanation required).
Given Data:
o
Flue gas exit temperature = 450 C
o
Flue gas temperature after Waste heat recovery boiler = 230 C
o
Specific heat of flue gases = 0.25 kCal/kg/ C
Specific gravity of diesel oil = 0.85
Air to fuel ratio = 28 kg/kg
Specific fuel consumption = 4.2 kWh/liter
2
Enthalpy of steam at 10 kg/cm = 660 kCal/kg
o
Feed water temperature = 60 C
Operating hours per year = 7500 hrs
7
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
Solution:
Average load of DG set = 5 x 0.8 = 4.0 MW or 4000 kW
1 Mark
Heat available for WHR boiler = [809.52 + (809.52 x 28)] x 0.25 (450 230) = 1291184
kCal/hr
1 Mark
2
Steam generation at 10 kg/cm = 1291184 / (660 60) = 2152 kg/hr or 2.152 tons/hr
Annual steam generation = 2.152 X 7500 = 16,140 tons /year.
2 Marks
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.
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.
2 Marks
Sensible heat loss in flue gas
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
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
L-6 A boiler utilizes bio-mass as fuel and the ultimate analysis (by weight %) of the fuel is
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:
11
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
2 Marks
2 Marks
12
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
th
10 NATIONAL CERTIFICATION EXAMINATION July, 2010
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 17.7.2010 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General 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%
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
a) slightly superheated steam b) dry saturated steam
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
kg of furnace oil generate?
a) 2.4 b) 4.0 c) 3.6 d) 3.1
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
18. Removal of dissolved gases from the boiler feed water is called
a) descaling b) deaeration c) deoxidation d) none of the above
a) poor water treatment b) low steam pressure c) high excess air d) incomplete combustion
2
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
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
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
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
39. Which of the following fuel requires the largest amount of excess air for complete combustion?
a) furnace oil b) LDO c) coal d) natural gas
40. Which of the following fuels needs minimum stoichiometric air for combustion?
a) coal b) natural gas c) LPG d) fuel oil
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
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?
a) superheated steam b) saturated steam
c) high pressure condensate d) condensate at atmospheric pressure
. End of Section I .
4
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
Solution:
Average load of DG set = 5 x 0.8 = 4.0 MW or 4000 kW
1 Mark
Heat available for WHR boiler = [809.52 + (809.52 x 28)] x 0.25 (450 230) = 1291184
kCal/hr
1 Mark
2
Steam generation at 10 kg/cm = 1291184 / (660 60) = 2152 kg/hr or 2.152 tons/hr
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
5
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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.
S-5 Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing
Turbine Cogeneration systems (Note: no explanation required).
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)
1 Mark
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
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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.
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
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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:
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
L-3 A boiler utilizes bio-mass as fuel and the ultimate analysis (by weight %) of the fuel is
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:
C + O2 = CO2
2H2 + O2 = 2H2O
S + O2 = SO2
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.
10
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
= 36.68 + 1
= 37.68 kg/kg of oil
Cp = Specific heat of flue gas
= 0.25
2 Marks
Sensible heat loss in flue gas
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
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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.
12
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
th
11 NATIONAL CERTIFICATION EXAMINATION February, 2011
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 05.02.2011 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
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
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
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
18. Magnesite, chrome magnesite and dolomite are ________ type of refractory;
a) acidic b) basic c) neutral d) none of the above
2
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
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
28. With increase in the percentage of excess air for combustion of coal, percentage of CO 2 in flue gas.
a) increases b) decreases c) remains same d) none of the above
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
3
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
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)
4
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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
c) rise in the total dissolved solids in boiler water d) greater purity of feed water
. End of Section I .
5
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
th
11 NATIONAL CERTIFICATION EXAMINATION February, 2011
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 05.02.2011 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
o
All questions are compulsory
All parts of a question should be answered at one place
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
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.
4*1000*4200
= 70.23%
Ans:
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?
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
Ans:
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:
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.
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
Ans:
Theoretical energy required for melting = 1500 (0.682 x (1650 40) + 272)/3600 kWh
= 570.8 kWh
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)
L-2 Briefly explain the working principle of any two of the following
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
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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.
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.
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
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Bureau of Energy Efficiency
Paper 2 Set A Solutions
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.:
= 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
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.
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.
Ans:
HotBlastCupola
Thetemperatureofexhaustgasofacupolaisashighas800C,makingitpossibletopreheat
blastairuptoashighas400Cbyheatexchange.Inaddition,boththesensibleandlatentheatof
exhaustgascanberecycledforpreheatingblastairbycombustionofCOgasincludedinexhaust
gas.Whenblastairispreheatedto300Corhigher,thesensibleheatofblastairisaddedtoheat
input,activatingcombustionofcoke,leadingtotheriseincombustiontemperature
14
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
th
11 NATIONAL CERTIFICATION EXAMINATION February, 2011
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 05.02.2011 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
1. With increase in the percentage of excess air for combustion of coal, percentage of CO 2 in flue gas.
a) increases b) decreases c) remains same d) none of the above
3. Which of the following fuel requires maximum air for stochiometric combustion?
a) butane b) propane c) hydrogen d) coal
1
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
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
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:
a) acidic solution b) alkaline solution c) neutral solution d) none of the above
14. 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
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
19. The difference in temperature between steam and condensate refers to the principle of operation of
a;
2
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
28. Magnesite, chrome magnesite and dolomite are ________ type of refractory;
a) acidic b) basic c) neutral 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
3
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
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
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
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;
a) increases & remains the same b) increases & decreases
4
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
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
46. A rise in conductivity of boiler feed water indicates
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
End of Section I .
5
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Bureau of Energy Efficiency
Paper 2 Set B Solutions
th
11 NATIONAL CERTIFICATION EXAMINATION February, 2011
FOR
ENERGY MANAGERS & ENERGY AUDITORS
Date: 05.02.2011 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
S-1 Calculate the induction melting furnace efficiency from the following melt cycle data
Ans:
Theoretical energy required for melting = 1500 (0.682 x (1650 40) + 272)/3600 kWh
= 570.8 kWh
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.
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Paper 2 Set B Solutions
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.
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:
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:
Ans:
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.
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Paper 2 Set B Solutions
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
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Paper 2 Set B Solutions
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.
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.
Ans:
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.:
= 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
= 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
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.
ln 210
140
L-5 Briefly explain the working principle of any two of the following
Ans:
Condenser: In steam applications, condenser is associated with condensing steam turbines and
with ejector systems. In steam turbine applications, condenser remove
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Paper 2 Set B Solutions
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)
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Paper 2 Set A Key
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12 NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUDITORS October, 2011
Date: 15.10.2011 Timings: 14:00 - 17:00 HRS Duration: 3 HRS Max. Marks: 150
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
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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
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
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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
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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
32. Chemical used for dozing boiler drum to reduce dissolved gases is
a) hydrazine b) chlorine c) alum d) all 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
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40. A coal fired FBC boiler can operate at ___ excess air
a) 3 4 % b) 20 -25 % c) 30 40 % d) 10 15 %
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
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
. End of Section I .
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53. The amount of heat required to raise the temperature of 1 kg of a substance by 1oC is
called
a) sensible heat b) latent heat c) specific heat d) net calorific value
54. Which among the following fuels is likely to contain maximum percentage of sulphur?
a) kerosene b) diesel oil c) LSHS d) furnace oil
55. Which of the following grades of Indian coal will have the highest calorific value?
a) B b) F c) A d) E
57. Which of the following is not measured in the ultimate analysis of a fuel ?
a) oxygen b) fixed carbon c) sulphur d) nitrogen
59. 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
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In an oil fired heat treatment furnace which of the following is not required to determine its
efficiency by direct method
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76. 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
77. What is the best-suited pump for pumping heavy fuel oil?
a) centrifugal pump b) gear pump c) diaphragm pump d) plunger pump
78. 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
79. Which of the following requires the largest amount of oxygen/kg of substance for
combustion?
a) carbon b) hydrogen c) sulphur d) nitrogen
80. 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
82. Chemical used for dozing boiler drum to reduce dissolved gases is
a) hydrazine b) chlorine c) alum d) all of the above
86. Which of the following fuel fired steam boiler will have the least evaporation ratio?
a) coal b) bagasse c) oil d) gas
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90. A coal fired FBC boiler can operate at ___ excess air
a) 3 4 % b) 20 -25 % c) 30 40 % d) 10 15 %
94. By installing a recuperator ,1% fuel reduction is possible for every ___ reduction in flue
gas temperature
a) 5C b) 33C c) 22C d) 10C
96. Which among the following uses a working fluid for heat recovery ?
a) heat pipe b) recuperator c) heat wheel d) regenerator
97. Which of the following is most suitable for high temperature waste heat recovery ?
a) heat wheel b) heat pump c) heat pipe d) recuperator
98. Among the following, cogeneration concept is not applicable to which type of industry?
a) sugar b) paper & pulp c) refinery d) refractory
99. A device used to convert low pressure steam to high pressure steam is called
a) heat pump b) heat pipe c) thermocompressord) economizer
. End of Section I .
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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.
= 14.63 kg / kg of FO
Actual mass of air supplied = 16.5 Kg/Kg of FO
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.
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o
Tout = 37.95 C
Ln (60/42.5)
o
= 50.49 C
S-4 List five energy saving measures in an oil fired reheating furnace
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Ans
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.
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
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
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21 x 0.23 x (310-180) = 10 x 1 x T
T = 62.8 C
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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)
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
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Option B:
Answer:
a) b) (c)
d)
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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 6.8 = 24.4 C
LMTD
ln1.32
A = 67.3 m2
Area of the heat exchanger surface is 67.3 m2
Abilitytowithstandhightemperatures.
Abilitytowithstandsuddenchangesoftemperatures.
Abilitytowithstandactionofmoltenmetalslag,glass,hotgases,etc.
Abilitytowithstandloadatserviceconditions.
Abilitytowithstandloadandabrasiveforces.
Lowcoefficientofthermalexpansion.
Shouldbeabletoconserveheat.
Shouldnotcontaminatethematerialwithwhichitcomesintocontact.
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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.
c) Thermocompressor
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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
th
12 NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUDITORS October, 2011
Section - I: OBJECTIVE TYPE Marks: 50 x 1 = 50
4. A device used to convert low pressure steam to high pressure steam is called
a) heat pump b) heat pipe c) thermocompressord) economizer
5. 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
An increase in the steam pressure from 3 bar to 10 bar, will result in a decrease of
9. By installing a recuperator ,1% fuel reduction is possible for every ___ reduction in flue
gas temperature
a) 5C b) 33C c) 22C d) 10C
11. Chemical used for dozing boiler drum to reduce dissolved gases is
a) hydrazine b) chlorine c) alum d) all of the above
18. 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
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
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33. What is the best-suited pump for pumping heavy fuel oil?
a) centrifugal pump b) gear pumpc) diaphragm pump d) plunger pump
35. Which among the following fuels is likely to contain maximum percentage of sulphur?
a) kerosene b) diesel oil c) LSHS d) furnace oil
36. Which among the following uses a working fluid for heat recovery ?
a) heat pipe b) recuperator c) heat wheel d) regenerator
39. Which of the following fuel constituents releases maximum amount of heat per kg during
combustion ?
a) hydrogen b) carbon c) sulphur d) nitrogen
40. Which of the following fuel fired steam boiler will have the least evaporation ratio?
a) coal b) bagasse c) oil d) gas
41. Which of the following grades of Indian coal will have the highest calorific value?
a) B b) F c) A d) E
43. Which of the following is most suitable for high temperature waste heat recovery ?
a) heat wheel b) heat pump c) heat pipe d) recuperator
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46. Which of the following is not measured in the ultimate analysis of a fuel ?
a) oxygen b) fixed carbon c) sulphur d) nitrogen
47. 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
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
49. Which of the following requires the largest amount of oxygen/kg of substance for
combustion?
a) carbon b) hydrogen c) sulphur d) nitrogen
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 .
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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.
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
15.High reliability
16.Reduced maintenance
17.Quick response to changing demand
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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
For 1 kg of fuel makeup water is = 10 kg
For 1 kg of fuel required combustion air is = 20 kg
For 1 kg of fuel flue gas generated is = 20 +1= 21 kg
In economizer heat given by flue gas = heat received by makeup water
21 x 0.23 x (280-180) = 10 x 1 x T
T = 48.3 C
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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.
= 14.63 kg / kg of FO
Actual mass of air supplied = 20.5 Kg/Kg of FO
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.
o
Tout = 39 C
S-8 List five energy saving measures in an oil fired reheating furnace
Ans
9
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a) b) c)
d)
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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
= 24.81 C
A = 58.85 m2
2
Area of the heat exchanger surface is 58.85 m
Abilitytowithstandhightemperatures.
Abilitytowithstandsuddenchangesoftemperatures.
Abilitytowithstandactionofmoltenmetalslag,glass,hotgases,etc.
Abilitytowithstandloadatserviceconditions.
Abilitytowithstandloadandabrasiveforces.
12
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Lowcoefficientofthermalexpansion.
Shouldbeabletoconserveheat.
Shouldnotcontaminatethematerialwithwhichitcomesintocontact.
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.
c) Thermocompressor
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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
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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)
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
6
Boiler Efficiency = 2.56 * 10 / (320 * 9550) * 100
Answer:
Boiler Efficiency = 83.76 %
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Option B:
Answer:
Complete
If 10% air is entrained in a steam system at 3 kg/cm 2 g then the saturation temperature of steam will
be
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?
The amount of flash steam generated from the condensate mainly depends on _____
In determining the economic thickness of steam pipe insulation which of the following is not required?
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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
Glass mineral wool can be applied for temperature range application upto
The storage heat losses in a batch type furnace can be best reduced by
Complete
Which of the following contributes to erosive effect on burner tips during combustion?
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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:
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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.
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.
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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
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 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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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
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.
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
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:
= 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 %
Complete
2
Roof : 0.95 x 4.5 = 4.3 m
Refractory Type : Fire Bricks
Wall Thickness
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
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
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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
Heat reduction from total roof area = 80798 x 4.3 = 347431.4 Kcal
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
Feed water temperature : 75 C
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.
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.
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= Rs.7.0 crore
Annual coconut shell Cost = 5000 hrs x 0.85x Rs.5000
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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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
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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
19. The cogeneration system which has high overall system efficiency is
a) back pressure steam turbine b) combined cycle
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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
Power is to be generated from a cement kiln exhaust gas. The applicable type of
cogeneration is called
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32. Instrument used for measuring billet temperature in a reheating furnace is ___.
In determining the economic thickness of steam pipe insulation which of the following is
not required?
If 10% air is entrained in a steam system at 3 kg/cm 2 g then the saturation temperature
of steam will be
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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
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
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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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.
m = 395 kg/hr
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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
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:
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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?
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
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:
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
Feed water temperature : 75 oC
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 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.
substitution?
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= Rs.9.8 crore
Annual coconut shell Cost =7000 hrs x 0.85x Rs.5000
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.
b) Topping and bottoming cycles for cogeneration with examples
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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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.
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Boilers
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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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
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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
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
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Paper 2 Set A
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
2. Which of the following fuel fired steam boiler will have the least evaporation ratio?
a) coconut shell b) natural gas c) oil d) rice husk
8. In a gas turbine, air compressor alone consumes about _____of the energy
generated
_________________________ 1
Bureau of Energy Efficiency
Paper 2 Set A
10. The cogeneration system which has high overall system efficiency is one which
uses
a) back pressure steam turbine b) combined cycle
c) extraction condensing steam turbine d) reciprocating engine
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
.
19. Which of the following in fuel contributes to erosive effect on burner tips?
a) ash b) water c) sulphur d) volatile matter
_________________________ 2
Bureau of Energy Efficiency
Paper 2 Set A
20. 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
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
a) dry saturated steam b) slightly superheated steam
c) mildly wet steam d) very high pressure steam
26. The inverted bucket trap operates on the principle of _______ difference between
water and steam
a) pressure b) density c) temperature d) velocity
28. The insulation material suitable for low temperature application to prevent heat
gain is
a) mineral fiber b) fiber glass c) silica d) polyurethane
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
Bureau of Energy Efficiency
Paper 2 Set A
37. Micro turbine can be used to replace _______ for energy savings
a)gas turbines b) diesel generator c) HRSG d) PRV
40. Which of the following requires the lowest stoichiometric oxygen demand (kg/kg of
fuel)?
a) hydrogen b) carbon c) sulphur d) methane
_________________________ 4
Bureau of Energy Efficiency
Paper 2 Set A
c) reducing the surface heat loss d) minimizing the CO loss and un-burnt losses
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
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
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
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 %
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
_________________________ 6
Bureau of Energy Efficiency
Paper 2 Set A
= Rs. 15750
Cost of one unit of electricity generated = 15750 / 1503
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.
How many kg of steam at 4 bar does this steam coil unit require per hour?
S6 List three functions of steam traps. What type of trap is generally used for main
steam lines?
S7 Explain with sketch the working principle of a regenerator used for high temperature
furnace
_________________________ 7
Bureau of Energy Efficiency
Paper 2 Set A
S8 Explain briefly the bottoming cycle cogeneration system and mention any two of its
application in industry
_________________________ 8
Bureau of Energy Efficiency
Paper 2 Set A
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
T2 = 130 30 = 100C
LMTD of counter flow = (100-90)/ ln(100/90) = 95C
_________________________ 9
Bureau of Energy Efficiency
Paper 2 Set A
Area of heat exchanger for counter flow = 731.5 x 1000 / (814x 95 )
= 9.5 m2
T1 = 180 30 = 150C
T2 = 130 90 = 40C
LMTD of parallel flow = (150-40)/ ln(150/40) = 83C
Overall heat transfer coeff. = 814 W/m2C
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
= 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
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.
b) Steam systems
_________________________ 11
Bureau of Energy Efficiency
Paper 2 Set A
b) Steam Systems
L5 A boiler utilizes Coconut shell as fuel and the ultimate analysis (by weight %) of the fuel is
given below:
Ans a)
Total oxygen required =45x2.67+ 5 x 8+.08 x 1 = 160.23kg
Oxygen present in the fuel =32 kg
_________________________ 12
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
_________________________ 13
Bureau of Energy Efficiency
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
= Rs 53,760
Additional coal requirement per hour = 4000 x(780-135) / (0.8 x 4300)
= 750 kg/hr
_________________________ 14
Bureau of Energy Efficiency
Paper 2 Set B
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
.
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
Bureau of Energy Efficiency
Paper 2 Set B
8. 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
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%
15. In a gas turbine, air compressor alone consumes about _____of the energy
generated
a) 5-10% b) 20-30% c) 30-40% d) 40-45%
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
Bureau of Energy Efficiency
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
21. Micro turbine can be used to replace _______ for energy savings
a)gas turbines b) diesel generator c) HRSG d) PRV
c) reducing the surface heat loss d) minimizing the CO loss and un-burnt losses
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
a) back pressure steam turbine b) combined cycle
c) extraction condensing steam turbine d) reciprocating engine
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
30. The difference in temperature between steam and condensate is the principle of
operation in a
_________________________ 3
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
a) mineral fiber b) fiber glass c) silica d) polyurethane
35. The inverted bucket trap operates on the principle of _______ difference between
water and steam
a) pressure b) density c) temperature d) velocity
36. 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
42. Which of the following fuel fired steam boiler will have the least evaporation ratio?
a) coconut shell b) natural gas c) oil d) rice husk
_________________________ 4
Bureau of Energy Efficiency
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
47. Which of the following will be ideal for heat transfer in a heat exchanger?
a) hot water b) super heated steam
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
Bureau of Energy Efficiency
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.
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
= Rs. 17,500
Cost of one unit of electricity generated = 17500 / 1503
_________________________ 6
Bureau of Energy Efficiency
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.
S5 Explain with sketch the working principle of a regenerator used for high temperature
furnace
S6 Explain briefly the bottoming cycle cogeneration system and mention any two of its
application in industry
_________________________ 7
Bureau of Energy Efficiency
Paper 2 Set B
S7 List three functions of steam traps. What type of trap is generally used for main
steam lines?
_________________________ 8
Bureau of Energy Efficiency
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.
How many kg of steam at 4 bar does this steam coil unit require per hour?
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
Bureau of Energy Efficiency
Paper 2 Set B
Ans
% salt concentration at inlet = 30%
% salt concentration at outlet = 55%
Input quantity of caustic solution to drier = 100 TPD
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?
_________________________ 10
Bureau of Energy Efficiency
Paper 2 Set B
Area of heat exchanger for counter flow = 731.5 x 1000 / (760 x 95 )
= 10.13 m2
T1 = 180 30 = 150C
T2 = 130 90 = 40C
LMTD of parallel flow = (150-40)/ ln(150/40) = 83C
Overall heat transfer coeff. = 760 W/m2C
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
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
Bureau of Energy Efficiency
Paper 2 Set B
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.
b) Steam systems
_________________________ 12
Steam Systems
_________________________ 13
Bureau of Energy Efficiency
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
= Rs 46,080
Additional coal requirement per hour = 4000 x(780-135) / (0.8 x 4300)
= 750 kg/hr
_________________________ 14
Bureau of Energy Efficiency
REGULAR Paper 2 Set A
Name : __________________
(To be written by the candidate)
th
16 NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUDITORS September, 2015
Date: 19.09.2015 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
o Please check that this question paper contains 8 printed pages
o Please check that this question paper contains 64 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
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
5. Which of the following requires the largest amount of oxygen/kg of substance for
combustion
a) carbon b) hydrogen c) sulphur d) nitrogen
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)
a) hydrogen b) carbon c) sulphur d) methane
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
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
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
_________________________ 2
21. The parameter assumed to remain constant during LMTD calculation of a Heat exchanger
is
a) temperature drop b) heat transfer area
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
_________________________ 3
37. Heat transfer rate for indirect heating application will be less if we heat with
a) saturated steam b) dry steam
_________________________ 4
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
Bureau of Energy Efficiency
REGULAR Paper 2 Set A
Solution:
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
= 10,500.4 Kg/hr
. (1 mark)
% CO2 in the flue gas = (1375 / 10,500.4)x 100
= 13.1 %
. (1 mark)
_________________________ 6
Bureau of Energy Efficiency
REGULAR Paper 2 Set A
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
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
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.
_________________________ 7
Ans:
Nitrogen 0.9 -
Moisture 10.8 -
.. (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
.. (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
Bureau of Energy Efficiency
REGULAR Paper 2 Set A
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
Mild steel (MS) scrap charged : 1250 kg
Ans:
Theoretical energy required for melting = 1250 (0.68 x (1450 35) + 270)/3600
= 427.8 kWh
. (3 marks)
. (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
Therefore x = 0.37
= 135.7 KJ/sec
=135.7 /4.18
= 32.46 kcal/sec
. (2.5 marks)
LMTD: DT1 = 55 10 = 45 C
DT2 = 18 10 = 8 C
. (2.5 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:
Type of boiler : Furnace oil fired
Solution:
a) Efficiency of furnace oil fired boiler (Direct method)
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)
50,00,000
= 3.8 % . (3 marks)
_________________________ 11
Bureau of Energy Efficiency
REGULAR Paper 2 Set A
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
Solution :
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
Bureau of Energy Efficiency
REGULAR Paper 2 Set A
L-3 Write short notes on any two of the following: (5 marks each)
a) Plate heat exchanger (page 242 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
The quantity of annual raw material consumption and its heating values are given in table.
Raw material Quantity Heating Value
consumption
Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing
Turbine Cogeneration systems (Note: no explanation required).
Answer :
_________________________ 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
Efficiency of furnace : 73 %
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
. (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.
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
Bureau of Energy Efficiency
REGULAR Paper 2 Set B
Name : __________________
(To be written by the candidate)
th
16 NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUDITORS September, 2015
Date: 19.09.2015 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
o Please check that this question paper contains 8 printed pages
o Please check that this question paper contains 64 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
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
3. Which of the following requires the largest amount of oxygen/kg of substance for
combustion
a) carbon b) hydrogen c) sulphur d) nitrogen
4. 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
_________________________ 1
6. Which of the following boiler utilizes the combination of suspension firing and great firing
a) traveling grate stoker boiler b) packaged boiler
_________________________ 2
17. Heat transfer rate for indirect heating application will be less if we heat with
a) saturated steam b) dry steam
28. Which of the following has the lowest stoichiometric oxygen demand (kg/kg of fuel)
a) hydrogen b) carbon c) sulphur d) methane
_________________________ 3
a) low Volatile matter b) low fixed carbon c) less ash d) none of the above
30. Which of the following boiler water treatment ensures complete removal of salts
a) demineralization b) softening c) de-aeration d) all of the above
31. Which fuel among the following needs temperature control during storage
a) coal b) furnace oil c) diesel oil d) kerosene
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
c) high load under partial pressure d) low load under partial pressure
37. The amount of CO2 produced in complete combustion of 18 Kg of carbon
a) 50 b) 44 c) 66 d) 792
42. 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
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
S-1 Calculate the electricity consumption in an induction melting furnace from the following melt
cycle data,
Mild steel (MS) scrap charged : 1250 kg
Specific heat of MS : 0.68 kJ/kg 0C
Latent heat of MS : 270 kJ/kg
MS melting temperature : 1650 0C
Inlet MS charge temperature : 35 0C
Efficiency of furnace : 65%
Ans: Theoretical energy required for melting = 1250 (0.68 x (1650 35) + 270)/3600
= 475.1 kWh
. (3 marks)
_________________________ 5
. (2 marks)
S-2 (a) Why should LPG cylinders not be stored in basements or cellars? (2.5 marks)
(b) Why should the stack temperature of furnace oil fired boilers not be maintained below
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:
_________________________ 6
Bureau of Energy Efficiency
REGULAR Paper 2 Set B
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
. (2.5 marks)
LMTD:
DT1 = 60 10 = 50 C
DT2 = 22 10 = 12 C
= 26.6 C
. (2.5 marks)
S-5 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.
_________________________ 7
Nitrogen 0.9 -
Moisture 11.8 -
. (4 marks)
Total Oxygen required = 93.04 kg oxygen / 100 kg fuel
Therefore theoretical quantity of dry air reqd. = 93.04 / 0.23 = 404.5 kg air / 100 kg fuel
..(1 mark)
S-6 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 =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
H = 760kcal/kg Alternator 0.7 MW
_________________________ 8
Bureau of Energy Efficiency
REGULAR Paper 2 Set B
Solution
S-7 For combustion of 500 kg/hr of Natural Gas containing 100% Methane, Calculate the
percentage of CO2 in the flue gas while 20% excess air is supplied.
Ans:
CH4 + 2 O2 CO2 + 2H2O
1 mole of Methane requires 2 moles of Oxygen.
. (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)
S-8 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 25 m/s, determine the pipe diameter size for distribution of steam.
_________________________ 9
D U 4Volumetric flowrate
Flow velocity
D U 40.333
25
D U 0.130 m or 130 mm
. (3 marks)
Since the steam velocity must not exceed 25 m/s, the pipe size must be at least 130 mm; the
nearest commercially available size, 150 mm, would be selected.
L-1 Write short notes on any two of the following: (5 marks each)
a) Plate heat exchanger (page 242 of book-2)
_________________________ 10
L-2 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:
Type of boiler : Furnace oil fired
Solution:
a) Efficiency of furnace oil fired boiler (Direct method)
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
.. (1 mark)
Annual net monetary savings after conversion
.. (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
The quantity of raw material consumption and its heating values are given in table.
Raw material Quantity Heating Value
consumption
Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing
Turbine Cogeneration systems (Note: no explanation required).
Answer
a) Specific Energy Consumption(SEC) of Ammonia
kWh
1250850
Ammonia 133200 Ton
production 2 marks
Specific Energy Consumption(SEC) of Ammonia 9.39 Gcal per
production = Ton
Answer
L-4 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
_________________________ 13
Solution:
Amount of Air flow = 240 * 60 * 1.15
= 16560 Kg/hr
. (1mark)
Amount of fuel = 16560 / 17
= 974.12 Kg/hr
. (1mark)
Amount of flue gas = 16560 + 974.12
= 17534.1 Kg/hr
. (1mark)
Heat absorbed by combustion air = 16560 * 0.23 * (250 30)
= 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
= 445816 W = 445.82 kW
ii) mh ch (th1 th2) = mc cc (tc1 tc2) . (2 marks)
th2 = 44.6 o C
..(3 marks)
_________________________ 14
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)
= (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.
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
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
Date: 19.09.2015 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
3. 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
12. For flash steam calculation, flash steam quantity available depends upon
a) condensate pressure and flash steam pressure b) steam pressure
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
17. 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
_________________________ 2
25. The difference in temperature between steam and condensate is the principle of
operation in a
a) thermodynamic trap b) thermostatic trap
29. The parameter assumed to remain constant during LMTD calculation of a Heat
exchanger is
a) temperature drop b) heat transfer area
32. The TDS level in boiler water for boiler blow down, is measured through
a) alkalinity of water b) thermal conductivity of water
_________________________ 3
38. Which fuel among the following needs temperature control during storage
a) coal b) furnace oil c) diesel oil d) kerosene
39. 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
40. Which of the following boiler utilizes the combination of suspension firing and great
firing
a) traveling grate stoker boiler b) packaged boiler
43. 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
_________________________ 4
50. 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
S-1 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
_________________________ 5
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
Ans:
Considering a sample of 100 kg of paddy husk.
Therefore theoretical quantity of dry air reqd. = 98.38 / 0.23 =427.7 kg air / 100 kg fuel
S-2 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
Therefore, using:
Volumetric flow rate (m3/s) = Velocity (m/s) x Cross sectional area (m2)
(1 mark)
_________________________ 6
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
D U 4 Volumetric flowrate
Flow velocity
D U 4 0.333
28
D U 0.123 m or123 mm
Since the steam velocity must not exceed 25 m/s, the pipe size must be at least 123 mm; the
S-3 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
_________________________ 7
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
S-4 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
H =650kcal/kg Plant Condensate
P= 4 kg/cm2
T= 165oC
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
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
Boiler efficiency : 80%
Ans:
Heat loss through non-insulated pipe = [10 + (Ts Ta) / 20] * (Ts Ta) ]
Ts = Surface temperature
Ta = Ambient temperature
_________________________ 8
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
Heat loss through insulated pipe = [10 + (45 25) / 20] * (45 25) ]
= 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)
= 86 kg/hr
Steam cost = 86 x Rs.4
= 51 kWh
= 51 x Rs. 6
= Rs.306/ hr
Electrical heating will be more economical (2 mark)
S-7 Calculate the electricity consumption in an induction melting furnace from the following melt
cycle data
Mild steel (MS) scrap charged : 1250 kg
_________________________ 9
Ans:
Theoretical energy required for melting = 1250 (0.68 x (1450 35) + 270)/3600
S-8 (a) Why should LPG cylinders not be stored in basements or cellars? (2.5 marks)
(b) Why should the stack temperature of furnace oil fired boilers not be maintained below
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)
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
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
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:
(4 marks)
_________________________ 11
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
L-2 Write short notes on any two of the following: (5 marks each)
a) Plate heat exchanger (page 242 of book-2)
L-3 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:
Type of boiler : Furnace oil fired
Solution:
a) Efficiency of furnace oil fired boiler (Direct method)
Boiler Efficiency () = 5000 x (665-75) / (350 x 10400)
_________________________ 12
(1 mark)
Annual fuel cost of coconut shell fired boiler = 924.2 x 7200 x 12
= 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
1) The heat transfer rate
(2 marks)
mh ch (th1 th2) = mc cc (tc1 tc2)
x 4190 x (70 - th2) = 2 x 4190 x (50 -10) th2
= 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)
= 335200 800 x
27.69
Area =15.13 m2
(2.5 marks)
_________________________ 13
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
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)
(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
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set A
L-6 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
Solution:
= 16560 Kg/hr
(1 mark)
Amount of fuel = 16560 / 18
= 920 Kg/hr
(1 mark)
Amount of flue gas = 16560 + 920
= 17480 Kg/hr
(1 mark)
Heat absorbed by combustion air = 16560 * 0.23 * (250 30)
= 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
_________________________ 15
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
th
16 NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUDITORS September, 2015
Date: 19.09.2015 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150
General instructions:
o Please check that this question paper contains 8 printed pages
o Please check that this question paper contains 64 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
3. 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
5. 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
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7.Which of the following requires the largest amount of oxygen/kg of substance for
combustion
a) carbon b) hydrogen c) sulphur d) nitrogen
Which of the following boiler utilizes the combination of suspension firing and great firing
10. The TDS level in boiler water for boiler blow down, is measured through
a) alkalinity of water b) thermal conductivity of water
_________________________ 2
21. Heat transfer rate for indirect heating application will be less if we heat with
a) saturated steam b) dry steam
28. 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
_________________________ 3
40. Which of the following has the lowest stoichiometric oxygen demand (kg/kg of fuel)
a) hydrogen b) carbon c) sulphur d) methane
45. Which of the following boiler water treatment ensures complete removal of salts
_________________________ 4
50. On an inverted bucket trap, what happens to the bucket as the trap fills with water
a) it risesb) it inclinesc) it sinks d) it remains stationary
S-1 (a) Why should LPG cylinders not be stored in basements or cellars? (2.5 marks)
(b) Why should the stack temperature of furnace oil fired boilers not be maintained below
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)
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Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
(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,
Boiler efficiency : 80%
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)
S-3 Calculate the electricity consumption in an induction melting furnace from the following melt
cycle data,
Mild steel (MS) scrap charged : 1250 kg
Specific heat of MS : 0.68 kJ/kg 0C
Latent heat of MS : 270 kJ/kg
MS melting temperature : 1650 0C
Inlet MS charge temperature : 35 0C
Efficiency of furnace : 65%
Ans:
Theoretical energy required for melting = 1250 (0.68 x (1650 35) + 270)/3600
_________________________ 6
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 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
Considering a sample of 100 kg of paddy husk.
Nitrogen 0.9 -
Moisture 11.8 -
_________________________ 7
(4 marks)
Total Oxygen required = 93.04 kg oxygen / 100 kg fuel
Therefore theoretical quantity of dry air reqd. = 93.04 / 0.23 = 404.5 kg air / 100 kg fuel
S-5 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 =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 BPT Power
H = 760kcal/kg Alternator 0.7 MW
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
percentage of CO2 in the flue gas while 20% excess air is supplied.
_________________________ 8
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
Ans:
CH4 + 2 O2 CO2 + 2H2O
= 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
flow velocity not to exceed 25 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 = 25 m/s
Volumetric flow rate(m3/s) = Velocity (m/s) x cross sectional area (m2) (1 mark)
D2 U 4 Volumetric flowrate
Therefore, Flow velocity
D U 4 Volumetric flowrate
Flow velocity
D U 4 0.333
25
D U 0.130 m or 130 mm
Since the steam velocity must not exceed 25 m/s, the pipe size must be at least 130 mm; the
nearest commercially available size, 150 mm, would be selected.
(3 marks)
_________________________ 10
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
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
1) The heat transfer rate
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)
((75-50)-(44.6-12) ln
(75-50)/(44.6-12)
25-32.4
ln(25/32.4)
LMTD = 28.54oC
(2.5 marks)
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Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
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)
Initial blow down = 450 * 10 / (3000 450)
L-3 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
= 16560 Kg/hr
(1 mark)
Amount of fuel = 16560 / 17
= 974.12 Kg/hr
(1 mark)
Amount of flue gas = 16560 + 974.12
= 17534.1 Kg/hr
(1 mark)
Heat absorbed by combustion air = 16560 * 0.23 * (250 30)
= 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
(1 mark)
L-4 Write short notes on any two of the following: (5 marks each)
a) Plate heat exchanger (page 242 of book-2)
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L-5 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:
Type of boiler : Furnace oil fired
Solution:
a) Efficiency of furnace oil fired boiler (Direct method)
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)
50,00,000
=3.8 % (3 marks)
_________________________ 14
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)
(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
Bureau of Energy Efficiency