Paper 2 – Set A Key

Regn No: _________________

Name: ___________________

(To be written by the candidates)

8th NATIONAL CERTIFICATION EXAMINATION – MAY, 2009

FOR
ENERGY MANAGERS & ENERGY AUDITORS

Paper – 2: Energy Efficiency in Thermal Utilities

Date: 23.05.2009 Timings: 1400 to 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

Section – I: OBJECTIVE TYPE Marks: 50 x 1 = 50

(i) Answer all 50 questions

(ii) Each question carries one mark
(iii) Please hatch the appropriate oval in the OMR answer sheet with Black Pen or
HB pencil, as per instructions

1 The amount of theoretical air required for complete combustion of one ton of coal as compared
to that required for one ton of fuel oil is:

a) higher b) lower c) equal d) none of the above

2 2
2 If saturated steam at a pressure of 20 Kg/cm (a) is reduced to 10 Kg/cm (a), through a pressure
reducing valve, the steam will

a) condense b) remain saturated

c) get superheated d) be a mixture of 50% steam and 50% condensate
3 The unit of specific gravity in SI system is ___________
3 3 2
a) N/m b) kgf/m c) kg/m d) no unit
4 In a furnace, an oxygen rich combustion air (Oxygen – 30% vol. and Nitrogen – 70% vol) is
supplied instead of normal air (oxygen – 21% vol. and Nitrogen – 79% vol). By maintaining the
other parameters same, the % age of carbon dioxide in the flue gases will be

a) same b) lower c) higher d) zero

5 What type of steam is generally used for electrical power generation?
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a) high pressure steam with super heat b) dry saturated steam

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 %
9 Which of the following is used as insulation in low temperature applications ?

a) ceramic fibre b) calcium silicate c) fibre glass d) polystyrene

10 The coefficient of thermal expansion of refractory material should be

a) low b) high c) medium d) very high

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

12 A rise in conductivity of boiler feed water indicates

a) drop in the contamination of feed water

b) greater purity of feed water
c) rise in the contamination of feed water
d) it has got no relation with the contamination of feed water
13 Pick the boiler, which can be considered as most combustion efficient?

a) fluidized bed combustion boiler b) lancashire boiler

c) stoker fired boiler d) chain grate boiler
14 Instrument used for measuring temperature in a glass furnace is

a) Leaf type thermocouple b) Infrared pyrometer

c) Pt/Pt-Rh thermocouple with indicator d) Chrome alumnel thermocouple with indicator
15 Recuperator will be more efficient if the flow path of hot and cold fluids is in:

a) co-current mode b) counter current mode

c) cross current mode d) none of the above
16 Which of the following best indicates the overall efficiency of a Combined Cycle thermal power
plant?

a) 33 % b) 42 % c) 55% d) 60%

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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%

18 Which of the following heat recovery equipment works on a refrigeration cycle ?

a) thermocompressor b) heat wheel c) heat pump d) heat pipe

19 High % of carbon monoxide presence in the flue gas of boiler is an indicator of

a) high excess air b) complete combustion

c) good control of pollutants d) low excess air
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 120ºC is supplied with 50 kCal of heat at same pressure,
its temperature will be

a) 220ºC b) 190ºC c) 170ºC d) 120ºC

24 The purpose of venting air from steam systems is because air is a

a) insulator b) good conductor c) inert substance d) dilutant

25 Oxygen (O2) percentage measurement by volume basis can be done by using:

a) ultrasonic tester b) potassium oxide probe

c) copper tubes d) zirconium oxide probe
26 ““Turndown ratio” for oil fired burner is the ratio of

a) air to fuel
b) maximum fuel input to actual fuel input
c) maximum fuel input over minimum fuel input at same percentage of excess air
d) maximum air input over minimum air input
27 The type of firing used for a pulverized coal fired boiler is

a) over firing b) tangential firing

c) vertical firing d) mixed firing for effective heat transfer
o
28 The percentage raise in boiler efficiency by a 20 C raise in combustion air temperature is

a) 0.1% b) 0.2% c) 10% d) 1%

29 The steam generation in a boiler is 16 tonnes for four hours. The oil consumption for the same
period is 1.3 Tonnes. The evaporation ratio is
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a) 12.3 b) 11.5 c) 9.2 d) 14

30 The normal velocities encountered in pipes for saturated steam is

a) 60 to 80 m/sec b) 10-20 m/sec c) 5 to 10 m/sec d) 30 to 40 m/sec

31 In industrial applications the type of trap used for main steam lines are

a) thermodynamic b) thermostatic c) bimetallic d) float

32 Which steam trap operates on the principle of difference in density between steam and
condensate

a) thermodynamic trap b) inverted Bucket c) thermostatic trap d) none of the above

33 Which of the following will be the ideal pressure to be maintained in a reheating furnace

a) –20 mm b) +1 mm c) +30 mm d) +20 mm

O
34 When the furnace is operated below 370 C, then it is called

a) muffle furnace b) kiln c) oven d) all the above

35 The percentage efficiency of a reheating furnace, operating at 10 tonnes per hour and
consuming furnace oil of 230 kg/hour for reheating the material from 40 °C to 1100 °C (specific
heat of material is 0.13 kCal / kg °C and calorific value of furnace oil is 10,000 kCal /kg) is

a) 60 b) 70 c) 80 d) 50
36 The emissivity of ceramic coatings used in furnace

a) decreases with increase in temperature b) Increases with increase in temperature

c) remains constant irrespective of temperature d) decreases with increase in furnace pressure
37 Which is not a property of Ceramic fibre insulation

a) low thermal conductivity b) light weight

c) high heat storage d) thermal shock resistant
38 In a CFBC Boiler the capture and recycling of bed materials is accomplished by

a) settling chamber b) cyclone c) back filter d) scrubber

39 In FBC boiler the combustion is carried out at a temperature

a) closer to steam temperature b) at adiabatic combustion temperature

c) at and above ash fusion temperature d) below ash fusion temperature of fuel used
40 Reverse osmosis for water treatment involves

a) removal of total salts b) removal of only hardness causing salts

c) removal of alkali salts d) removal of non-hardness salts
41 The percentage of energy consumed by air compressor in gas turbine plants is typically

a) 10% b) 22% c) 55% d) 80%

42 Capillary wick is a part of

a) heat pump b) heat wheel c) heat pipe d) regenerator

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43 Thermo-compressor is commonly used for

a) compressing hot air b) upgrading low pressure steam

c) distillation d) reverse compression of CO2
44 Which of the following is not required in the boiler efficiency evaluation by direct method

a) steam flow b) fuel flow c) feed water temperature d) O2 % in flue gas

45 The inlet gas temperature in a gas turbine is around
o o o o
a) 1700 C b) 1000 C c) 650 C d) 500 C
46 Controlled wetting of coal (during the coal preparation) would result in

a) reduction in flue gas exit temperature b) decrease in the percentage of unburnt carbon
c) improper combustion d) increase in the fines of coal
47 Ceramic fibre gives the maximum savings when used in

a) continuous furnace b) batch furnace c) arc furnace d) induction furnace

48 The major limitation of metallic recuperator is

a) handling COx, NOx etc.

o
b) reduced life for handling temperature more than 650 C
c) manufacturing difficulty of the required design
d) none of the above
49 Which of the following when added to alumino silicate helps to reduce the shrinkage level of
ceramic fibre

a) Zr O2 b) SiO2 c) Al2O3 d) CaSO4

50 In flue gas the theoretical CO2 is 15% and the measured CO2 is 9% by volume. The % excess
air is:

a) 66% b) 150% c) 25% d)20%

-------- End of Section - I ---------

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 Paper 2 – Set A Key

Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 40

(i) Answer all Eight questions

(ii) Each question carries Five marks

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.

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 Influences secondary air requirement and distribution aspects.

 Influences secondary oil support

S-4 Given the choice would you paint the outer surface of a reheating furnace
black, or with a shiny glossy colour (such as silver colour)? Explain.

ANS :

The emissivity of the outer surface should be kept to a minimum since the skin losses
would increase with high emissivity. A black colour acts like a black body with highest
emissivity, while a glossy and shiny aluminium foil has about the lowest emissivity.
Therefore, radiation loss is minimized. Shiny glossy colour, which has a lower emissivity
should be used.

S-5 What is the major advantage of a self recuperative burner (SRB). For a SRB
the quantity of heat brought in by pre heated air is 1000 kCal/kg fuel and
the quantity of heat taken away by exhaust gases is 4000 kCal per kg fuel. If
the calorific value of the fuel is 10,000 kCal/kg, find the % fuel saving rate?
ANS :

Self Recuperative Burners

Self-recuperative burners (SRBs) are based on traditional heat recovery techniques in that
the products of combustion are drawn through a concentric tube recuperator around the
burner body and used to pre-heat the combustion air

A major advantage of this type of system is that it can be retro-fitted to an existing furnace
structure to increase production capability without having to alter the existing exhaust gas
ducting arrangements. SRBs are generally more suited to heat treatment furnaces where
exhaust gas temperatures are lower and there are no stock recuperation facilities.

Estimation of fuel savings

By using preheated air for combustion, fuel can be saved. The fuel saving rate is given by
the following formula:

S = P X 100 /(F + P - Q)
where S: fuel saving rate, %
F: Calorific value of fuel (kCal/kg fuel)
P: quantity of heat brought in by preheated air (kCal/kg fuel)
Q: quantity of heat taken away by exhaust gas (kCal/kg fuel)

S = 1000 X 100 / (10000 + 1000 - 4000)

S = 14.28 %

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S-6 A 5 MW DG Set is operating at 70% load. A waste heat recovery boiler is

installed to recover heat from exhaust gas to generate steam at 10 kg/cm2.
Find out the quantity of steam generated annually after installing the waste
heat recovery boiler
Given Data:
 Flue gas exit temperature = 500 oC
 Flue gas temperature after Waste heat recovery boiler = 250 oC
 Specific heat of flue gases = 0.25 kCal/kg/oC
 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
 Feed water temperature = 30 oC
 Operating hours per year = 6000 hrs
ANS :
Solution:
Average load of DG set = 5 x 0.7 = 3.5 MW or 3500 kW
Diesel consumption = 3500 x 0.85 /4 = 744 kg/hr
Heat available for WHR boiler = 744 x 30 x 0.25 x (500 – 250) = 1395000 kCal/hr
Steam generation at 10 kg/cm2 = 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
steam enthalpy is 650 kCal/kg; feed water temperature is 650C 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

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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.

Ans. Pressure drop = 4fLV2

--------------
2gD

Pressure drop with 250 mm = 4 x 0.005 x 500 x 22 / (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
Pressure drop with 350 mm = 4 x 0.005 x 500 x 1.022 / (2 x 9.81 x0. 350)
= 1.51 m
Pressure drop reduction = 8.15 – 1.51 = 6.64 m

-------- End of Section – II ---------

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Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all Six questions

(ii) Each question carries Ten marks

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:
a. Water/steam circulation design
b. Furnace bottom-grate clearance
c. Type of particulate control device
d. Fan capacity
e. Availability of space.

Retrofitting of a fluidized bed combustor to a conventional stoker fired water tube

boiler may involve:
a. The replacement of grate by a distributor plate with short stand pipes for
admitting air from the wind box located underneath.
b. Installation of stand pipes to remove ash from the bed.
c. Provision of horizontal hair pin tubes in the bed with a pump for forced
circulation from the boiler drum.
d. Modification of crusher to size the coal/limestone mixture for pneumatic
under bed injection of the mixture.

It may be emphasized that conversion of a conventional coal fired system to a fluidized

bed combustion system can be accomplished without effecting major changes, after
making a cost-benefit analysis. Oil fired boilers can also be converted to coal fired fluidized
bed combustion systems.

L-2 Analyse the diagram as given below and calculate:

(i) Boiler Efficiency by direct method

(ii) Water Temperature in the condensate tank
(iii) Estimate fuel loss due to the drop in feed water temperature, assuming the boiler
efficiency to be the same

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Given that:
Enthalpy of steam at 10kg/cm2 = 665 kCal/kg
Furnace Oil consumption = 600 liters/hr
Specific Gravity of furnace oil = 0.89
G.C.V. of furnace oil = 10,000 kCal/kg

Solution : Oil Consumption = 600 x 0.89 = 534 kg/hr

1) Boiler Efficiency = 7000 (665 - 60) X 100/ 534 X 10000

= 79.3 %

2) Feed water temperature in condensate tank

= [5000 x 95 + 2000 x 28]/ 7000 = 75.85oC = 76 oC

3) Fuel Loss = [ 7000 x (76 – 60)]/ 10000 x 0.793 = 14 kg/hr

L-3 What is a steam phase diagram? Draw the steam phase diagram and mark the
following: 60oC

a. Critical Point
b. Two phase region
c. Saturated liquid line
d. Saturated vapor line
e. Lines of constant pressure
f. Super heated region
g. Liquid region

Solution: The relationship between the enthalpy and the temperature at various different
pressures, is known as a phase diagram

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L-4 Calculate the steam generation requirement and fuel oil consumption for the
co-generation scheme depicted below

Assumption = Losses across turbine including steam loss = 3 million kCal/hr

GCV of fuel oil = 10,000 kCal/kg

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Solution:
6
Heat in process steam = 80 x 1000x 660 = 52.8 x 10 kCal/hr

6
Heat equivalent to power generation = 17 x 1000 x 860 = 14.62 10 kCal/hr

6
Heat loss across turbine = 3 x 10 kCal/hr

6 6
Total Heat input to turbine = (52.8 + 14.62 + 3) x 10 kCal/hr = 70.42 x 10 kCal/hr

6
Equivalent steam generation at 100 kg/cm 2 at 760 kCal/kg = 70.42 x 10 / 760

= 92.7 tons/hr

Fuel Oil Consumption at 80% efficiency = [92.7 (760 – 80)]/ (0.8 x 10000)

= 7.8 tons/hr

L-5 A textile plant has an extensive stream distribution network and the steam
condensate is not being recovered. The plant management is planning to
recover the condensate and generate flash steam for use as low pressure
process steam for fuel economy. The following are the parameters about the
system.

Condensate quantity 1000 kg/hr

Condensate Pressure 10 bar
Cost of steam Rs 1100/ T
Annual operating hours 8000
Low pressure process steam (flash steam) pressure 2 bar
Sensible heat of condensate at 10 bar 188 kCal/kg
Sensible heat of condensate at 2 bar 135 kCal/kg
Latent heat of steam at 2 bar 518 kCal/kg
Boiler Efficiency 82 %
GCV of fuel oil 10,200 kCal/kg
Specific Gravity of fuel oil 0.92
Condensate temperature when recovered 95 oC
Make up water temperature 35 oC

Calculate the Quantity of flash steam which can be recovered, and the annual fuel oil
savings on account of condensate recovery

Solution :
a) Flash steam available % = S1- S2/(L2)
Where: S1 is the sensible heat of higher pressure condensate.
S2 is the sensible heat of the steam at lower pressure
L2 is the latent heat of flash steam (at lower pressure).

% of Flash steam recoverable = (188 – 135)/518 = 10.2 %

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Quantity of flash steam recovered from condensate = 1000 x 0.102 = 102 kg/hr

Condensate available for recovery after flash steam = 1000 – 102 = 898 kg/hr

Heat recovered = 898 x (95 – 35 ) = 53880 kCal/hr

Oil saved = 53880 x 8000 / (0.82 x 10200) = 51.2 tons/yr

L-6 In an engineering industry, resistance heating type furnace was used for heat
treatment of the product. The power consumption of the furnace at 1/3 load
and full load is 860 kWh and 1600 kWh per cycle respectively. The furnace heat
treatment cycle and loading of the furnace was analysed. The details are as
follows:

Furnace capacity : 180 kW

Loading capacity of furnace : 10 Tonnes
Heat treatment cycle : Heating up to 650 °C – 6 hours
: Soaking at 650 °C – 8 hours
: Cooling in furnace – 4 hours
Quantity of the stock to be treated : 1000T/year
Evaluate the annual energy savings at full load operation of the furnace.

Solution Sp. Power consumption of stock:

Load in furnace (1/3) = 10 x 1/3
= 3.3 MT
Power consumption for 1/3rd load = 860 kWh/cycle

Sp. Power consumption at 1/3rd load = 860/3.3

= 260.6 kWh/MT
Load in the furnace (full) = 10 MT
Power consumption at full load = 1600 kWh/cycle
Sp. Power consumption at full load = 1600/10
= 160 kWh/MT

Reduction in power consumption at optimum load (full load)

= 260.6 – 160
= 100.6 kWh/MT

Annual stock production = 1000 T

By operating furnace with each batch of 10T (full load)
Reduction in power consumption = 1000 x 100.6
= 100600 kWh /year
-------- End of Section – III ---------

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 Paper 2 –Set B Solutions

Regn No: _________________

Name: ___________________
(To be written by the candidate)

9th NATIONAL CERTIFICATION EXAMINATION – December, 2009

FOR
ENERGY MANAGERS AND ENERGY AUDITORS

PAPER – 2: Energy Efficiency in Thermal Utilities

Date: 19.12.2009 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150

General instructions:
o Please check that this question paper contains 14 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

Section - I: OBJECTIVE TYPE Marks: 50 x 1 = 50

(i) Answer all 50 questions

(ii) Each question carries one mark
(iii) Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB
pencil, as per instructions

1 The material used to control SO x in the FBC boiler is

a) lime b) alumina c) silica d) limestone

2 Carpet loss occurs in

a) coal combustion b) atomization of oil c) furnaces d) coal storage

3 In industrial applications the commonly used trap for main steam lines is

a) thermostatic trap b) inverted bucket trap

c) thermodynamic trap d) open bucket trap
4 Mark the best choice of insulation material for electric heat treatment furnace among the
following

a) glass wool b) calcium silicate c) fire bricks d) ceramic fibre

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 Paper 2 –Set B Solutions

5 The low combustion temperature in FBC boilers results in minimal formation of

a) CO b) SOx c) NOx d) CO2

6 For same inlet conditions of the steam which of the following will generate the maximum power

a) condensing turbine b) back pressure turbine

c) extraction-cum-condensing turbine d) extraction-cum-back pressure turbine
7 Demineralisation of water is the process to remove

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

8 In a glass industry waste heat is used for power generation. This type of cogeneration is called

a) topping cycle b) bottoming cycle

c) gas turbine cycle d) reheat cycle
o
9 If the furnace temperature is T ( K) and the area of opening is A, quantity of radiation loss in a
reheating furnace is directly proportional to
4 4 2
a) T b) T c) A d) A
10 Water hammer is common in

a) water pipes b) condensate pipes

c) steam pipes with steam and condensate d) main steam lines with good traps
11 Which of the following requires the least amount of oxygen/ kg of substance for combustion

a) methane b) carbon c) sulphur d) hydrogen

12 Good opportunity for energy savings from continuous blow down of boiler is by

a) recovery of flash steam for use in deaerator

b) using the blow down steam to run steam turbine
c) reusing the hot water so formed as make-up water
d) none of the above
13 Which of the following benefits is not achieved by maximizing condensate recovery?

a) minimization of boiler exit flue gas temperature b) maximization of boiler output

c) reduction in water treatment costs d) reduction in energy input costs
14 Furnace wall heat loss does not depend on

a) temperatures of external wall surfaces b) velocity of air around the furnace

c) material of stock to be heated d) brick thermal conductivity of wall
15 Which fuel requires the lowest amount of excess air for combustion?

a) pulverised coal b) bagasse c) fuel oil d) natural gas.

16 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) 0.65 kg b) 250 gram c) 0.2 kg d) none of the above

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 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

c) calorific value of fuel d) blow down rate
18 The pour point of furnace oil is
o o o o
a) 100 C b) 25 C c) 50 C d) 20 C
19 Which property is the most important for an insulating brick?

a) mechanical strength b) chemical resistance

c) compact strength d) porosity
20 In which of the following equipment is stored heat used for preheating combustion air

a) convective recuperator b) radiation recuperator

c) regenerator d) heat pump
21 “Turndown ratio” for oil fired burners is the ratio of

a) air to fuel input

b) maximum fuel input to actual fuel input
c) maximum air input to minimum air input
d) maximum fuel input to minimum fuel input with same excess air
22 Flame flickering occurs in an oil fired burner because of

a) oil not preheated b) moisture in oil

c) oil pressure not sufficient d) high excess air
23 The unit of specific heat is
3 o
a) kCal/kg b) kCal/m c) kCal/kg C d) kCal
24 LPG is predominantly a mixture of propane and ___

a) isopropane b) methane c) ethane d) butane

25 The amount of oxygen required to burn one kg of hydrogen is

a) 3 b) 9 c) 8 d) 0.5
26 An axial compressor is used in conjunction with which of the following

a) back pressure steam turbine b) condensing turbine

c) gas turbine d) none of the above
27 If the pressure of saturated steam is reduced through a pressure reducing valve

a) enthalpy of evaporation will reduce b) it will get superheated

c) enthalpy will reduce d) it will produce wet steam
28 What is the average yield in re-rolling mill furnace?

a) 40-50% b) 70-80% c) 80-85% d) 90-95%

29 Radiation losses from a boiler practically

a) increase with increase in its % loading b) decrease with increase in its % loading
c) are independent of its % loading d) none of the above.
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 Paper 2 –Set B Solutions

30 Scale losses in reheating furnaces will

a) increase with CO in combustion gases b) increase with excess air

c) decrease with excess air d) have no relation with excess air
31 Ceramic fibre gives the maximum energy savings when used in

a) continuous furnace b) annealing furnace c) arc furnace d) re-heating furnace

32 Air compressor alone consumes about _____ of the energy generated in a gas turbine

a) 5-10% b) 10-20% c) 20-30% d) 50-60%

33 Drain pockets are provided in a steam line for

a) effective removal of line condensate b) effective removal of steam

c) removal of dirt d) checking of steam line
34 Which of the following heat recovery equipment works on a vapour compression cycle?

a) thermocompressor b) heat wheel c) heat pump d) heat pipe

35 Maximum heat transfer to the stock in a reheating furnace is by

a) radiation b) conduction c) convection d) none of these

36 What should be the appropriate coal size for fixed grate coal firing?

a) 25-50 mm b) 50-75 mm c) 75-100 mm d) 100-125 mm

37 Which type of the following co-generation system has high heat-to-power ratio?

a) gas turbine b) back pressure turbine

c) extraction condensing turbine d) reciprocating engine
38 When 100 kg of fuel with 60% carbon is burnt with theoretical air, the mass of CO2 released will
be

a) 319 kg b) 4400 kg c) 4500 kg d) 220 kg

39 The efficiency of a typical FBC boiler is of the order of

a) 80% b) 30% c) 40% d) 70%

40 Flash steam can be recovered from

a) leaking steam b) condensate at vacuum

c) condensate at high pressure d) condensate at atmospheric pressure
41 In a chain grate coal firing system primary air pressure is 75 mmWC. What should be the
secondary air pressure with respect to primary air pressure?

a) lower b) same c) double d) more than double

42 The pressure in the heating zone of a furnace should be

a) slightly positive b) slightly negative

c) highly negative d) highly positive

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 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

c) dry saturated steam d) wet steam
44 Which of these fuels has the highest heating value?

a) LPG b) methane c) hydrogen d) diesel oil

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
46 For coal fired boilers the flame length is influenced by

a) moisture b) ash content c) volatile matter d) fixed Carbon

47 The difference in temperature between steam and condensate is the principle of operation in a

a) temperature trap b) thermodynamic trap

c) thermostatic trap d) orifice type trap
48 Fluidized bed combustion takes place in the temperature range of
0 0 0 0
a) above 1000 C b) below 500 C c) 600-700 C d) 800-900 C
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

50 Latent heat of any vapour at its critical point will be

a) highest b) above zero c) zero d) less then zero

……. End of Section – I …….

Section – II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 40

(i) Answer all Eight questions

(ii) Each question carries Five marks

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
(b) Rice husk ash deposition in heat transfer area
(c) High excess air as compared to oil firing
(d) Moisture content and fuel quality variation
(e) Boiler furnace temperature drops down during ash cleaning.
(1 Mark each)
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 Paper 2 –Set B Solutions

S-2 What are the disadvantages of “direct method” of boiler efficiency evaluation over the
“indirect method”?

Ans: Disadvantage of Direct Method

 Does not indicate individual losses
 If there is wetness in steam it may indicate higher efficiencies than actual
 Does not indicate the improvement to be made in various loss areas
 Fuel and steam flow measurements are difficult and may not be accurate
 Any small error in measurement would lead to large variation in efficiency
levels
(1 Mark each)

S-3 The efficiency of a billet heating furnace with an output of 15 tonne/ hr was 32%. Find
out the specific fuel consumption in litres/ tonne of billet heating and total fuel
consumption per hour as per data given below:
Billet heating furnace:
Initial temp. = 50oC
Final temp. = 1150oC
Specific heat of billet = 0.12 kCal/ kgoC
Density of fuel oil = 0.95 kg/ litre
GCV of fuel oil = 10,000 kCal/kg
Determine the specific fuel consumption in litres/ tonne and total fuel consumption in
litres/hr.

Ans. MgCp t
 = ---------------
Mf X GCV
(1 Mark)

Fuel consumption per tonne S.F.C. = 1000 X 0.12 X (1150 – 50) / 0.32 X 10000
= 41.25 kg/ hr
= 41.25 / 0.95
= 43.42 litres/ tonne
(2 Marks)

Fuel consumption for 15 TPH production = 15 X 43.42 = 651.3 litres/hr

(2 Marks)

S-4 A gas turbine was running with naphtha as a fuel. The following are the data collected
during the gas turbine operation:

a) Fuel (Naphtha) consumption = 360 kg/hr

b) GCV of naphtha fuel = 11500 kCal/kg

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 Paper 2 –Set B Solutions

c) Overall efficiency of gas turbine which

includes air compressor and alternator = 30 %
d) Cost of naphtha fuel = Rs 22000/ton
Find out the cost of generating one unit of electricity?

ANSWER:

Heat input to the turbine = 11500*360

= 4140000
Efficiency of gas turbine = 30 %
Gas Turbine Output = [(4140000*0.3)/860]
= 1444 kWh [3 marks]

Cost of generating 1444 units of electricity = 360 kgs * Rs 22

= Rs 7920
Cost of one unit of electricity generated = (7920)/1444
= Rs 5.49 [2 marks]

S-5 The fuel oil consumption in a 4 TPH oil fired boiler generating steam at 10 kgf/cm2g is
300 litres/ hours. Its efficiency by indirect method was found to be 80%. Find out the
evaporation ratio and the steam generation rate with the following data:
Enthalpy of Steam = 665 kCal/ Kg
Feed water temperature = 65oC
G.C.V. of fuel oil = 10,000 kCal/ Kg
Density of oil = 0.95 kg/ litre

Ans. Efficiency = ER (hs – hw) / G.C.V

(1 Mark)
Boilere efficiency = 0.80
hg = Enthalpy of steam = 665 kCal / Kg.
hw = Feed water enthalpy = 65 kCal / Kg.
G.C.V. of oil = 10,000 kCal / Kg.

0.80 X 10,000
ER = ---------------- = 13.33
(665 – 65)
(2 Marks)
Steam generation = 13.33 X 300 X 0.95 = 3799 Kg / hr
(2 Marks)

S-6 State the stoichiometric combustion equation for methane (CH4).

How many kg of carbon dioxide will be generated by 8 kg of methane?

Ans CH4 + 202 CO2 + 2H2O

(2 Marks)
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 Paper 2 –Set B Solutions

16 Kg 64 44 36

16 Kg methane produces 44 Kg. CO2

8 Kg methane produces 22 Kg. CO2
(3 Marks)

S-7 An oil fired bogie type re-heating furnace has 2.5 meter width, 2.5 meter height and 6
meter length. The furnace has 14 oil fired burners with 7 burners on each of the side
walls. The bogie height is 0.5 meter. Draw a sketch of one side wall indicating the
location of burners and chimney.

Ans:

2.5
mtr

To Chimney

Bogie 0.5 mtr

6 mtr

(5 Marks)
(Burner 3 marks, chimney 2 marks)

S-8 Mention five important areas which reduces yield in a re-rolling mill.

Ans. (i) High excess air

(ii) Non-uniform temperature
(iii) High scale losses
(iv) High negative furnace draft
(v) Insufficient soaking of charge.
(1 Mark each)

------- End of Section - II ---------

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Section – III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all Six questions

(ii) Each question carries Ten marks

L-1 In a chemical process industry a coal fired boiler of 77% efficiency is proposed to be
replaced with paddy husk fired boiler of 67% efficiency. Calculate the fuel cost savings
for changing over to paddy husk?
GCV of coal = 4800 kCal/kg
Cost of coal = Rs 4000/MT
GCV of paddy husk = 3500 kCal/kg
Cost of paddy husk = Rs 2200/MT
Quantity of steam requirement = 20 TPH
Enthalpy of steam = 760 kCal/kg
Enthalpy of feed water =120 kCal/kg
Annual operating hours of boiler = 7000 hours

Ans
(A) For Paddy Husk Fired Boiler:
Heat content in the output steam = 20000*(760-120)
= 12800000 kCal/hr
Paddy husk requirement = (12800000)/(3500*0.67)
=5458 kg/hr.
Annual operating hours = 7000
Annual paddy husk consumption = 5458*7000
= 38206 MT
Annual cost of paddy husk = 38206* Rs 2200
=Rs 840.53 lakh [5 marks]

(B) For Coal Fired Boiler :

Coal requirement = (12800000)/(4800*0.77)

= 3463 kg/hr
Annual operating hours = 7000
Annual coal consumption = 3463 * 7000 = 24241 MT
Annual cost of coal = 24241 * Rs 4000
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 Paper 2 –Set B Solutions

= 969.64 lakh [4 marks]

Cost saving = { 969.64 – 840.53 }
= Rs 129.11 lakh. [2 marks]

L-2 List 10 energy saving measures in a steam distribution and utilization system.

Ans

1. Monitoring Steam Traps

2. Avoiding Steam Leakage
3. Providing Dry Steam for Process
4. Proper Utilisation of Directly Injected Steam
5. Miminising Heat Transfer Barrier
6. Proper Air Venting
7. Condensate Recovery
8. Insulation of steam pipe lines and hot process equipments
9. Flash Steam Recovery
10. Reducing the work to be done by steam
11. Any other relevant options

(1 Mark each)

L-3 A process industry needs saturated steam at 5 kg/cm2(g) and 10 kg/cm2(g) pressure
level for process heating. A fluidized bed boiler generates steam at 22 kg/cm2(g)
pressure at the rate of 24 TPH. 4 TPH of steam is reduced through PRDS for meeting
the 10 kg/cm2(g) steam requirement. The balance steam is passed through a Back
pressure steam turbine. The turbine back pressure steam at 5 kg/cm2(g) is sent to a
process in the plant.

a) Mechanical Efficiency of steam turbine = 92 %

b) Losses in gear transmission = 4%
c) Efficiency of alternator = 96 %
d) The total heat of steam at turbine inlet condition at 22 kg/cm2 (g) = 708 kCal/kg
e) The total heat of steam at turbine outlet condition at 5 kg/cm2 (g) = 658 kCal/kg
Calculate the total power output from the system.

Ans.
Step 1:
Enthalpy drop across the turbine per kg of inlet steam (h1-h2)
= (708-658)
= 50 kcal/kg
(2 Marks)

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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

Efficiency of electrical furnace : 70%
Useful heat (heat duty) : 500 x 860 x 0.70 = 301000 kCal/ batch
(2 Marks)
FO required for meeting useful heat : 301000/10000 = 30.1 kg
Efficiency of FO fired furnace : 58%
Net FO required to meet useful heat : 30.1 / 0.58 = 51.9 kg
= 51.9 / 0.9 = 57.6 liters/ batch
Estimated furnace oil quantity : 57.6 litres/ batch
(6 Marks)

Cost savings = (500 x 4.5) – (57.6 x 20) = Rs. 1098/batch

(2 Marks)

L-5 Explain briefly with the schematic the following heat recovery devices.
a) Heat Pipe
b) Metallic recuperator
c) Plate heat exchanger

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 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

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.

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 Paper 2 –Set B Solutions

(3 Marks)
c) Plate heat exchanger

A plate type heat exchanger consists of a series of separate parallel plates

forming thin flow pass. Each plate is separated from the next by gaskets and the
hot stream passes in parallel through alternative plates whilst the liquid to be
heated passes in parallel between the hot plates. To improve heat transfer the
plates are corrugated.
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
b) Explain with the help of enthalpy equation the impact of dryness fraction on the enthalpy
of wet steam
c) Why should one use dry saturated steam at the lowest possible pressure for indirect
steam heating?

Ans a) Dry saturated steam is the preferred choice because:

 Superheated steam gives up heat at a slower rate than saturated steam.
 Dry steam alone condenses quickly, thereby providing a higher heat transfer rate.
(3 Marks)
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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)

-------- End of Section - III ---------

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13th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS - September 2012

PAPER – 2: Energy Efficiency in Thermal Utilities

Date: 15.9.2012 Timings:14:00-17:00Hrs Duration:3 Hrs Max.Marks:150

Section – I: OBJECTIVE TYPE Marks: 50 x 1 = 50

(i) Answer all 50 questions

(ii) Each question carries one mark

1. Steam mains are run with a slope primarily to

a) avoid water hammer b) increase the velocity of steam

c) avoid condensation of steam d) reduce radiation and convection losses
2. Which of the following is not true of condensate recovery?

a) reduces water charges b) reduces fuel costs

c) increases boiler output d) increases boiler blow down
2
3. If 10% air is entrained in a steam system at 3 kg/cm g then the saturation temperature of steam
will be
2
a) less than the saturation temperature at 3 kg/cm g
2
b) more than the saturation temperature at 3 kg/cm g
2
c) equal to the saturation temperature at 3 kg/cm g
d) equal to the saturation temperature at 3.3 kg/cm2 g

4. The mineral matter in coal after combustion mostly becomes

a) carbon dioxide b) carbon monoxide c) nitrous oxide d) ash

5. Conditioning of coal with water in certain boilers is done to

a) increase unburnt losses b) increase GCV

c) minimize losses of fine coal particles d) increase convection heat transfer
6. Which of the following is false?

a) LPG vapour is twice as light as air b) LPG is a mixture of propane and butane

c) LPG is a gas at normal atmospheric pressure d) LPG is required to be odorized

7.
,
Of the following fuels which will have the highest carbon content?

a) furnace oil b) coal c) natural gas d) paddy husk

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8. 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
9. In the direct method of efficiency evaluation of boilers which of the following is not required?

a) enthalpy of steam b) calorific value of fuel

c) O2 in flue gas d) mass flow rate of steam
10. Select the incorrect statement with respect to steam

a) evaporation is a constant temperature process

b) higher the pressure higher is the steam saturation temperature
c) higher the pressure higher is the latent heat
d) latent heat at critical point is zero

11. The amount of flash steam generated from the condensate mainly depends on _____

a) sensible heat of high pressure condensate b) sensible heat of flash steam

c) latent heat of flash steam d) all of the above

12. Tuyeres is a terminology associated with

a) induction furnace b) pusher type furnace c) arc furnace d) cupola

13. In determining the economic thickness of steam pipe insulation which of the following is not
required?

a) cost of fuel b) boiler efficiency c) steam pressure d) heat content of fuel

14. The softening temperature of a refractory is indicated by

a) Pyrometric cone equivalent (PCE) b) refractoriness under load (RUL)

c) creep d) cold crushing strength
15. Which of the following is not a property of ceramic fibre ?

a) low thermal conductivity b) light weight

c) high heat capacity d) thermal shock resistant
16. Low combustion temperature in FBC boilers results in the reduced formation of

a) NOx b) SOx c) CO d) CO2

17. An axial compressor is used in conjunction with which of the following

a) gas turbine b) back pressure steam turbine

c) condensing steam turbine d) all of the above
18. Power is to be generated from a cement kiln exhaust gas. The applicable type of cogeneration is
called

a) topping cycle b) trigeneration c) bottoming cycle d) none of the above

19. The effectiveness of a heat exchanger does not depend on

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a) specific heat of hot fluid b) specific heat of cold fluid

c) inlet temperature of hot fluid d) LMTD
20. An element in fuel oil responsible for corrosion in exhaust system of a boiler is

a) carbon b) hydrogen c) sulphur d) chlorine

21.
The presence of calcium and magnesium bicarbonates in feedwater to a boiler would form:
a) acidic solution b) alkaline solution
c) neutral solution d) none of the above
22. Turn down ratio of a burner is the ratio of

a) maximum to minimum fuel input without affecting optimum excess air levels
b) minimum to maximum fuel input without affecting optimum excess air levels
c) maximum to average fuel input
d) average to minimum fuel input
23. Comparatively, lowest excess air is required in a

a) coal burner b) low pressure oil burner

c) high pressure gas burner d) high pressure oil burner
24. The velocity of steam in steam pipe is directly proportional to

a) number of bends in pipe b) specific volume of steam

c) length of pipe d) diameter of the pipe
25. The emissivity of ceramic coatings used in furnace

a) decreases with increase in furnace temperature

b) Increases with increase in furnace temperature
c) remains constant
d) decreases with increase in furnace pressure
26. Scale losses in reheating furnaces will

a) increase with excess air b) decrease with excess air

c) have no relation with excess air d) increase with CO in combustion gases
27.
Instrument used for measuring billet temperature in a reheating furnace is ___.
a) thermograph b) infrared pyrometer
c) Pt/Pt-Rh thermocouple with indicator d) chrome alumel thermocouple with indicator
28. Glass mineral wool can be applied for temperature range application upto
o o o o
a) 950 C b) 500 C c) 1200 C d) 750 C
29. Heat transfer in a reheating furnace is achieved by

a) Conduction b) Convection c) Radiation d) All of the above

30. 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

31. The cogeneration system which has high overall system efficiency is

a) back pressure steam turbine b) combined cycle

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c) extraction condensing steam turbine d) reciprocating engine

32. The Brayton cycle is a characteristic of

a) steam turbine b) petrol engine c) gas turbine d) none of the above

33. Recuperator as a waste heat recovery system is used mainly in a

a) boiler b) reheating furnace

c) compressor d) gas turbine
34. The device used for recovering waste heat from the textile drier exhaust

a) heat wheel b) recuperator c) economizer d) regenerator

35. Density of liquid fuels are measured at a reference temperature of

a) 0°C b) 15°C c) 25°C d) 30°C

36. Which of the following contributes to erosive effect on burner tips during combustion?

a) ash content b) water content c) sulphur content d) volatile matter

37. In the context of cogeneration turbine, the thermodynamic process taking place is

a) expansion b) condensation c) contraction d) both (a) & (c)

38. Reduction of steam pressure will increase

a) sensible heat b) enthalpy of steam

c) saturation temperature d) specific volume

39. Ten meter lift of condensate in a distribution pipe work will result in

a) 0.1 bar back pressure b) 1 bar back pressure

c) 10 bar back pressure d) none of the above

40. ____________ 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

41. The recommended TDS level for package fire tube boilers is

a) 10,000 ppm b) 5,000 ppm c) 2,000 ppm d) 3,000 ppm

42. Ideal furnace for melting & alloying is

a) induction furnace b) cupola furnace

c) rotary hearth d) recirculating bogie furnace

43. Commonly used flux medium in a cupola furnace

a) calcium carbide b) fluorspar

c) calcium carbonate d) sodium carbonate

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44. Dolomite is a ________ type of refractory

a) acidic b) basic c) neutral d) none of the above

45. The unit of specific gravity in SI system is

3 3
a) kg/ m b) m /kg c) gm/cc d) none of the above

46. Insulation used for temperatures more than 350°C is

a) polyurethane b) polystyrene c) calcium silicate d) wood

47. Time dependent property that determines the deformation of a refractory is

a) creep b) refractoriness under load

c) porosity d) crushing strength

48. Capillary wick is a part of

a) heat pump b) heat wheel c) heat pipe d) heat recovery steam generator
49. The working fluid for thermo compressor is

a) low pressure steam b) high pressure steam

c) compressed air d) waste heat from chimney
50. Fly ash in a FBC boiler is in the range of

a) 20% b) 30% c) 40% d) none of the above

Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 40

(i) Answer all 8 questions

(ii) Each question carries 5 marks

S-1 In a paper industry, 35,000 kg/hr of soda liquor with specific heat of 0.38 kCal/kg°C
is heated using saturated steam at 8 bar in a heat exchanger from 65°C to 115°C.
Calculate the LMTD of the exchanger & the amount of steam required for heating
using the following data :
Steam Steam Enthalpy kcal/kg
Pressure Temperature
(bar) °C Water Evaporation Steam

8.0 170 170 490 660

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Ans a) Heat gain by soda liquor = 35000 x 0.38 x (115-65)

= 665000 Kcal/hr
Heat lost by saturated steam = 665000 Kcal/hr
Steam required for heating = 665000 / 490
= 1357 Kg/hr
Amount of steam required for heating is 1.36 Ton/hr

b)LMTD calculation = (170-115)-(170-65)

Ln (170-115)
(170-65)
= (55-105)/ln(55/105)
= 77.3°C

S-2 A process requires 5.5 tonnes/hr of dry saturated steam at 7 kg/cm2g having specific
volume of 0.28 m3/kg. For the flow velocity not to exceed 25 m/s, determine the pipe
diameter.

Ans Volumetric flow rate = 5500 x 0.28 = 1540 m3/hr

= 1540/3600
= 0.43 m3/s

Cross sectional area = volumetic flow rate / velocity

= 0.43 / 25
3.14 x D2/4 = 0.017
D2 = 0.0217
Diameter, D = 0.149 m (or) 150 mm

S-3 a) 230 kg/hr of hot condensate from a heat exchanger is coming out at 6 bar(g) with a
sensible heat of 166 kCal/kg. Using a flash vessel, the condensate is flashed to 1
bar(g) with a sensible heat of 120 kCal/kg and latent heat of 526 kCal/kg. Find out
the flash steam generation in kg/hr.

b) The flash steam produced above is used to heat water from 30oC to 80oC by direct
injection. Calculate the quantity of hot water in that can be obtained per hour.

Ans a) Flash steam available % =( S1 - S2 ) / L2

S1 = is the sensible heat of higher pressure steam
S2 = is the sensible heat of the steam at lower pressure
L2 = is the latent heat of flash steam (at lower pressure)
Flash Steam generated = ( 166 – 120) x 230
526
= 20.11 Kg/hr.

b) Quantity of hot water generated

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m x cp x (80-30) = 20.11 x (120+526)

m = 260 kg/hr

S-4 The evaporation ratio of a coal fired boiler is 4.50. A quantity of 600 kCal/kg of heat
is added to the feed water in the boiler to produce the steam.

a) If the GCV of coal is 3800 kCal/kg, find out the efficiency.

b) Find out the total enthalpy of the steam as per the details of the data given below
Saturation temperature = 143 oC
Sensible heat = 143.7 kCal/kg
Latent heat = 509.96 kCal/kg
Specific volume = 0.47 m3/kg
Dryness fraction of steam = 96%

Ans
a) Boiler efficiency (%) = Evaporation ratio x enthalpy added x 100
GCV of coal

Boiler efficiency = 4.5 x 600/3800

= 71 %

b) Total enthalpy of steam = 143.7 + (0.96 x 509.96 )

= 633.26 kCal/kg

S-5 a. ‘Steam should be used in the process at the lowest acceptable pressure ‘ . Explain
the significance of the terms ‘lowest’ and ‘acceptable’

b. Explain briefly about ‘turbine heat rate’. How is it related to turbine efficiency ?

Ans a.
‘lowest’ : Lower the pressure higher is the latent heat which is primarily used in the
process. Hence the lowest pressure would be desirable.

‘acceptable’: However the lower the steam pressure lower will be the steam
temperature. Since the temperature is the driving force for heat transfer, rate of heat
transfer reduces and increases process time. Therefore there is a limit to the reduction
in steam pressure.

b.
Heat rate is the heat input to turbine, needed to produce 1 kWh of electricity

Turbine efficiency is the ratio useful heat and power output, to the heat input to the
turbine in Kcal or KJ, expressed as a percentage. Performance of steam turbine is
also expressed as heat rate, which is the quantity of heat in kCal or KJ required to
generate 1 kWh of electrical power output.

Turbine heat rate is expressed in kJ/kWh. The inverse relation between heat rate and
efficiency is applicable only to a power plant, since all the input energy is deployed
for power generation alone.

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S-6 Write short notes on factors affecting wall losses in batch type reheating furnaces?

Ans a) Emissivity of walls : Emissivity of fire brick refractory should be high

Emissivity of most of the refractory bricks decreases with increase in
temperature. High emissivity coatings whose emissivity increases with
temperature can be used to increase emissivity and decrease wall losses.

b) Conductivity of refractories: The refractory and insulating bricks should have

low thermal conductivity. Chosing low thermal conductivity bricks will
reduce wall losses. Conductivity raises with rise in temperature. Batch type
furnaces can use ceramic fibre to reduce storage losses.

c) Wall thickness of batch furnaces: Heat losses can be reduced by increasing the
wall thickness, or through the application of insulating bricks. Outside wall
temperature and heat losses for a composite wall of a certain thickness of
firebrick and insulation brick are much lower due to lesser conductivity of
may be worked out to reduce the heat storage.

S-7 Explain any two proven methods of testing steam traps?

ANS There are two proven methods of testing of steam traps: - Sound method and
Temperature method.

1.Sound Method : Mechanisms within steam traps and the flow of steam and
condensate through steam traps generate sonic (audible to the human ear) and
supersonic sounds. Proper listening equipment, coupled with the knowledge of
normal and abnormal sounds, can yield reliable assessments of steam trap working
condition. Listening devices range from a screwdriver or simple mechanic's
stethoscope that allow listening to sonic sounds.

2.Temperature Method: Saturated steam and condensate exist at the same

temperature. So it's not possible to distinguish between the two based on temperature.
Still, temperature measurement provides important information for evaluation
purposes.

A cold trap (i.e., one that is significantly cooler than the expected saturated steam
temperature) indicates that the trap is flooded with condensate, assuming the trap is in
service. On the other hand, the temperature downstream of the trap will be nearly
constant if significant steam is getting past the trap. At the low-end, spitting on the
trap and watching the sizzle provides a general indication of temperature.

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Finally, non-contact (i.e., infrared) temperature measuring devices provide the

precision of thermometers and thermocouples without requiring physical contact.
Non-contact temperature measurement makes it easier to evaluate traps that are
relatively difficult or dangerous to access closely.

S-8 A vessel has to be cooled from 90°C to 55°C. 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 28°C. The maximum allowed increase in water temperature is
5°C. Calculate the quantity of water required for vessel cooling.
Ans
Mass of vessel (m) = 2000 kg
Specific heat (Cp) = 0.18 kCal/kg °C
Initial vessel temperature (T1) = 90°C
Desired vessel temperature (T2) = 55°C

Total heat that has to be removed from the vessel = m x Cp x (T1 - T2)
= 2000 x 0.18 x (90-55)
= 12600 kCal

Quantity of water required = M kg

Specific heat of water = 1 kCal/kg °C
Inlet cooling water temperature (T3) = 28°C
Maximum cooling water outlet temperature (T4) = 33°C
Heat removed by water, 12600 = M x 1 x (33 - 28)

Quantity of water required , M = 12600/5 = 2520 kg

------- End of Section - II ---------

Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all 6 questions

(ii) Each question carries 10 marks

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 CO2, H2O and SO2 generated per 100 kg
of fuel. The ultimate analysis of paddy husk is given below.

Ultimate analysis of paddy husk %

Moisture 10.8
Mineral Matter 16.7
Carbon 34.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5
GCV (kCal/kg) 3570

ANS Considering a sample of 100 kg of paddy husk. The chemical reactions are:

Oxygen required for complete combustion of carbon:

C+ O2 à CO2
(34.0) C + (34 x 2.67) O2 à 124.78 CO2
90.78

Oxygen required for complete combustion of hydrogen:

H2 + O2 à H2O
(5) H2 + (5 x 8) O2 à 45 H2O
40

Oxygen required for complete combustion of sulphur:

S + O2 à SO2

(0.1) S + (0.1 x 1) O2 à 0.2 SO2

0.1
Total Oxygen required = 90.78 + 40 + 0.1 = 130.88

Oxygen already present in 100 kg fuel (given) = 32.5 kg

Additional Oxygen Required = 130.88 -32.5 = 98.38
Therefore quantity of dry air reqd. = (98.38) / 0.23 = 427 kg

CO2 generated per 100 kg of fuel = 124.78 kg

H2O generated per 100 kg of fuel = 45 kg

SO2 generated per 100 kg of fuel = 0.2 kg

L-2 In a crude distillation unit of a refinery, furnace is operated to heat 500 m3/hr of crude
oil from 255°C to 360°C 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 195°C.
Calculate the efficiency of the furnace before & after the installation of APH.

Consider the following data:

• Specific heat of crude oil = 0.6 kcal/kg°C
• Specific heat of air = 0.24 kcal/kg°C
• Specific gravity of Crude oil = 0.85
• Ambient temperature = 28°C.
ANS Before the installation of APH

Heat gain by the crude = 500 x 1000 x 0.85 x 0.6 x (360-255)

= 26775000 Kcal/hr
Heat input to the furnace = 3.4 x1000x 9850
= 33490000 kcal/hr
Efficiency of the furnace = 26775000 / 33490000
= 80 %

After the installation of APH

Heat gain by the crude = 500 x 1000 x 0.85 x 0.6 x (360-255)

= 26775000 Kcal/hr

Heat gain by Air-preheater = 57 x 1000 x 0.24 x (195-28)

= 2284560 Kcal/hr
Heat reduction in input to the furnace = Heat gain by Air-preheater

New Heat input to the furnace= 33490000 – 2284560

= 31,205,440
Efficiency of furnace after installation of APH = 26775000 / 31,205,440
= 85.8 %

L3 The management of a foundry is considering retrofitting the existing heat treatment

furnace with hot face insulation of 75 mm ceramic fibre. (Note: Hot face insulation is
known as veneering: ie over the existing refractory lining, ceramic fibre modules are
applied to reduce the heat loss during operation and heat storage loss in refractory
structure).

Furnace Operating data:

Heat Treatment furnace : (Bogey Type) Batch Operation

Furnace Capacity : 5 Ton (per batch)
Fuel type : Furnace Oil

Surface Area of
Side walls : (1.4 x 4.5) x 2 = 12.6 m2
Back Wall : 0.95 x 1.4 = 1.33 m2

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Roof : 0.95 x 4.5 = 4.3 m2

Refractory Type : Fire Bricks

Wall Thickness
Side walls : 18 inches
Arch : 13.5 inches
Number of cold starts per month: 5 Nos.
Number of batches per month : 15 Nos.
Fuel Cost : Rs 48/ kg
GCV of furnace oil : 10200 kCal/kg

Heat Storage (kCal /m2) for batch operation and cold start from walls and roof area
are given below.
For batch operation Cold Start
Existing(with 75 mm Existing(with 75 mm
only fire bricks) Veneering+ only fire Veneering+ fire
fire bricks bricks) bricks
Wall 79480 45350 116697 23,964

Roof 74770 31,401 97,236 16,438

For batch operation furnace is heated from 300oC to 850oC

For cold start up furnace is heated from ambient 30 oC to 850oC

Calculate the following due to veneering

a) Total heat loss reduction per month from wall and roof during batch operation.
b) Total heat loss reduction per month from wall and roof during cold starts.

Ans
Heat loss calculation for batch operation
Heat reduction from Wall per m2 = 79480-45350 =34130 Kcal
Heat reduction from total side wall & back wall = 34130 x13.93 =475430.90 Kcal
Heat reduction from roof per m2 = 74770- 31401 =43369 Kcal
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

Heat reduction from Wall per m2 = 116697.5- 23,964.50 = 92733 Kcal

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Heat reduction from total side wall & back wall = 92733 x13.93 = 1291770.69 Kcal
Heat reduction from roof per m2 = 97,236 - 16,438.00 = 80798 Kcal
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
Feed water temperature : 75 oC
GCV of Furnace oil : 10400 kCal/kg
Enthalpy of saturated steam at 10 kg/cm2 : 665 kCal/kg
Enthalpy of feed water : 75 kCal/kg

b) The above furnace oil fired boiler was converted to coconut shell firing.
Determine the boiler efficiency by direct method after conversion.

GCV of coconut shell fuel : 4565 kCal/kg

Quantity of coconut shell consumed for the same steam demand and
pressure. : 850 kg/hr

c) The cost of fuel and operating hour of boiler are given below.
• Operating hour/ year = 5000 hr
• Cost of furnace oil per ton = Rs 40000/ton
• Cost of coconut per ton = Rs 5000/ton
Find out the annual cost saving due to the fuel substitution fuel in the
above boiler?
ANS a)Boiler efficiency with furnace oil firing :

Boiler Efficiency ( ) = 5000 x (665-75) x 100 / (350 x 10400)

Boiler efficiency = 81% (on GCV basis)

b)Boiler efficiency with coconut shell fuel firing :

Boiler Efficiency ( ) = 5000 x (665-75) x 100/ (850 x 4565)
Boiler efficiency = 76% (on GCV basis)

c) Annual cost saving

Annual furnace oil cost = 5000Hr x 0.35 x Rs 40000

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= Rs.7.0 crore

Annual coconut shell Cost = 5000 hrs x 0.85x Rs.5000

= Rs. 2.125 crore

Annual cost saving = 7.0- 2.125= Rs 4.875 Crore

L5 Explain briefly any two of the following

a) Heat Wheel
b) Topping and bottoming cycles for cogeneration with examples
c) Economic thickness of insulation

Ans a) Heat wheel

Widely used in low to medium temperature waste heat recovery systems.

A disk rotates between two side-by-side ducts: one a cold gas duct, the other a hot gas duct.
As the disk slowly rotates, sensible heat (moisture that contains latent heat) is transferred to
the disk by the hot air and, as the disk rotates, from the disk to the cold air.
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
requirements ex. steam turbine, Diesel engine, Gas turbine etc.
In a bottoming cycle, the primary fuel produces high temperature thermal energy and the
heat rejected from the process is used to generate power through a recovery boiler and a
turbine generator Power production from waste heat of cement plant, sponge iron plant etc
c) Economic thickness of insulation

As the insulation thickness increases heat loss cost reduces, At the same time insulation cost
increases. Hence there is an optimum limit to thickness. The economic thickness of insulation
is the thickness at which the combined cost is least.

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List five energy conservation measures in ANY TWO of the following:

L6
a) Furnaces
b) Steam distribution systems
c) Boilers
a) Furnaces
Ans
1) Complete combustion with minimum excess air
2) Correct heat distribution
3) Operating at the desired temperature
4) Reducing heat losses from furnace openings
5) Maintaining correct amount of furnace draught
6) Optimum capacity utilization
7) Waste heat recovery from the flue gases
8) Minimum refractory losses
9) Use of Ceramic Coatings

b) Steam Distribution systems

1. Monitoring Steam Traps

2. Avoiding Steam Leakages
3. Providing Dry Steam for Process
4. Utilising Steam at the Lowest Acceptable Pressure for the Process
5. Minimising Heat Transfer Barriers
6. Proper Air Venting
7. Condensate Recovery
8. Insulation of Steam Pipelines and Hot Process Equipments
9. Flash Steam Recovery
10. Reducing the Work to be done by Steam

c) Boilers

1. Reduce Stack Temperature

2. Feed Water Preheating using Economiser
3. Combustion Air Preheating
4. Ensure complete Combustion
5. Control excess air
6. Radiation and Convection Heat Loss
7. Automatic Blowdown Control
8. Reduction of Boiler Steam Pressure
9. Variable Speed Control for Fans, Blowers and Pumps
10. Ensure boiler Loading for Efficiency
11. Boiler Replacement for efficiency

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14th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS – August, 2013

PAPER – 2: Energy Efficiency in Thermal Utilities

Date: 24.8.2013 Timings:14:00 -17:00 Hrs Duration:3 Hrs

Max.Marks:150

Section – I: OBJECTIVE TYPE Marks:

50 x 1 = 50

(i) Answer all 50 questions

(ii) Each question carries one mark
(iii) Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB
pencil

1. In coal fired combustion, the flame length is influenced by

a) moisture b) ash content c) volatile matter d) fixed

carbon
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. 100 kg of a fuel contains 3% sulphur. For complete combustion of sulphur in the fuel
it will require _________kg of oxygen

a) 3 b) 6 c) 30 d) 103
4. Which property indicates the lowest temperature at which fuel oil is readily pumpable?

a) flash point b) pour point c) specific heat d) specific

volume

5. Which of the following contributes to spluttering of flame at burner tip during

combustion of fuel oil ?

a) ash content b) water content c) sulphur content d) humidity of

air
6. In an oil fired steam boiler the air to fuel ratio is 15:1 & evaporation ratio is 14:1. The
flue gas to fuel ratio will be

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a) 29:1 b) 16:1 c) 14:1 d) 15:1

7. Which among the following fuels, on combustion ,has higher tendency towards acid
corrosion in the flue gas path?

a) a) LSHS b) furnace oil c) Diesel

d) kerosene
8. The balanced draft furnace is one that is operated with

a) a) positive pressure b) induced and forced

draft fan
b) c) negative pressure d) Natural draft
9. The factor that influences atomisation of fuel oil is

a) viscosity b) density c) flash point d) pour point

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

a) carbon b) sulphur c) hydrogen d)

moisture
11. In flue gas, the oxygen measured is 4% by volume. The percentage excess air will be

a) a) 23.5% b) 40% c) 21%

d) 36%
12. A boiler generates 5 TPH of steam at an efficiency of 78 %. The enthalpy added to
steam in the boiler is 580 kcal/kg. The fuel consumption with a GCV of 4200 kcal/kg
is

a) 885 kg/hr b) 985 kg/hr c) 1038 kg/hr d) 1200

kg/hr
13. Automatic blowdown controls for boilers work by sensing

a) dissolved gases b) dissolved solids c) pH d) conductivity

and pH
14. Dissolved CO2 in boiler feed water when left untreated would result in occurrence of
_____in boiler tubes

a) creep b) water side corrosion c) scale d) water

hammer
15. Recommended boiler feed water pH value at 25 oC is ---------

a) 8.0 - 9.0 b) 5.2 - 6.2 c) 9.8-10.2 d) 10-10.5

16. Which of the following is not applicable in the preservation of boiler by dry method ?

a) un-slacked lime b) activated alumina

c) anhydrous calcium cloride d) hydrazine

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17. Which one of the following is true of a water softening process?

a) It reduces hardness but not TDS b) It reduces both hardness and TDS
c) It reduces TDS but not hardness d) None of the above
18. Soot deposit in boiler tubes is predominantly due to

a) poor water treatment b) low steam pressure

c) incomplete combustion d) high excess air

19. Which of the following will be the most suitable heating medium for heat transfer in
indirect heating?

a) dry saturated steam b) superheated steam c) wet steam d) hot

water
20. Ten meter lift of condensate in a distribution pipe will result in a back pressure of

a) 0.1 bar b) 1 bar c) 10 bar d)

1.1 bar
21. The difference in temperature between steam and condensate is the principle of
operation of

a) thermodynamic trap b) thermostatic trap c) orifice type trap d) float trap

22. Water flows at a rate of 30 m 3/hr. at 15oC in a 150 mm bore pipe horizontally. What is
the velocity of water flow in the pipe?

a) 0.47 m/s b) 0.94 m/s c) 1.88 m/s d) 3.7 m/s

23. To drain condensate from tracer steam lines , the most common trap used
is_________

a) thermodynamic b) bimetallic c) inverted bucket d) float trap

24. The velocity of steam in steam pipe is directly proportional to

a) number of bends in pipe b) specific volume of steam

c) length of pipe d) fifth power of pipe diameter
25. Condensate, at 3 bar pressure & 160°C, when exposed to atmosphere will

a) fully convert to flash steam b) partly convert to flash steam

c) remain as condensate d) convert to superheated steam
26. Steam at 4 bar has sensible heat of 144 kcal/kg and latent heat of 510 kcal/kg. If the
steam is 90% dry than the total enthalpy of steam in kcal/kg is

a) 588 b) 654 c) 603 d) 459

27. For transporting steam to a long distance, the most suitable among the following will
be

a) slightly superheated steam b) dry saturated steam

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c) mildly wet steam d) high pressure steam

28. Heat transfer in a reheating furnace is achieved by

a) conduction b) convection c) radiation d) all of the above

29. Which of the following is not a property of ceramic fibre ?

a) low thermal conductivity b) light weight

c) high heat capacity d) thermal shock resistant
30. The unit of overall heat transfer coefficient is

a) kcal/m-hr-°C b) kcal/ m²-hr-°C c) kcal/m²-°C d)

kcal/ m-°C
31. Which property of ceramic coating influences energy savings in furnaces?

a) emissivity b) coating thickness

c) conductivity d) convective heat transfer coefficient
32. In a CFBC boiler the capture and recycling of bed materials is accomplished by

a) elecrostatic precipitator b) bag filter c) cyclone d) scrubber

33. 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) maintain slightly positive pressure inside the
furnace
34. The storage heat losses in a batch type furnace can be best reduced by use of

a) hot face insulating bricks b) hot face ceramic fibre

c) cold face insulating bricks d) cold face ceramic fibre
35. Tuyeres is a terminology associated with

a) forging furnace b) cupola c) open hearth furnace d) heat treatment

furnace
36. Which of the following is a synthetic refractory?

a) MgO b) Al2O3 c) SiC d) SiO2

37. Alumina is a __________________ type of refractory

a) basic b) acidic c) neutral d) none of the above

38. An increase in bulk density of a refractory increases its

a) volume stability b) heat capacity

c) resistance to slag penetration d) all of the above

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39. Which of these is used in a fluidised bed boiler to control sulphur dioxide emissions?

a) charcoal b) limestone c) sand d) silica

40. In FBC boiler the combustion is carried out at a temperature

a) closer to steam temperature b) at adiabatic combustion temperature

c) at and above ash fusion temperature d) below ash fusion temperature of fuel used
41. Low combustion temperature minimises___ in FBC boilers

a) NOx b) SOx c) CO d) Suspended particulate matter

42. A chemical plant needs steam at 3 bar and 10 bar in addition to electric power. The
most suitable co-generation choice among the following will be

a) extraction cum condensing b) condensing turbine

c) back pressure turbine d) extraction cum back pressure turbine
43. Power is to be generated from a cement kiln exhaust gas. The applicable type of
cogeneration is called

a) topping cycle b) Carnot cycle c) bottoming cycle d) Brayton

cycle
44. Which of the following works on a refrigeration cycle?

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

45. Which of these devices can be used for recovering waste heat from the textile drier
exhaust?

a) heat wheel b) recuperator c) economizer d)

regenerator
46. Wick in heat pipe is provided to facilitate

a) forward movement of hot vapors b) forward movement of hot liquid

c) return of condensed liquid d) return of hot vapors
47. Which of the following requires electrical energy for equipment operation?

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

economizer
48. The exhaust from which of the following is not suitable for waste heat boiler
application?

a) gas turbine b) hot air dryer c) diesel engine d) furnace

49. Pinch analysis of process streams depicts the plot of

a) temperature vs entropy b) temperature vs area

c) temperature vs specific heat d) temperature vs enthalpy
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50. Correction factor for LMTD calculation is applicable for

a) parallel flow b) counter current flow c) cross flow d) both (a)

& (b)

……. End of Section – I …….

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Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 =

40

(i) Answer all Eight questions

(ii) Each question carries Five marks

The following are the parameters obtained from a steam audit of a cylindrical
S-1
dryer used for drying cloth.

Cloth Throughput = 20 m/minute

Cloth Density = 9.8 m/kg

Measured Condensate Rate = 135 kg/hour

Calculate the specific steam consumption per kg of cloth.

Cloth throughput per hour = 20 x 60 = 1200 m/hr

Weight of cloth = 1200 / 9.8

= 122.45 kg/hr
Steam consumption = condensate collected

Specific steam consumption = 135/122.45 =1.1 kg of steam per kg of cloth

In a crude distillation unit of a refinery, furnace is operated to heat 300 kilo

S-2
Litres/hr of crude oil at an inlet temperature of 255°C by firing 2.5 kilolitres/hr
of furnace oil having GCV of 9880 kcal/kg. If the efficiency of the furnace is
82% ,calculate the outlet temperature of the crude oil from the furnace.
Consider the following data:

Specific heat of Crude Oil = 0.65 kcal/kg°C

Specific gravity of Crude Oil = 0.86
Specific gravity of furnace Oil = 0.98
Solution:
Furnace oil consumption = 2.5 X 0.98 = 2.45 TPH

Heat input to the furnace = 2.45 x 1000 x 9880 = 24.2 x 10 6 Kcal/hr

Heat absorbed by the crude = 24.2 x 106 x 0.82 = 19.85x 106 Kcal/hr

Q = m * Cp * Del T
19.85 * 106 = 300 * 0.86 * 1000 * 0.65 * T
T = 118 °C

T out = 255 + 118 = 373 °C

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Temperature of crude at furnace outlet is 373 °C

S-3
In a process plant, 20 TPH of steam after pressure reduction with pressure
reducing valve to 20 kg/cm2 gets superheated. The temperature of steam is
280oC. The management wants to install a de-superheater to convert
superheated steam into saturated steam at 20 kg/cm 2 for process use, and
its saturation temperature is 210oC.

Calculate quantity of water at 30oC to be injected in de-superheater to get the

desired saturated steam using the following data.

Specific heat of superheated steam = 0.45 kcal/Kg oC

Latent heat of steam at 20kg/cm2 = 450 kcal/kg

Answer
Quantity of heat available above saturation = 20,000 x 0.45 x (280-210)
= 6,30,000 kCal

Quantity of water required in de-superheater = Q x{1x (210-30) + 450}= 630000

= 1000 Kg/hr

S-4 A 5 TPH capacity boiler is generating saturated steam at 8 kg/ cm2g .The
following operating parameters was measured during the survey.
Furnace oil consumption - 200 kg/hr.
GCV of furnace oil - 10,500 kcal/kg
Qty of steam generation - 3000 kg/hr
Feed water temperature - 60 oC
Enthalpy of dry saturated steam - 660 kcal/kg
Dryness fraction - 0.9
Saturation temperature of steam - 170 oC

Calculate the boiler efficiency by direct method.

Boiler Efficiency = 2700 kg x (660-60) kcal/kg + 300 x (170-60) x 100

200 kg x 10500 kcal/kg
= 78.7%

In a pharma industry, a chemical process requires 5000 kg/hr of dry

S-5
saturated steam at 7 kg/cm 2 (g). Specific volume of steam at 7 kg/cm 2g is
0.24 m3/kg . Determine the pipe diameter size for a steam flow velocity of 25
m/s.

The velocity of steam = 25 m/s

Specific volume at 7 kg/cm2 g = 0.24 m3/kg
Mass flow rate of steam = 5000 kg/hr

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 Paper 2 - Set A Key

= 5000/3600 = 1.389 kg/sec

Volumetric flow of steam = 1.389 x 0.24 =0.333 m3/sec

Therefore, using formula:

S-6 Distinguish between plate heat exchanger and shell and tube heat
exchanger ?
Shell and Tube heat Exchangers
Ans Shell-and-tube heat exchangers consist of a bundle of parallel tubes that provide the heat-transfer
surface separating the two fluid streams. The tube-side fluid passes axially through the inside of
the tubes; the shell-side fluid passes over the outside of the tubes. Baffles external and
perpendicular to the tubes direct the flow across the tubes and provide tube support.

Tube sheets seal the ends of the tubes, ensuring separation of the two streams. The process fluid
is usually placed inside the tubes for ease of cleaning or to take advantage of the higher pressure
capability inside the tubes. The thermal performance of such an exchanger usually surpasses a coil
type but is less than a plate type. Pressure capability of shell-and-tube exchangers is generally
higher than a plate type but lower than a coil type.
Plate Heat Exchangers
Plate heat exchangers consist of a stack of parallel thin plates that lie between heavy end plates.
Each fluid stream passes alternately between adjoining plates in the stack, exchanging heat
through the plates. The plates are corrugated for strength and to enhance heat transfer by directing
the flow and increasing turbulence. These exchangers have high heat-transfer coefficients and
area, the pressure drop is also typically low, and they often provide very high effectiveness.
However, they have relatively low pressure capability.

The biggest advantage of the plate and frame heat exchanger, and a situation where it is most
often used, is when the heat transfer application calls for the cold side fluid to exit the exchanger at
a temperature significantly higher than the hot side fluid exit temperature i.e. “temperature
cross”. This would require several shell and tube exchangers in series due to the lack of purely
counter-current flow.
The overall heat transfer coefficient of plate heat exchangers under favorable circumstances can
be as high as 8,000 W/m2 ºC. With traditional shell and tube heat exchangers, the U-value will be
below 2,500 W/m2 ºC.

Give reasons for the following

S-7
a) Explain why natural gas requires less amount of excess air compared to
solid/liquid fuels
b) Why steam is to be used at the lowest practicable pressure for indirect
process heating ?

a) Natural gas requires less amount of excess air compared to solid/liquid fuels
Ans
Natural gas is in the gaseous form and lighter than air, it mixes with air readily (intimate mixing of
air (oxygen) and fuel takes place) and aids to complete combustion with less amount of excess air.
It does not produce smoke or soot. It has no sulphur content. It is lighter than air and disperses into
air easily in case of leak. Natural gas is also free of ash.

Solid or liquid fuels must be changed to a gaseous form before they will burn. Hence it requires
more excess air compared to natural gas for complete combustion. Solid fuels need to be
pulverized properly to get uniform sizes and liquid fuels need to be preheated and atomized
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properly for intimate mixing with air to ensure complete combustion. Hence more excess air is
provided for solid and liquid fuels.

b) Steam is to be used at the lowest practicable pressure for indirect process heating
A study of the steam tables would indicate that the latent heat in steam reduces as the steam
pressure increases. It is only the latent heat of steam, which takes part in the heating process
when applied to an indirect heating system. Thus, it is important that its value be kept as high as
possible. This can only be achieved if we go in for lower steam pressures. As a guide, the steam
should always be generated and distributed at the highest possible pressure, but utilized at as low
a pressure as possible since it then has higher latent heat.
However, it may also be seen from the steam tables that the lower the steam pressure, the lower
will be its temperature. Since temperature is the driving force for the transfer of heat at lower steam
pressures, the rate of heat transfer will be slower and the processing time greater. In equipment
where fixed losses are high (e.g. big drying cylinders), there may even be an increase in steam
consumption at lower pressures due to increased processing time. There are, however, several
equipment in certain industries where one can profitably go in for lower pressures and realize
economy in steam consumption without materially affecting production time.
Therefore, there is a limit to the reduction of steam pressure. Depending on the equipment design,
the lowest possible steam pressure with which the equipment can work should be selected without
sacrificing either on production time or on steam consumption.

S-8 List down five major advantages of waste heat recovery in rolling mill
furnace
1. Fuel economy
2. Improved combustion/less excess air/reduction in stack losses
3. Increased output
4. Reduction in scale losses
5. Uniform temperature across the material
6. Reduced pollution
7. Less auxiliary energy consumption
8. Reduction in equipment sizes

------- End of Section - II ---------

Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all Six questions

(ii) Each question carries Ten marks

An oil fired reheating furnace has an operating temperature of around 1000 oC.
L-1
Average furnace oil consumption is 440 litres/hour. The flue gas exit
temperature after the air preheater is 300 oC. Combustion air is preheated from
ambient temperature of 35oC to 200oC through the air preheater. The other data
are as given below.

Specific gravity of oil = 0.92

Calorific value of oil = 10,200 kcal/kg
Average O2 percentage in flue gas = 14%
Theoretical air required = 14 kg of air per kg of oil

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 Paper 2 - Set A Key

Specific heat of air = 0.24 kcal/kgoC

Specific heat of flue gas = 0.23 kcal/kgoC

Find out the sensible heat carried away by the exhaust gases and heat
recovered by the combustion air in kcal/hr as a percentage of the energy input.

Ans
Energy input = 440 litres/hr
= 440 x 0.92 kg/hr
= 404.80 kg/hr
= 404.80 x 10,200
= 41,28,960 kCal/hr
:
Excess air = ( %O2 ) x 100
(21-O2%)
= 14 x 100
(21-14)
= 200%

Theoretical air required = 14 kg of air to burn 1 kg of oil

Actual mass of air required = 14 x (1 + 200/100) kg/kg of oil
= 42 kg/kg of oil

Sensible heat loss in the flue gas = m x Cp x ΔT

m = mass of flue gas
= 42 + 1
= 43 kg/kg of oil

Cp = Specific heat of flue gas

= 0.23

ΔT = Temperature of flue gas – Ambient Temperature

= 300oC – 35oC
= 265 oC

Heat loss = 43 x 0.23 x (300-35)

= 43 x 0.23 x 265
= 2620.85 kCal/kg of oil
= 2620.85 x 404.80 Kcal/hr
= 10,60,920 Kcal/hr

Sensible heat loss in the flue gas

as % heat loss to input energy = 10,60,920 x 100
41,28,960
= 25.7 %

Heat gained by combustion air = 42 x 0.24 x (200-35)

= 1663.2 kCal/kg of oil
= 1663.2 x 404.80 Kcal/hr
= 673263.36 Kcal/hr
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Heat gained by combustion air

as % of input energy = 673263.36 x 100
41,28,960
= 16.3 %

L-2 Describe briefly any two of the following

a) Mechanical de-aeration and chemical de-aeration
b) Functions of a steam trap
c) Describe the operation of regenerator for high temperature furnace

An
a) Mechanical de-aeration and chemical de-aeration
s
In de-aeration, dissolved gases, such as oxygen and carbon dioxide, are expelled by preheating the
feed water before it enters the boiler.

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 is based on Charles' and Henry's laws of
physics. Simplified, these laws state that removal of oxygen and carbon dioxide can be accomplished by
heating the boiler feed water, which reduces the concentration of oxygen and carbon dioxide in the
atmosphere surrounding the feed water. Mechanical de-aeration can be the most economical. They
operate at the boiling point of water at the pressure in the de-aerator. They can be of vacuum or
pressure type.

Chemical de-aeration

While the most efficient mechanical deaerators reduce oxygen to very low levels (0.005 mg/litre), even
trace amounts of oxygen may cause corrosion damage to a system. Consequently, good operating
practice requires removal of that trace oxygen with a chemical oxygen scavenger such as sodium sulfite
or hydrazine. Sodium sulphite reacts with oxygen to form sodium sulphate, which is removed through
blow down. Hydrazine reacts with oxygen to form nitrogen and water. It is invariably used in high
pressures boilers when low boiler water solids are necessary, as it does not increase the TDS of the
boiler water.

b) Functions of a steam trap

The three important functions of steam traps are:
1 • To discharge condensate as soon as it is formed in the steam line / pipes.
2
3 • Not to allow steam to escape.
• To be capable of discharging air and other incondensable gases from the steam pipe.

c) Operation of regenerator for high temperature furnace

There are two sets of regenerators consisting of refractory bricks. In one path, the flue
gases flow heating up the chequered refractory bricks on one side, while through the

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 Paper 2 - Set A Key

other path, air for combustion flows which picks up the heat from heated chequered
refractory bricks on the other side. The cycle reverses with the time interval.
A heat exchanger is to be designed to condense the hydrocarbon vapor mixture
L-3
from a distillation column at the rate of 11.0 kg/sec which is available at its
saturation temperature of 120°C. The latent heat of condensation of the
hydrocarbon vapor mixture is 450 kJ/kg. The cooling water at 32°C is used in
counter-current direction at the rate of 58 kg/sec to condense the vapor mixture.
The specific heat of cooling water is 4.18 kJ/kg oC. Determine LMTD and area of
the heat exchanger surface if the overall heat transfer co-efficient is 550 J/m 2s°C.
Heat loss in hydrocarbon vapour mixture = heat gain in cooling water
Ans
11 * 450 = 58 * 4.18 * (T – 32)
T = 52.4 °C

Water leaves the exchanger at 52.4°C

LMTD = (120-32)-(120-52.4)/ln(120-32)/(120-52.4)

LMTD of counter flow pattern = 77.4 °C

Q = m*Cp* T = U * A * LMTD

58 * 4.18 * (52.4 – 32) * 1000 = 550 * A * 77.4

A = 116.3 m2

Area of the heat exchanger surface is 116.3 m2

A steam pipeline of 250 mm outer diameter & 100 meters long is insulated with
L-4
150 mm Mineral wool insulation. As an energy conservation measure, the
management has upgraded the existing Mineral wool insulation with efficient
calcium silicate insulation.

Calculate the economics in terms of payback if the insulation is upgraded at a

cost of 20 lakhs.

Given:
Operating hours : 8000
Boiler efficiency : 87 %
Fuel Oil Cost : Rs. 45,000 per
ton
GCV of the fuel : 10,200 kcal/kg
Thickness of Mineral wool insulation : 150 mm
Thickness of Calcium Silicate insulation : 100 mm
Surface temperature with Mineral wool insulation : 70 °C
Surface temperature with Calcium silicate insulation : 55 °C
Ambient temperature : 30 °C

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Ans
Heat loss with Mineral wool insulation = {10 + (Ts –Ta)/20} x (Ts – Ta)
= ( 10 + (70 – 30)/20 } x (70 – 30)
= 480 kCal/hr per Square meter

Heat loss with Calcium silicate insulation = ( 10 + (55 – 30)/20 } x (55 – 30)
= 281.25 kCal/hr – Sq. m

Surface Area with Mineral wool = 3.14 D L

= 3.14 x 0.550 x 100 = 172.7 Square meter

Surface Area with Calcium Silicate= 3.14 x 0.450 x 100 = 141.3 Square meter

Heat loss with Mineral wool = 480 x 172.7 = 82896 kCal/hr

Heat loss with Calcium silicate = 281.25 x 141.3 = 39741 kCal/hr
(82,896 - 39,741) x 8,000 x
45,000

10,200 x 1000 x 0.87

Annual savings =

= Rs. 17.5 Lakhs / year

Payback period = 20 / 17.5

= 1.14 years = 13.7 months
L-5 The energy flow diagram in a cogeneration plant in paper industry is given
below.

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 Paper 2 - Set A Key

Calculate the following

i) Input coal consumption per hour if feed water temperature is 50 oC
ii) Heat to power ratio of cogeneration plant
iii) % turbine and generator losses

Ans Input coal consumption = Q=50,000 x(770-50) / (0.8 x 4000) =11.25 Tons/ hr

Heat to power ratio = (50,000 x 660) / (4600 x 860) = 8.34

Turbine and generator loss = 50000 x 770 –(4600 x 860 +50,000 x 660)/10 6 = 1.544
Million kCal
% loss = 1.544 x 106 x 100 / (50,000 x 770) =4%

L-6 List down any ten points that need attention while selecting biomass fluidised
bed combustion boiler

The following areas need attention with biomass fed boilers:

 Uneven spreading of biomass fuel on boiler grate can lead to secondary combustion in the
super-heater zone, resulting in overheating of super heater tubes and fluctuations in steam
pressure.
 Frequent erosion of super-heater and economizer coils can occur, due to high silica content
in the biomass, especially in rice husk.
 High extraneous matter in biomass (sand and mud) causes tube fouling and fluidized bed to
be drained more frequently, with resultant heat loss.
 Carbon and dust coating of boiler tubes results in lowering of steam temperatures,
especially during soot blowing.
 Presence of Pesticides (used during farming) adds to tube failure frequencies; mainly due to
potassium constituents.
 Corrosive constituents in biomass adversely affect boiler internals, especially the super-
heater tubes. Chloride content in certain types of biomass (like cotton stalk, 8–9%) can combine
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with sodium and potassium in high temperature regime to aggravate the corrosion process.
 Some boilers which use Red Gram husk/twigs as fuel pose corrosion problems at the cold
end (i.e., secondary super-heater and economizer tubes), due to the sulfur content.
 The biomass fuel mix fed to the boiler, in quite a few cases, contains a combination of 6 to 7
biomass types. Each biomass has a separate air-to fuel ratio, and it is difficult to set a workable
air–fuel ratio.
 High moisture content in the biomass causes frequent jamming of the fuel in feeders,
leading to fluctuations in steam pressure and temperature.
 High moisture content in the biomass also leads to plugging and choking of closely spaced
heating surfaces. This situation is further aggravated by the super-heater tube coil with very
close spacing, often the result of a desire to achieve a compact design.
 Due to biomass fuel size variation, occurance of unburnts in flue gases and bottom ash is
high, resulting in lower efficiency and also variation in steam pressure and temperature.
 Absence of biomass feed rate measurement mechanism leaves little room for accurate
assessment of heat rate/efficiency. Providing a weighing mechanism is difficult on account of
different biomass fuel combinations being used, with different (and low) bulk densities.
 Degradation of biomass during storage in exposed ambient wet atmosphere leads to loss of
heat value. Loss of material due to windage and carpet loss, coupled with loss of heat value on
account of decay (inherent biomass characteristics), can cause an error in assessment of input
fuel energy (as the input heat is customarily evaluated based on received biomass quantities
and GCV).

------- End of Section - III ---------

16
 Paper 2 – Set A

15th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS– August, 2014

PAPER – 2: Energy Efficiency in Thermal Utilities

Date:23-8-2014 Timings:14:00-17:00 Duration: 3 HRS Max. Marks: 150

Section – I: OBJECTIVE TYPE Marks: 50 x 1 = 50

(i) Answer all 50 questions

(ii) Each question carries one mark
(iii) Please hatch the appropriate oval in the OMR answer sheet with black pen or HB pencil.

1. If the terminal temperature differences at the hot and cold end of a heat exchanger
is same, then the LMTD is
a) 100 oC b) 0 oC c) 50 oC d) none of the above

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

3. Which of these is not true of ‘critical point’ of steam/water mixture?

a) the temperature at critical point is 374.15oC

b) the pressure at critical point is 221.2 bar
c) saturated liquid and saturated vapour lines meet at critical point
d) enthalpy of evaporation is maximum at critical point

4. Which of these fuels has the highest heating value?

a) LPG b) methane c) hydrogen d) diesel

5. The difference in temperature between steam and condensate is the principle of

operation in a
a) thermodynamic trap b) thermostatic trap
c) orifice type trap d) none of the above
6. Which of the following will be ideal for heat transfer in a heat exchanger?

a) hot water b) super heated steam

c) saturated dry steam d) wet steam

7. What is the predominant mode of heat transfer in reheating furnaces?

a) convection b) radiation c) conduction d) pulsation

8. In a gas turbine, air compressor alone consumes about _____of the energy
generated

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a) 5-10% b) 20-30% c) 30-40% d) 40-45%

9. In an oil fired steam boiler the Air to fuel ratio by mass is 15:1 & evaporation ratio is
14:1. The flue gas to fuel ratio will be

a) 29:1 b) 16:1 c) 1:1 d) 15:1

10. The cogeneration system which has high overall system efficiency is one which
uses

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

c) compressor d) gas turbine

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

13. Which of the following works on a refrigeration cycle?

a) thermo compressor b) heat pipe

c) heat wheel d) heat pump
14. Which agro-residue has the lowest gross calorific value?

a) deoiled bran b)paddy husk c)sawdust d) coconut shell

15. The highest % of sulphur is present in

a) LDO b) Furnace oil c) LSHS d) Kerosene

16. Which of the following is not a property of ceramic fibre insulation?

a) low thermal conductivity b) high heat capacity

c) light weight d) thermal shock resistance
17. For stoichiometric combustion of 1 kg of carbon, the required amount of air will be
about
a) 31 kg b) 21 kg c) 11.6 kg d) 2.67 kg
18. For coal fired system, the flame length is influenced by

a) moisture b) volatile matter c) ash content d) fixed carbon

.
19. Which of the following in fuel contributes to erosive effect on burner tips?

a) ash b) water c) sulphur d) volatile matter

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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

c) radiation losses d) moisture in the air
21. Water treatment for steam boilers is generally required to

a) remove hydrogen b) prevent scale formation

c) help improve combustion efficiency d) reduce stack temperature

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

23. A rise in conductivity of boiler feed water indicates

a) drop in the contamination of feed water b) greater purity of feed water

c) rise in the TDS of feed water d) rise in oxygen level

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

25. In a steam system, the purpose of air venting is because air

a) is a good conductor b) acts as insulator c) is inert d) is diluent

26. The inverted bucket trap operates on the principle of _______ difference between
water and steam
a) pressure b) density c) temperature d) velocity
27. Furnace wall heat loss does not depend on ______
a) temperatures of external wall surfaces b) velocity of air around the furnace
c) thermal conductivity of wall brick d) material of stock to be heated.

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

29. In FBC boiler, the combustion is carried out at a temperature

a) closer to steam temperature. b) adiabatic combustion temperature
c) below ash fusion temperature d) above ash fusion temperature

30. The material used to control SOx in the FBC boiler is

a) limestone b) alumina c) silica d) lime

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
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a) water at 0 oC to saturated steam at 100 oC

b)water at feed water temperature to saturated steam at 100 oC
c)water at 100 oC to saturated steam at 100 oC
d)water at ambient temperature to saturated steam at 100 oC
33. Pinch analysis of heat exchangers depicts plot of

a) temperature vs entropy b) temperature vs area

c) temperature vs specific heat d) temperature vs enthalpy

34. The effectiveness of a heat exchanger does not depend on

a) specific heat of hot fluid b) inlet temperature of hot fluid

c) inlet temperature of cold fluid d) LMTD

35. Parameter assumed to remain constant during LMTD calculation of a heat

exchanger is

a) temperature drop b) heat transfer area

c) specific heat of fluids d) all the above
36. How much kg of SO2 is produced in complete combustion of 32 kg of sulphur?

a) 16 b) 32 c) 64 d) 128

37. Micro turbine can be used to replace _______ for energy savings

a)gas turbines b) diesel generator c) HRSG d) PRV

38. When steam pressure reduces, which of the following increases ?

a ) sensible heat b) enthalpy of steam

c) saturation temperature d) specific volume
39. If excess air is 20% in a boiler, the excess oxygen in flue gas would be

a) 3.5% b) 4% c) 2% d) 1.5%

40. Which of the following requires the lowest stoichiometric oxygen demand (kg/kg of
fuel)?

a) hydrogen b) carbon c) sulphur d) methane

41. Temperature control in fuel oil storage tank is intended to control

a) viscosity b) density c) specific heat d) caloric value

42. An increase in bulk density of a refractory increases its

a) thermal conductivity b) heat capacity

c) resistance to slag penetration d) all of the above
43. In a CFBC boiler,the capture and recycling of bed material is accomplished by

a) bag filter b) settling chamber c) cyclone d) scrubber system

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44. Bomb calorimeter is used to measure

a) atmospheric pressure b) pour point of liquid Fuels
c) calorific value of fuels d) viscosity of fuel
45. 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

46. In a steam turbine power plant, vacuum is generated at

a) turbine inlet b) condenser c) deaerator d) all of the above

47. Heat wheels are mostly used in a situation of….
a) high temperature exhaust gases
b) heat exchange between large masses of air having small temperature
differences
c) heat transfer between a liquid and gas
d) corrosive gases
48. In a condenser, which part of the heat of the steam is rejected?

a) super heat b) latent heat

c) sensible heat d) latent heat and super heat

49. The highest energy loss occurs in which of the following thermal power plant
equipment ?

a) boiler b) steam turbine c) generator d) condenser

50. Which of the following gives a rough estimate of calorific value of coal ?

a) moisture content b) volatile matter c) fixed carbon d) ash content

-------- End of Section - I ---------

Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 40

(i) Answer all eight questions

(ii) Each question carries five marks

S1 An economizer was installed in the furnace-oil fired boiler. The following are the data
monitored after commissioning the economiser.

Air to fuel ratio = 20

Evaporation ratio of the boiler = 12
Specific heat of flue gas = 0.25 kcal/kgOC.
Condensate recovery in the plant = Nil.

Calculate the rise in temperature of feedwater in an economizer, which brings down the flue
gas temperature from 280 OC to 180 OC.

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 Paper 2 – Set A

Ans For 1 kg of fuel, steam generated = 12 kg

For 1 kg of fuel, required combustion air = 20 kg
For 1 kg of fuel, flue gas generated = 20 +1= 21 kg
In economizer heat given by flue gas = heat received by water

21 x 0.25 x (280-180) = 12 x 1 x T
Rise in temperature of water T = 43.75 ºC

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.

Ans % Excess air = (Theoretical CO2 / Actual CO2 ) – 1

= (14.5 / 10) – 1

= 45 %

Theoretical air required for combustion = 20 / 1.45

= 13.8 kg of air / kg of fuel

S4 A gas turbine generator is operating with naphtha as a fuel. The following are the data
collected during the gas turbine generator operation:

Fuel (Naphtha) consumption = 350 kg/hr

GCV of naphtha fuel = 10550 kcal/kg
Overall efficiency of gas turbine generator = 35 %
Cost of naphtha fuel = Rs 45000 / ton

Find out the cost of generating one unit of electricity.

Ans
Heat input to the turbine = 10550 * 350
= 3692500 kcal/hr

Efficiency of gas turbine = 35 %

Gas Turbine Output = [(3692500x0.35) / 860]
= 1503 kWh

Cost of generating 1503 units of electricity = 350 kg/hr x Rs 45.0

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 Paper 2 – Set A

= Rs. 15750

Cost of one unit of electricity generated = 15750 / 1503

= Rs 10.5 per kWh

S5
A paint drier requires 75.4 m3/min of air at 93°C, 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/kg°C. Inlet air temperature to drier is 32°C.

Steam Steam Enthalpy kcal/kg

pressure temperature
bar °C Water Evaporation Steam

4.0 143 143 510 653

How many kg of steam at 4 bar does this steam coil unit require per hour?

Air flow rate (vol) = 75.4 m3/min x 60

Ans
= 4524 m3/hr
Air flow rate (mass) = 4524 x 1.2
= 5428.8 kg/hr

Sensible heat of air = m x Cp x T

= 5428.8 x 0.24 x (93-32)
= 79477 kcal/hr

Latent heat of Steam = 510 kcal/kg

Steam required = 79477 / 510
Steam required = 156 kg/hr

S6 List three functions of steam traps. What type of trap is generally used for main
steam lines?

Ans i) Page no 80 & 81

To discharge condensate as soon as it is formed
Not to allow steam to escape
To be capable of discharging air and other incondensable gases

ii) Thermodynamic steam trap is used in the main line

S7 Explain with sketch the working principle of a regenerator used for high temperature
furnace

Ans Ref page no 222

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S8 Explain briefly the bottoming cycle cogeneration system and mention any two of its
application in industry

Ans i) Ref page no 191

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ii) steel, cement, ceramic, glass industry

-------- End of Section - II ---------

Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all SIX questions

(ii) Each question carries Ten marks

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 180°C and leaves
at 130°C. The inlet and exit temperature of water are 30°C and 90°C respectively. Specific
heat of water is 4.18 kJ/kg°C.

a) Calculate the heat transfer area, if overall heat transfer coefficient is 814 W/m2°C..
b) What would be the percentage increase in area, if the fluid flows were parallel?
Ans Water flow rate = 10.5 x 1000 = 10500 kg/hr

Heat content in water = m x Cp x T

= 10500 x 4.18 x (90 – 30)
= 2633400 KJ/hr
= 2633400 / 3600
= 731.5 kW
For Counter current flow:

T1 = 180 – 90 = 90°C
T2 = 130 – 30 = 100°C
LMTD of counter flow = (100-90)/ ln(100/90) = 95°C

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 Paper 2 – Set A

Overall heat transfer coeff. = 814 W/m2°C

Area of heat exchanger for counter flow = 731.5 x 1000 / (814x 95 )

= 9.5 m2

For Parallel flow:

T1 = 180 – 30 = 150°C
T2 = 130 – 90 = 40°C
LMTD of parallel flow = (150-40)/ ln(150/40) = 83°C
Overall heat transfer coeff. = 814 W/m2°C

Area of heat exchanger for parallel flow = 731.5 x 1000 / (814 x 83 )

= 10.8 m2
Increase in the area for parallel flow = [(10.8 – 9.5) / 9.5] x 100
= 14 %
L2 In a chlor-alkali plant, 100 TPD caustic solution at 30% concentration is dried to 55%
concentration in a single effect evaporator, where the ratio of steam input to moisture
removal is 1.0 kg/kg. It is proposed to be replaced by a triple effect evaporator at an
investment cost of Rs. 5 crore, for which the ratio of steam input to moisture removal is 0.45
kg/kg. Steam for the evaporator is generated from an oil fired boiler at an evaporation ratio
of 14 which operates for 300 days in a year.

Calculate payback period if the cost of Fuel Oil is Rs.50,000 per ton.

Ans
% salt concentration at inlet = 30%
% salt concentration at outlet = 55%
Input quantity of caustic solution to drier = 100 TPD

Amount of salt at drier inlet = 100x 0.3 = 30 TPD

Flow rate of salt solution at drier outlet = 30 / 0.55 = 54.5 TPD

Amount of water removed = 100 – 54.5

= 45.5 TPD
Ratio of steam / moisture for single effect = 1.0
Amount of steam required for single effect = 45.5 TPD

Ratio of steam / moisture for triple effect = 0.45

Amount of steam required for triple effect = 45.5 x 0.45
= 20.475 TPD
Amount of steam saved by triple effect = 45.5 – 20.45
= 25 TPD
Evaporation ratio = 14
Amount of fuel savings = 25 / 14 = 1.79 TPD
_________________________ 10
Bureau of Energy Efficiency
 Paper 2 – Set A

FO savings per year = 1.79 x 300

= 537 Tons/year
Cost of FO saved = 537 x 50,000
= Rs. 2.69 Crores per year

Investment on triple effect evaporator = Rs. 5 Crores

Payback period = 5 / 2.69

= 1.86 years (or) 22 months

L3 a) List the advantages of CFBC boilers over AFBC boilers.

b) What are the advantages of plate heat exchanger over shell and tube heat exchanger?

Ans a)
List the advantages of CFBC boilers over AFBC boilers.
i. Higher processing temperature because of high gas velocity through the system.
ii. Lower combustion temperature of about 870 oC can be achieved constantly, which
results in minimal NOx formation.
iii. The combustion air is supplied at 1.5 to 2 psig rather than 3 to 5 psig as required by
bubbling bed combustors.
iv. Higher combustion efficiency.
v. Better turndown ratio.
vi. Erosion of heat transfer surface in the combustion chamber is reduced, since the
surface is parallel to the flow. In AFBC system, the surface is generally
perpendicular to the flow.

b)
i. The heat recovery efficiency is higher for plate heat exchanger when compared with
shell and tube heat exchanger
ii. Plate heat exchanger is compact in size.
iii. If the temperature difference is small between cold and hot stream, then plate heat
exchanger is used more effectively when compared with shell and tube heat
exchanger
iv. Heat exchange surface is easily increased or decreased by addition or removal of
plates.

L4 List five energy saving measures in each of the following

a) Oil fired industrial reheating furnace.

b) Steam systems

_________________________ 11
Bureau of Energy Efficiency
 Paper 2 – Set A

b) Steam Systems

1) Avoiding Steam Leakages

2) Providing Dry Steam for Process
3) Utilising Steam at the Lowest Acceptable Pressure for the Process
4) Proper Utilization of Directly Injected Steam
5) Minimising Heat Transfer Barriers
6) Proper Air Venting
7) Condensate Recovery
8) Insulation of Steam Pipelines and Hot Process Equipments
9) Flash Steam Recovery
10) Pipe Redundancy
11) Reducing the Work to be done by Steam
12) Monitoring Steam Traps

L5 A boiler utilizes Coconut shell as fuel and the ultimate analysis (by weight %) of the fuel is
given below:

Ultimate ANALYSIS
COMPONENT
%
Carbon 45
Hydrogen 5
Nitrogen 0.6
Oxygen 32
Sulfur 0.08
Mineral matter 4
Moisture 13.32

The CO2 content of the exit flue gas measured is 10%.

For 100 kg of coconut shell fuel fired calculate the following

(a) Theoretical amount of air required for combustion
(b) Theoretical CO2 content in flue gas.
(c) % excess air supplied

Ans a)
Total oxygen required =45x2.67+ 5 x 8+.08 x 1 = 160.23kg
Oxygen present in the fuel =32 kg

_________________________ 12
Bureau of Energy Efficiency
 Paper 2 – Set A

Net oxygen required =160.23 - 32 = 128.23 kg

Air required =128.23/0.23 = 557.52kg
Theoretical amount of air required for combustion =557.52 kg/100 kg of fuel.

b)
Nitrogen in the air =557.52 - 128.23 = 429.29kg
Nitrogen in the fuel =0.6kg
Moles of Nitrogen = 429.89 / 28 = 15.35
Amount of carbon dioxide in flue gas = 45 x 44/12 = 165 kg
Moles of Carbon dioxide =165 / 44 = 3.75
Moles of sulphur = 0.08 x 2/64 =0.0025
b)Theoretical CO2 content in flue gas = 3.75 / (3.75+15.35+.0025) =19.7%
c) % Excess air supplied = 100x(19.7/10) -1 = 97%

L-6 The schematic of a back pressure steam turbine cogeneration system of process plant
operating round the clock with operating data is depicted below.

If the steam requirement of the process is to be increased to 44TPH which can be met by
the existing boiler through the back pressure turbine,

a) 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

b) also find out the additional coal requirement per day?

_________________________ 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

Additional power generation potential = 4000 kg/hr /12.5 kg/kWh
=320 kW

Daily saving due to additional power generation =320 kW x24 hr x Rs.7

= Rs 53,760

Additional coal requirement per hour = 4000 x(780-135) / (0.8 x 4300)

= 750 kg/hr

b)Additional coal requirement per day =750 kg/hr x 24

= 18,000 kg/day = 18 Ton/day

-------- End of Section - III ---------

_________________________ 14
Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

MODEL SOLUTIONS

16th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS – September, 2015

PAPER – 2: Energy Efficiency in Thermal Utilities

Date: 19.09.2015 Timings: 1400-1700 HRS Duration: 3 HRS Max.

Marks: 150

Section – I: OBJECTIVE TYPE Marks: 50 x 1 = 50

a) Answer all 50 questions

b) Each question carries one mark
c) Please hatch the appropriate oval in the OMR answer sheet with
Black Pen or HB pencil

1. Which one of the following is not true with respect to the role of nitrogen
in the combustion of any fuel

a) produces oxides of nitrogen

b) reduces the volume of combustion by-products
c) dilutes the flue gases
d) carries useful heat in flue gases
2. Which one of the following fuel has the highest hydrogen content and
lowest sulphur content

a) coal b) fuel oil c) natural gas d) LSHS

3. Which of the following yields a low CO2 reading

a) soot deposits on boiler tubes b) flue gas bypass in air pre-heater

c) proper air-fuel mixture d) air ingress in flue gas duct

1
 REGULAR Paper 2 – Set A

4. Which of the following salt causes temporary hardness in water

a) calcium sulphate b) calcium bicarbonate

c) calcium chloride d) calcium nitrate
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

c) LMTD (Log Mean Temperature Difference) d) effectiveness
9. Which of the following contribute to spontaneous combustion of coal

a) low Volatile matter b) low fixed carbon c) less ash d) none

of the above
10. Which of the following can be used as desiccant in boiler preservation

a) silica gel b) activated carbon c) un-slaked lime d) all of the

above
11. Which of the following boiler water treatment ensures complete removal
of salts

a) demineralization b) softening c) de-aeration d) all of the

2
 REGULAR Paper 2 – Set A

above
12. Which of the following boiler utilizes the combination of suspension
firing and great firing

a) traveling grate stoker boiler b) packaged boiler

c) spreader stoker boiler d) pulverized fuel boiler
13. Which of the component is common to supercritical boiler and sub critical
boiler for power generation

a) economizer b) water walls c) re-heaters d) all of the above

14. Which fuel among the following needs temperature control during storage

a) coal b) furnace oil c) diesel oil d) kerosene

15. What happens when the float in a float trap develops a puncture

a) loss of condensate b) loss of live steam c) fails to open d)

fails to close
16. Transfer of heat without a conveying medium is possible with

a) conduction b) radiation c) convection d) none of

the above
17. The velocity of steam in steam pipe is directly proportional to

a) number of bends in pipe b) 5th power of the diameter of pipe

c) length of pipe d) specific volume of steam
18. The unit of overall heat transfer coefficient is

a) W/m2 K b) W2/m2 K c) W2 /m3 K d) W/m3 K

19. The thermal resistance of an insulation

a) decreases with increased thermal conductivity

b) increases with increased thermal conductivity
c) decreases with decreased thermal conductivity
d) has no relation with thermal conductivity
20. The stoichiometric amount of air required to burn 1 kg of methane is

3
 REGULAR Paper 2 – Set A

a) 69.57 b) 4 c) 17.39 d) 16
21. The parameter assumed to remain constant during LMTD calculation of a
Heat exchanger is

a) temperature drop b) heat transfer area

c) specific heat of fluids d) none of the above
22. The material used to control SOx in the FBC boiler is

a) limestone b) alumina c) silica d) fly ash

23. The heat loss in a furnace depends on

a) emissivity of walls b) conductivity of refractory

c) wall thickness d) all of the above
24. The chemical used to prevent oxidation in boiler feedwater is

a) sodium sulphite b) sodium phosphate

c) calcium phosphate d) magnesium phosphate
25. The best time for intermittent blow down in a boiler

a) High load under full pressure b) low load under full pressure
c) high load under partial pressure d) low load under partial
pressure
26. The amount of CO2 produced in complete combustion of 18 Kg of carbon

a) 50 b) 44 c) 66 d) 792
27. Scale losses in reheating furnaces will

a) increase with excess air b) decrease with excess air

c) have no relation with excess air d) increase with CO in combustion
gases
28. Removal of condensate from main steam line is done to prevent

a) steam locking b) air locking c) water hammer d) all of the

above

4
 REGULAR Paper 2 – Set A

29. Presence of _____ in flue gas confirms incomplete combustion in furnace

a) CO b) NOx c) SOx d) all of the above

30. Portable fyrite is used for the measurement of

a) CO2 content in flue gas b) O2 content in flue gas

c) stack temperature d) both (a) & (b)
31. On an inverted bucket trap, what happens to the bucket as the trap fills
with water

a) it rises b) it inclines c) it sinks d) it remains stationary

32. NOx formation in FBC boilers is minimised because of

a) higher velocity of flue gas in combustion chamber

b) higher pressure of the air supplied
c) lower temperatures in the bed and combustion chamber
d) higher contact of solid particles in the flue gas
33. In which zone of cupola furnace does the conversion of CO2 to CO take
place?

a) combustion zone b) melting zone c) reduction zone d) preheating

zone
34. In a fire-tube boiler, soot forms on

a) outside tube surface b) inside tube surface

c) waterside surface d) water wall surface
35. If the volatile matter in coal is low, which of the following equipment is
the best waste heat recovery option in a boiler

a) economiser b) air preheater c) deaerator d) heat pipe

36. Hydrometer is used for the measurement of

a) viscosity b) density c) water content d) humidity

37. Heat transfer rate for indirect heating application will be less if we heat
with

5
 REGULAR Paper 2 – Set A

a) saturated steam b) dry steam

c) superheated steam d) high pressure steam
38. Furnace wall heat loss depends on

a) temperatures of external wall surfaces b) velocity of air around

the furnace
c) thermal conductivity of wall brick d) all of the above
39. For flash steam calculation, flash steam quantity available depends upon

a) condensate pressure and flash steam pressure b) steam pressure

c) steam enthalpy at atmospheric pressure d) total heat of flash
steam
40. Enthalpy of evaporation of any vapour at its critical point will be

a) more than zero b) zero c) less than zero d)

unpredictable
41. Corrosion in chimney, air pre-heater and economizer is mainly influenced
by

a) sulphur content in fuel b) ash content in fuel

c) moisture content in fuel d) all of the above
42. Condensate at pressure of 4 kg/cm2 and 160oC temperature when
exposed to atmosphere will

a) become super heated b) partly convert to flash steam

c) remain as condensate d) fully convert to flash steam
43. Coal size of 75% below 75 micron is required for use in

a) spreader stoker boiler b) chain grate stoker boiler

c) fluidized bed boiler d) pulverized fuel boiler
44. Ceramic coating is used in furnaces because it enhances

a) conductivity b) convective heat transfer coefficient

c) emissivity d) radiation factor
45. As the pressure of water increases from 1kg/cm2 to 8 kg/cm2, the values

6
 REGULAR Paper 2 – Set A

of enthalpy of steam and enthalpy of evaporation respectively

a) increases & remains the same b) increases & decreases

c) decreases & increases d) decreases & remains the same
46. An increase in bulk density of a refractory increases its

a) volume stability b) heat capacity

c) Resistance to slag penetration d) all of the above
47. A small quantity of leakage of stored Liquid LPG evaporates to produce
about ____ times of volume of gas.

a) 100 b) 150 c) 250 d) 350

48. A high carbon monoxide reading indicates

a) moisture in the fuel b) high furnace temperature

c) high excess air d) none of the above
49. 2 m lift of condensate in steam pipe will result in back pressure of

a) 0.02 bar b) 0.2 bar c) 2 bar d) 20 bar

50. _____ gives an estimate of heating value of coal

a) ash content b) moisture content c) fixed carbon d) volatile matter

-------- End of Section I------------

7
 REGULAR Paper 2 – Set A

Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 =

40

(i) Answer all eight questions

(ii) Each question carries five marks
S-1 Determine the Energy Utilization Factor (EUF) from the following back pressure
cogeneration plant diagram and data given.
Back Pr.Steam
P =4 kg/cm2
T =165 °C
Q =12MT/hr
Process
Plant Condensate
H =650kcal/kg P= 4 kg/cm2
T= 165oC
Inlet Steam
P = 42 kg/cm2
T = 410 °C
Q = 12 MT/hr
H = 760kcal/kg
 Power
0.7 MW
Alternato
r
BPT
Back Pr Turbine Cogeneration Plant

Solution:
Input heat to turbine = 12,000 x 760 = 91,20,000 Kcal/hr

Useful heat to process Plant = 12,000 x 650-165 = 5820,000 Kcal/hr

Useful Electrical output in alternator = 700x860= 602000 Kcal/hr

Energy Utilization Factor (EUF) = [(602000+5820,000) /91,20,000] x 100

= 70.42%

S-2 For combustion of 500 kg/hr of natural gas containing 100% methane, calculate

8
 REGULAR Paper 2 – Set A

the percentage of CO2 in the flue gas while 15% excess air is supplied.

Ans:
CH4 + 2 O2  CO2 + 2H2O

1 mole of Methane requires 2 moles of Oxygen.

16 Kg of Methane requires 64 Kg of Oxygen.

16 Kg of Methane produces 44 Kg of CO2.

500 Kg/hr of Methane requires 2000 Kg/hr of Oxygen.

500 Kg/hr of Methane produce 1375 Kg/hr of CO2.

Theoretical air required for combustion = 2000 / 0.23 = 8696 Kg/hr

Considering 15% excess air,

Actual air supplied for combustion is = 8696 * 1.15

= 10,000.4 Kg/hr of air

Flue gas generation with 15% excess air = 500 + 10,000.4

= 10,500.4 Kg/hr

% CO2 in the flue gas = (1375 / 10,500.4)x 100

= 13.1 %

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.

9
 REGULAR Paper 2 – Set A

Ans:

The velocity of steam maximum = 28 m/s

Specific volume at 7 kg/cm2 = 0.24 m3/kg

Mass flow rate = 5000 kg/hr

= 5000/3600 = 1.389 kg/sec

Volumetric flow = 1.389 x 0.24 = 0.333 m3/sec

Therefore, using:

Volumetric flow rate(m3/s) = Velocity (m/s) x Cross sectional area (m2)

4  Volumetric flowrate
D 
  Flow velocity

4  0.333
D 
  28

D  0.123 m or 123 mm

Since the steam velocity must not exceed 28 m/s, the pipe size must be at least
123 mm; the nearest commercially available size, 150 mm, would be selected.

S-4 Paddy husk is being used as a combustion fuel in a water tube boiler. The
ultimate analysis of fuel is given below. Calculate theoretical amount of air
required per 100 kg of husk for the combustion from the following data.

Ultimate Analysis of Typical Agro Residues %

Moisture 10.8
Mineral Matter 16.7
Carbon 34.0
Hydrogen 5.0
Nitrogen 0.9

10
REGULAR Paper 2 – Set A

Sulphur 0.1
Oxygen 32.5

Ans:

Considering a sample of 100 kg of paddy husk.

Component % (wt) Equation Specific Actual

in fuel in fuel stoichiometric stoichiometric
oxygen oxygen
required required

Carbon 34 C + O2 = CO2 2.67 90.78

12 + 32 = 44 (32/12) (34 x 2.67)

Hydrogen 5 H2 + 0.5 O2 = H2O 8.0 40.0

2 + 16 = 18 (16/2) (5 x 8)

Sulphur 0.1 S + O2 = SO2 1.0 0.1

32 + 32 = 64 (32/32) (0.1 x 1)

Oxygen 32.5 (-)32.5

Nitrogen 0.9 -

Moisture 10.8 -

Mineral 16.7 -
matter

Total 100 98.38

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 /

11
 REGULAR Paper 2 – Set A

100 kg fuel

(air contains 23% oxygen by wt.)

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 160-170°C?

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.

(b) For fuels containing sulphur, low temperatures (below 160-170°C) 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.

S-6 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

12
 REGULAR Paper 2 – Set A

MS melting temperature : 1450 0C

Inlet MS charge temperature : 35 0C
Efficiency of furnace : 70%

Ans:
Theoretical energy required for melting = 1250 (0.68 x (1450 – 35) +
270)/3600
= 427.8 kWh

Actual energy input to the furnace = 427.8 / 0.7

Electricity consumption = 611.2 kWh

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:

27x + (1 – x) 80 =60

Therefore x = 0.37
(37 percent makeup water or only 63 per cent of condensate is recovered).

13
 REGULAR Paper 2 – Set A

S-8 Milk is flowing in a pipe cooler at a rate of 0.95 kg/sec. Initial temperature of
the milk is 55 °C and it is cooled to 18 °C using a stirred water bath with the
constant temperature of 10°C around the pipe. Specific heat of milk is 3.86
KJ/kg°C. Calculate the heat transfer rate (kcal/hr) and also LMTD of the
exchanger.

Ans:

Heat transfer in cooling milk = 0.95 * 3.86 * (55 – 18)

= 135.7 KJ/sec

=135.7 /4.18

= 32.46 kcal/sec

=(32.46*3600)= 116856 kCal/hr

LMTD: DT1 = 55 – 10 = 45 °C

DT2 = 18 – 10 = 8 °C

LMTD of the heat exchanger = (45 – 8) / ln (45 / 8)

LMTD of the heat exchanger = 21.4 °C

-------- End of Section - II ---------

14
 REGULAR Paper 2 – Set A

Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all SIX questions

(ii) Each question carries Ten marks

L-1 a) Find out the efficiency of the furnace oil fired boiler by the direct method in
an agro product manufacturing plant given the following data:

Type of boiler : Furnace oil fired

Quantity of steam (dry) generated : 5 TPH
Steam pressure / temp : 10 kg/cm2(g)/
180 0C
Quantity of oil consumed : 0.350 TPH
Feed water temperature : 75 0C
GCV of Furnace oil : 10400 kCal/kg
2
Enthalpy of saturated steam at 10 kg/cm pressure : 665 kCal/kg
Enthalpy of feed water : 75 kCal/kg
Cost of furnace oil : Rs 32/kg
Annual operating hours : 7200 hrs /year

b) The oil fired boiler was converted to coconut shell firing maintaining
the same steam and feed water parameters.
i) Determine the fuel consumption per hour
ii) Return on investment for the conversion scheme.

Fuel fired in the boiler : coconut shell fuel

GCV of coconut shell : 4200 kCal/kg
Efficiency with coconut shell firing : 76%
Cost of coconut shell : Rs 12/kg
Annual interest on capital : Rs 6 lakhs /yr
Annual operating hours : 7200 hrs /year
Investment towards boiler conversion : Rs 50 lakhs

15
 REGULAR Paper 2 – Set A

Solution:

a) Efficiency of furnace oil fired boiler (Direct method)

Boiler Efficiency (η) = 5000 x (665-75) / (350 x 10400)

= 81% (on GCV basis)

b) i) Coconut shell fuel consumption after conversion:

Fuel consumption = 5000 x (665-75) / (0.76 x 4200)

= 924.2 kg/hr

ii) ROI for the conversion scheme:

Annual fuel cost of furnace oil fired boiler = 350 x 7200 x 32 = Rs

8,06,40,000 /year

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

= [(8,06,40,000 - 7,98,50,880) – 6,00,000] x 100

50,00,000
= 3.8 %

L-2 A liquid waste stream has a flow rate of 3.5 kg/s and a temperature of 70o C
with a specific heat capacity of 4190 J/kgK. Heat recovered from the hot waste
stream is used to pre-heat boiler make-up water. The flow rate of the make-up
water is 2 kg/s, its temperature is 10oC and its specific heat capacity is 4190
J/kg/K. The overall heat transfer coefficient of the heat exchanger is 800
W/m2K. If a make-up water exit temperature of 50oC is required, and assuming
that there is no heat losses from the exchanger, determine

1) The heat transfer rate

2) The exit temperature of the effluent and
3) The area of the heat exchanger required

16
REGULAR Paper 2 – Set A

Solution :

i) Heat gained by makeup water = Qc= mc cc ∆T = 2 x 4190 x (50-10)

= 335200 W = 335.2 kW

ii) mh ch (th1 – th2) = mc cc (tc1 – tc2)

3.5 x 4190 x (70 - th2) = 2 x 4190 x (50 -10)

th2 = 47.14 o C

iii) Now because the water outlet temperature is above the outlet temperature
of the effluent a counter-flow heat exchanger is required.

LMTD = Δt1 – Δt2

ln (Δt1/ Δt2)

= ((70-50)-(47.14-10)
ln (70-50)/(47.14-10)

LMTD = 27.69oC

Q = UA (LMTD)

A= 335200
800 x 27.69

Area = 15.13 m2

17
 REGULAR Paper 2 – Set A

L-3 Write short notes on any two of the following:

a) Plate heat exchanger (page 242 of

book-2)

b) Multiple effect evaporator (page 247-248

of book-2)

c) Gas turbine cogeneration system (page 192 of

book-2)

L-4 a) In a typical fertiliser manufacturing plant, the quantity of 133200 Ton of

Ammonia is produced annually, using naphtha as fuel as well as raw
material (feed) and electricity from captive power plant.

Naphtha Electricity
as fuel

Naphtha Ammonia
as feed Ammonia
production Production
raw plant
material

The quantity of annual raw material consumption and its heating values are
given in table.
Raw material
Quantity Heating Value
consumption

1.Naphtha - feed 66800 Ton 10650 kCal / kg

2.Naphtha - fuel 31200 Ton 10650 kCal / kg
3.Electricity 1180 x Lakh kWh 2500 kCal/kWh

Calculate the specific energy consumption of ammonia production in Gcal /

Ton.

b) Sketch the schematic diagram of “Back Pressure Turbine” and “Extraction

Condensing Turbine” Cogeneration systems (Note: no explanation

18
 REGULAR Paper 2 – Set A

required).

Answer :

a) Specific Energy Consumption(SEC) of Ammonia

Raw material
Quantity Heating Value Gcal
consumption

1.Naphtha -
66800 Ton 10650 kCal / kg 711420
feed
2.Naphtha - fuel 31200 Ton 10650 kCal / kg 332280
1180 x Lakh
3.Electricity 2500 kCal/kWh 295000
kWh
1338700
Ammonia 133200 Ton
production
10.05
Specific Energy Consumption(SEC) of Ammonia
Gcal per
production =
Ton

b) Schematic diagram of (i) Back Pressure Turbine and (ii) Extraction

Condensing Turbine Cogeneration systems

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

19
REGULAR Paper 2 – Set A

250°C. Flue gas enters the APH at 375°C. Calculate the flue gas leaving the stack
and also determine the improvement in furnace efficiency after the installation
of APH with the following data

Density of air : 1.15 kg/m3

Specific heat of air : 0.23 Kcal/kg°C

Specific heat of flue gas : 0.26 Kcal/kg°C

Calorific value of fuel : 9850 Kcal/kg

Air to fuel ratio : 18

Efficiency of furnace : 73 %

Ambient temperature : 30°C

Solution:

Amount of Air flow = 240 * 60 * 1.15

= 16560 Kg/hr

Amount of fuel = 16560 / 18

= 920 Kg/hr

Amount of flue gas = 16560 + 920

= 17480 Kg/hr

Heat absorbed by combustion air = 16560 * 0.23 * (250 – 30)

= 837936 Kcal/hr

Temperature difference in flue gas = 837936 / (17480 * 0.26)

= 184 °C

Flue gas leaves the stack at temp = 375 – 184 = 191 °C

Efficiency of APH = Heat absorbed by air / Heat input * 100

20
 REGULAR Paper 2 – Set A

= 837936 * 100 / (920* 9850)

= 9.2 %

Overall efficiency after APH = 73 + 9.2 % = 82.2 %

L-5 A process industry is equipped with a steam power plant generating 1,00,000
units/day and a separate low-pressure boiler generating at an average steam
production of 8.3 Tons of steam/hour at enthalpy of 630 kcal/kg for process
heating. The feed water temperature to the boiler is 70oC. The efficiencies of
the steam power plant and boiler are 29% and 75% respectively. Coal is used in
both cases and calorific value of coal is 3800 kcal/kg.

The management proposes to commission a cogeneration plant retaining the

coal as fuel. The expected energy utilization factor of the cogeneration plant is
75%.

Calculate coal savings with the new cogeneration plant.

SOLUTION:

Heat input for separate = (100000 x 860) / (24 x 0.29) + (8.3 x

production of power and useful (630-70) x 1000))/0.75
heat
= 12356321 + 6197333
= 18553654 kcal/hr

Heat input with cogeneration = [(100000 x 860) /24 + (8.3 x (630-70) x

plant 1000)] / 0.75
= (3583333 + 4648000) / 0.75
= 10975111 kcal/hr

Coal savings = (18553654 – 10975111) / 3800

= 1995 kg/h

…….……. End of Section – III ………..….

21
 REGULAR Paper 2 – Set A

Regn No: __________________

Name : __________________
(To be written by the candidate)

17th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS – September, 2016

PAPER – 2: Energy Efficiency in Thermal Utilities

Date: 24.09.2016 Timings: 1400-1700 HRS Duration: 3 HRS

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

Section – I: OBJECTIVE TYPE

1. The large difference between GCV and NCV of gaseous fuels is due to their

a) large moisture content b) negligible moisture content

c) low hydrogen content d) large hydrogen content
2. Which of the following contributes to spluttering of flame at burner tip during
combustion of fuel oil?

a) ash content b) water content c) sulphur content d) humidity of air

3. 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%

4. For coal fired system the flame length is dictated by

a) moisture b) volatile matter. c) ash content. d) fixed carbon

5. Dissolved CO2 in boiler feed water when left untreated would result in occurrence
of in boiler tubes

a) creep b) water side corrosion c) scale d) water hammer

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Bureau of Energy Efficiency
REGULAR Paper 2 – Set A

6. At saturation temp, there can be

a) Hot water b) Wet steam c) Saturated steam d) all of them are possible
7. Water flows at a rate of 30 m3/hr. at 15oC in a 150 mm bore pipe horizontally. What
is the velocity of water flow in the pipe?

a) 0.47 m/s b) 0.94 m/s c) 1.88 m/s d) none of the above

8. Which of the following is not true of condensate recovery?

a) reduces water charges b) reduces fuel costs

c) increases boiler output d) increases boiler blow down
9. Chemical used for dozing in boiler drum to reduce dissolved gases is

a) hydrazine b) chlorine c) alum d) all of the above

10. Which of the following is not a property of ceramic fibre ?

a) low thermal conductivity b) light weight

c) high heat capacity d) thermal shock resistant
11. In a reheating furnace, soaking time of a cycle depends typically on;

a) excess air level b) preheat temperature of charge

c) thickness of the charged material d) furnace atmosphere
12. Higher excess air in an oil fired furnace would result in

a) increased furnace temperature b) increase in CO2 presence in flue gas

c) reduced flame temperature d) increased flame length
13. In a pressure reduction valve, which of these does not change?

a) Temperature b) Pressure
c) Enthalpy d) None of above
14. In a counter-flow heat exchanger, cold fluid enters at 30°C and leaves at 50°C,
whereas the hot fluid enters at 150°C and leaves at 130°C. The LMTD is

a) 100°C b) 280°C c) 0°C d) 20

15. Deaerator is a ___________________ Heat exchanger.

a) Shell and tube type b) Plate type

c) Direct contact type d) Run Around Coil type

16. Pinch analysis uses the _____ law of thermodynamics

a) First b) Second c)Third d) Both (a) & (b)

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Bureau of Energy Efficiency
REGULAR Paper 2 – Set A

17. What is the most effective way to avoid ambient air infiltration into a
continuous reheating furnace?

a)maintain negative pressure in furnace b) increase the chimney height

c) operate at about 90%capacity d) maintain slightly positive
pressure in the furnace
18. Select the wrong statement with respect to furnace operations

a) the burner flame should not touch the stock

b) air infiltration leads to oxidation of billets
c) ceramic fibre linings are used in the exterior of the furnace
d) heat loss through openings is proportional to T4
19. The heat recovery device in which high conductivity bricks are used for storing heat
is

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

20. The exhaust from which of the following is not suitable for waste heat
boiler application?

a) gas turbine b) hot air dryer c) diesel engine d) furnace

21. Desirable boiler water pH should be?

a) 5-7 b) 7-9 c) 9-11 d) None of the above

22. Which of the following has the lowest stoichiometric oxygen demand (kg/kg of fuel)?

a) Hydrogen b) Carbon c) Sulphur d) Nitrogen

23. Which of the following is used for controlling pressure in a natural draft furnace?

a) Forced draft fan b)Induced draft fan c) Dampers d)Both (a) & (b)

24. The head loss due to friction in a pipe is

a) directly proportional to the diameter b) directly proportional to the gravitational

constant
c) inversely proportional to the velocity d) directly proportional to the square of
velocity
25. Which trap is preferred in discharge of condensate recovery from process
equipment?

a) Float trap b) Thermodynamic trap

c) Thermostatic trap d) All of the above

26. Enthalpy of Evaporation of any vapour at its Critical Point will be

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Bureau of Energy Efficiency
REGULAR Paper 2 – Set A

a) Maximum b) Zero c) Less than zero d) Unpredictable

27. Corrosion in stack, Air Pre-Heater, Economizer is mainly influenced by _____

a)Sulphur content in fuel b) Ash content in fuel

c) Moisture content in fuel d) All of the above

28. Which of the following fuels has the least viscosity?

a) Furnace Oil b) Diesel c) Kerosene d) Crude Oil

29. Select the odd one among the following

a) Condenser b) Distillation tower c) Evaporator d) Economiser

30. Which of the following depends on physical properties of fluids as well as geometry
of the heat exchanger?

a) Overall heat transfer coefficient b) Fouling coefficient

c) LMTD (Log Mean Temperature Difference d) Effectiveness

31. In a boiler Air preheater is installed

a) Before the economizer b) after economizer

c) after ESP d) Before superheater

32. Sulphur percentage in furnace oi

a) sets lower flue gas temperature limit b) improves viscosity

c) does not add to heat value d) forms soot

33. Controlled wetting of coal (during the coal preparation) would result in

a) reduction in flue gas exit temperature b) decrease in the percentage of

unburnt carbon
c) improper combustion d) increase in the fines of coal
34. Which of the following is considered in the calculation of ‘Evaporation ratio’?

a) calorific value of fuel b) latent heat of steam

c) fuel quantity d) all of the above
35. Which causes alkaline hardness

a) bicarbonates of Ca and Mg c) Chlorides of Mg and Ca

c) Silicates d) nitrates of Ca and Mg

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Bureau of Energy Efficiency
REGULAR Paper 2 – Set A

36. 1% of the fuel is saved in boiler fuel consumption, if the feed water temperature is
increased by

40C b) 9oC c) 6oC d) 10oC

37. Velocity of steam in steam pipe is directly proportional to;

a) number of bends in pipe b) specific volume of steam

c) length of pipe d) diameter of the pipe

38. The working media in a thermo-compressor is

a) electricity b) compressed air c) high temperature oil d) steam

39. The turbine heat rate is expressed as

a) kWh/kCal b) kg/kCal c) kCal/kWh d) none of the above

40. 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
41. The insulation used for temperatures more than 350oC

a) Polyurethane b) polystyrene

c) Calcium silicate d) magnesia

42. Which of these is not true of ‘critical point’ of steam/water mixture?

a) the temperature at critical point is 374.15oC

b) the pressure at critical point is 221.2 bar
c) saturated liquid and saturated vapour lines meet at critical point
d) enthalpy of evaporation is maximum at critical point
43.
The effectiveness of insulation with ingress of moisture would
a) increase b) decrease
c) may increase or decrease depending on d) remain unaffected
temperature and thickness of insulation
44.
The major limitation of metallic recuperator is -------
a) limitation of handling COx, NOx etc.
b) limitation of reduced life for handling temperature more than 1000oC
c) manufacturing difficulty of the required design
d) none of the above

45.
In a turbine, the thermodynamic process taking place is
a) contraction b) expansion c) condensation d) all the above

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Bureau of Energy Efficiency
REGULAR Paper 2 – Set A

46.
In an FBC boiler with low ash fusion coal, if the bed temperature exceeds 950°C,
the result is:
a) Low steam temperature b) clinker formation
c) Melting of lime stones d) Ash carry over
47. Electrical energy consumption for coal sizing will be maximum for

a) stoker fired boiler b) AFBC boiler

c) CFBC boiler d) pulverised coal boiler
48.
Ideal furnace for melting & alloying of special steels is
a) induction furnace b) Cupola furnace
c) rotary hearth d) recirculating bogie furnace
49. Arrange the following fuels by their GCV in decreasing order-

(p) Rice husk, (q) Diesel, (r) Grade-C Coal, (s) Hydrogen

a) s-q-r-p b) p-q-r-s c) r-s-q-p d) q-r-s-p

50. Water logging of 2 m lift of condensate at trap discharge will result in back pressure
of ____

a) 0.02 kg/cm2 b) 0.2 kg/cm2 c )2 kg/cm2 d) 20 kg/cm2

-------- End of Section - I ---------

_________________________ 6
Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

Section - II: SHORT DESCRIPTIVE QUESTIONS

In a plant, a boiler is generating saturated steam of 10 TPH at a pressure of 7 kg/cm 2(g)

S-1
with furnace oil as a fuel.
Feed water temperature = 60°C
Evaporation ratio = 14.
Calorific value of FO = 10000 kcal/kg
Specific gravity of FO = 0.95.
Enthalpy of steam at 7 kg/cm2(g) = 660 kcal/kg
Find out the efficiency of the boiler by direct method and volume of furnace oil tank (in m 3)
required for 120 hrs of operation

Ans
E. R x (hg – hf) 14 x (660-60)
Effy = --------------------------- = ----------------------- = 84%
GCV 10000

(Note: Deduct 1 mark if 60 is not subtracted from 660)

Furnace oil requirement = 10 / 14 = 0.714 TPH = 714 kg/hr

For 120 hrs of operation, Furnace Oil requirement = 714 x 120 = 85680 kg
Oil tank volume = 85680 / (0.950/(1/1000)) = 90.189 m3

OR

E. R x (hg – hf) 14 x (660-60)

Effy = --------------------------- = ----------------------- = 84%
GCV 10000

Furnace oil requirement = 10 / 14 = 0.714 TPH = 714 kg/hr = 714 / 0.95 = 751.57 ltr/hr

For 120 hrs of operation, oil requirement = 751.57 x 120 = 90189 ltr
Oil tank volume = 90189 / 1000 = 90.189 m3

In a process plant, 30 TPH of steam after pressure reduction with pressure reducing valve
S-2
to 20 kg/cm2 gets superheated. The temperature of steam is 280oC. The management
wants to install a de-superheater to convert superheated steam into saturated steam at 20
kg/cm2 for process use, and its saturation temperature is 210oC.

Calculate quantity of water at 30oC to be injected in de-super-heater to get the desired

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

saturated steam using the following data.

Specific heat of superheated steam = 0.45 kcal/KgoC,

Latent heat of steam at 20kg/cm2 = 450 kcal/kg

Ans Quantity of heat available above saturation = 30,000 x 0.45 x (280-210)

= 9,45,000 kCal/hr

Quantity of water required in de-superheater = Q x{1x (210-30) + 450}= 945000

= 1500 Kg/hr

A steam pipe of 100mm diameter is insulated with mineral wool. As a part of energy saving
S-3
measure, the insulation is upgraded with efficient Calcium silicate insulation. Calculate the
percentage reduction in heat loss due to above measure with the following data,

Boiler efficiency : 80%

Surface temperature with mineral wool : 95°C

Surface temperature with calcium silicate : 55°C

Ambient temperature : 25°C

Ans
Heat loss thru non-insulated pipe = [10 + (95 – 25) / 20] * (95 – 25) ]

= 945 kcal/hr-m2

Heat loss thru insulated pipe = [10 + (55 – 25) / 20] * (55 – 25) ]

= 345 kcal/hr-m2

% Reduction in heat loss = (945 – 345)*100 / 945

= 63.5 %

a) List any six losses in a Boiler

S-4
b) Name two sources of wet flue gas loss in a coal fired boiler

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

a)
Ans

(b)

Moisture in air, Moisture in fuel and H2 in fuel.

(a) Calculate the blow down rate for a boiler with an evaporation rate of 5 tons/hr, if
S-5
the maximum permissible TDS in boiler water is 3000 ppm and with 18 % make
up water addition. The feed water TDS is around 400 ppm.
(b) Briefly explain temporary hardness and permanent hardness in boiler water

Ans Feed water TDS x % Make up

a) Blow down (%) =
Permissible TDS in Boiler  FeedwaterT DS
Percentage blow down = 400 x 18/(3000 – 400) = 2.77 %
If boiler evaporation rate is 5000 kg/hr then required blow down rate is:
= 5000 x 2.77/100 = 138.5 kg /hr
(b) Ref Book-2 :; Page Nos. 45 & 46
Temporary hardness ; It is the hardness that can be removed by boiling. Calcium and
magnesium bi carbonate dissolve in water to form an alkaline solution and these salts
are called alkaline hardness. They decompose upon heating releasing carbon dioxide
and forming a soft sludge which settles out.
Permanent hardness: calcium and magnesium sulphates and chlorides, nitrates etc
when dissolved in water are chemically neutral and are known as non alkaline
hardness. These are called permanent hardness and form hard scale on the boiler
surface which are difficult to remove.

List down any five good practices in Furnaces for energy efficiency
S-6

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

Ans a) Improve capacity Utilisation

b) Minimise Excess air
c) Minimise heat loss due to radiation, walls and openings
d) Adopt Waste heat recovery
e) Ensure Complete combustion
f) Maintain Furnace in slightly positive pressure
g) Adopt Variable frequency drives for fans
h) Optimise cycle time.
i) Emissivity Coatings
Any five of the above can be awarded marks, 1 mark each.
A cogeneration plant has an electrical output of 5 MW with a back pressure turbine which
S-7
has a input steam conditions to the turbine as 32 TPH with Enthalpy of 3418 KJ/kg @ 64
ata and 500oC and the exit conditions of steam at the end of the back pressure turbine is
186oC, with enthalpy of 2835.8 KJ/kg. After the process heating, all the condensate @
730C returns to the boiler. Calculate the Heat to power Ratio and Energy Utilization factor
of the process. Fuel consumption of the boiler is 8.2 TPH Coal at 4800 GCV.

Ans
Heat to power Ratio = 32*((2835.8/4.18)-73)/(5*860) = 4.5
Energy Utilization Factor = ( 32* ((2835.8/4.18)-73) + 5*860))/(8.2*4800)
=68.7%

Two identical oil fired boilers of capacity 100 TPH are operated in a refinery. They have a
S-8
full load efficiency of 90%. The part load efficiencies at 70% and 40% load are 75% and
65% respectively. For meeting 140 TPH requirement of steam, which one of the case
would you prefer to run and estimate the % savings in the preferred case. The enthalpy of
steam generated is 550 Kcal/kg and feed water enters the boiler at 50°C in all the cases.
Calorific value of the fuel oil is 10,000 Kcal/hr.

Case 1: both the boilers operated at 70 TPH capacity each.

Case 2: one at full load capacity and other at 40% capacity.

Case-1:
Ans
Amount of Fuel energy required when both the boilers are run at 70% load i.e, at 70
TPH load
Enthalpy change = (550 – 50) = 500 Kcal/kg

= (2 * 70 * 1000 * 500)/ (0.75 * 10000)

= 9333 Kg/hr (or) 9.33 Tons/hr
Case-2:
Amount of Fuel required when one boilers is running at full load at 100 TPH and
other at part load of 40 TPH

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Bureau of Energy Efficiency
REGULAR Paper 2 – Set A

Enthalpy change = (550 – 50) = 500 Kcal/kg

= (100 * 1000 * 500) / (0.9*10000) + (40 * 1000 * 500) / (0.65*10000)

= 5555 + 3076.9
= 8.63 Tons/hr
Fuel required for Case 2 is less & hence Case 2 is preferred
% Fuel Savings = (9.33 – 8.63) / 9.33 x 100

= 7.5 %

-------- End of Section - II ---------

_________________________ 11
Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

Section - III: LONG DESCRIPTIVE QUESTIONS

A gaseous fuel has volumetric composition as CH4 – 70 % & C2H6 – 30%. The
L-1
Gross Calorific Value of CH4 & C2H6 is 45000 kJ/Nm3 & 70000 kJ/Nm3
respectively. Find out the Net Calorific Value of gaseous fuel in kJ/Nm3. (Latent
heat of water vapor – 2445 kJ/kg)
Ans CH4 + 2O2 = CO2 + 2H2O

1 Nm3 of CH4 + 2 Nm3 of O2 = 1 Nm3 of CO2 + 2 Nm3 of H2O

Hence, 0.70 Nm3 of CH4 will generate 0.70 x 2 = 1.4 Nm3 of H2O

C2H6 + 3.5 O2 = 2CO2 + 3H2O

1 Nm3 of C2H6 + 3.5 Nm3 of O2 = 2 Nm3 of CO2 + 3 Nm3 of H2O

Hence, 0.3 Nm3 of C2H6 will generate 0.30 x 3 = 0.9 Nm3 of H2O

Volume of water vapor = 1.4 + 0.9 = 2.3 Nm3/Nm3 of fuel

(We know that mass of 22.4 Nm3 of H2O = 18 kg i.e. mass of 1 kMol)

Mass of Water vapor, Mm = 2.3 x 18 / 22.4 = 1.85 kg/Nm3 of fuel

GCV of gaseous Fuel = (70% x 45000) + (30% x 70000)

= 52500 kJ/Nm3

NCV = GCV – (Mm x 2245)

= 52500 – (1.85 x 2245)
= 48346 kJ/Nm3
= 4.13 %

L-2 A Textile plant has an extensive steam 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 savings. The following
are the parameters about the system.

Condensate quantity = 1000 kg/hr

Condensate Pressure = 10 bar
Cost of steam = Rs 1100/ Ton
Annual operating hours = 8000
Low pressure process steam (flash steam) pressure = 2 bar
Sensible heat of condensate at 10 bar = 188 kCal/kg
Sensible heat of condensate at 2 bar = 135 kCal/kg
Latent heat of steam at 2 bar = 518 kCal/kg
Boiler Efficiency = 82 %
GCV of fuel oil = 10,200 kCal/kg
Specific Gravity of fuel oil = 0.92

_________________________ 12
Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

Condensate temperature when recovered = 95 oC

Make up water temperature = 35 oC

Calculate the Quantity of flash steam which can be recovered, and the annual fuel oil
savings on account of condensate recovery
Ans
a) Flash steam available % = S1- S2/(L2)
Where: S1 is the sensible heat of higher pressure condensate.
S2 is the sensible heat of the lower pressure condensate
L2 is the latent heat of flash steam (at lower pressure).

% of Flash steam recoverable = (188 – 135) / 518 = 10.2 %

Quantity of flash steam recovered from condensate = 1000 x 0.102 = 102 kg/hr

Condensate available for recovery after flash steam = 1000 – 102 = 898 kg/hr

Heat recovered = 898 x (95 – 35 ) = 53880 kCal/hr

Annual fuel oil saving = 53880 x 8000 / (0.82 x 10200) = 51.2 tons/yr

L3 Analyse the diagram as given below and calculate:

(i) Boiler Efficiency by direct method

(ii) Water Temperature in the condensate tank
(iii) Estimate fuel loss due to non-recovery of 2 TPH condensate, assuming the boiler
efficiency to be the same

Given data:
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

_________________________ 13
Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

CONDENSATE RETURN QUANTITY = 5 TPH

o
TEMPERATURE = 95 C

2 MAKE UP WATER QUANTITY = 2 TPH

o
STEAM FLOW AT 10 KG/CM
TEMPERATURE = 28 C

BOILER CAPACITY CONDENSATE

= 7 TPH TANK

FEED WATER
TEMPERATURE AT
o
BOILER INLET = 60 C

FEED WATER PUMP

ANS
Oil Consumption = 600 x 0.89 = 534 kg/hr
1) Boiler Efficiency = 7000 (665 - 60) X 100/ 534 X 10000
= 79.3 %
2) Feed water temperature in condensate tank

= [5000 x 95 + 2000 x 28]/ 7000 = 75.85oC = 76 oC

3) Fuel Loss = [ 7000 x (76 – 60)]/ 10000 x 0.793 = 14 kg/hr

L4 A heat exchanger is to be designed to condense the hydrocarbon vapor mixture from a

distillation column at the rate of 11.0 kg/sec which is available at its saturation temperature
of 120°C. The latent heat of condensation of the hydrocarbon vapor mixture is 450
kJ/kg. The cooling water at 32°C is used in counter-current direction at the rate of 58
kg/sec to condense the vapor mixture. The specific heat of cooling water is 4.18 kJ/kg oC.
Determine LMTD and area of the heat exchanger surface if the overall heat transfer co-
efficient is 600 J/m2s°C.
Ans
Heat removal rate from hydrocarbon vapour mixture = heat gain rate in cooling water
Qxh = M * cp* (T2-T1)
11.0 x 450 = 58 x 4.18 x (T2 – 32)
T2 = 52.4 °C

Water leaves the exchanger at 52.4°C

LMTD = (120-32)-(120-52.4)/ln(120-32)/(120-52.4)

LMTD of counter flow pattern = 77.4°C

Q = m*Cp* deltaT = U * A * LMTD

58 * 4.18 * (52.4 – 32) * 1000 = 600 * A * 77.4

A = 106.5 m2

_________________________ 14
Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

Area of the heat exchanger surface is 106.5 m2

L-5 a) Explain the process of Mechanical de-aeration and chemical de-aeration

b) How does an energy auditor assess the performance of steam trap during energy
audit?

Ans a)

Ref page no 47
b)

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

The three performance test methods of steam traps are

1. Visual testing,
2. Sound Testing
3. Temperature testing
Ref page no 95

Answer the followings:

L-6
(a) Explain why dry saturated steam is preferred over wet or superheated steam
for industrial process heating.
(b) Why should one use dry saturated steam at the lowest possible pressure for
indirect steam heating?
(c) What are the two major advantages of direct injection of steam for heating of
liquid?
(d) Why drain points are required in a steam system?
(e) What is flash steam?
a) Dry saturated steam is the preferred choice because:
Ans
 Wet steam has a lower heat content than dry steam.
 Superheated steam gives up heat at a slower rate than saturated steam.
 Dry steam alone condenses quickly, thereby providing a higher heat transfer
rate.
b) 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.

c) • No condensate recovery system is necessary

• The heating is quick, and the sensible heat in the steam is also used up along with
the latent heat, making the system thermally more efficient.

d) The drain points help in removing water in pipes due to condensation of steam.

e) Flash steam is produced when condensate at a high pressure is released to a lower

pressure.
…
…….……. End of Section – III ………..….

_________________________ 16
Bureau of Energy Efficiency
 Paper 2 – Set A with Solutions

Regn No: __________________

Name : __________________
(To be written by the candidate)

18th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS – September, 2017

PAPER – 2: Energy Efficiency in Thermal Utilities

Date: 23.09.2017 Timings: 14:00-17:00 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

Section – I: OBJECTIVE TYPE Marks: 50 x 1 = 50

a) Answer all 50 questions

b) Each question carries one mark
c) Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB pencil

1. In a Heat exchanger with a high LMTD results in

a) higher heat transfer area b) lower heat transfer area

c) higher u-factor d) none of the above
2. “ Heat Loss = Heat gain “ is the principle of ____
a) Boiler
b) Heat Exchanger
c) Steam traps
d) All of the above
3. Flash steam quantity per kg of condensate depends upon

a) condensate pressure only b) condensate pressure and flow

c) condensate pressure and flash steam pressure d) none of the above
4. Which of the following waste heat recovery systems is of thermal storage type?

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Bureau of Energy Efficiency
 Paper 2 – Set A with Solutions

a) ceramic recuperator b) metallic recuperator

c) regenerative burner d) waste heat boiler
5. 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) none of the above

6. The concentration of solids in a boiler is controlled by

a) steam venting b) blow down c) air venting d) deaeration

7. 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

8. Tangential firing is used in which type of boiler:

a) CFBC b) Chain Grate c) Spreader Stoker d) Pulverised Fuel

9. _____ is required for the simple estimation of flame temperature of the fuel.
a) Ultimate analysis
b) Proximate analysis
c) Size of the coal
d) All of the above
10. Overall heat transfer co-efficient in Heat exchangers depends on ____.
a) Conductivity of the wall separating the two fluids
b) Convective coefficients of hot and cold fluids
c) Fouling coefficients
d) All of the above
11. The key property of bio mass fuel which influences storage, handling and
transportation

a) Calorific Value b) Percentage of Ash

c) Bulk Density d) None of the above
12. Which of the following contributes to spluttering of flame at burner tip during
combustion of fuel oil?

a) ash content b) water content

c) sulphur content d) humidity of air
13. When 100 kg of fuel with 60% carbon is burnt with theoretical air, the mass of CO 2
released will be

a) 319 kg b) 4400 kg c) 4500 kg d) 220 kg

14. Which of the following heat recovery equipment works on a vapour compression
cycle?

a) thermo-compressor b) heat wheel

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c) heat pump d) heat pipe

15. Which of the following releases large amount of heat per kg during combustion?
a) Hydrogen
b) Carbon
c) Sulphur
d) Nitrogen
16. Auxiliary power consumption for coal preparation will be highest in a;

a) stoker fired boiler b) AFBC boiler

c) CFBC boiler d) pulverized coal fired boiler
17. 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
18. Which of the following increases, when steam is passed through PRV?
a) specific volume
b) enthalpy of steam
c) sensible heat
d) saturation temperature
19. Which of the following is not true with respect to improper sizing of coal

a) results in poor combustion

b) lowers excess air resulting in lesser stack loss
c) increases un-burnt in ash
d) lowers thermal efficiency
20. When solutions of differing concentrations are separated by a semi-permeable
membrane, water from less concentrated solution passes through the membrane to
dilute the liquid of high concentration. This is called

a) reverse osmosis b) ion exchange c) softening d) osmosis

21. ______ is used as heat carrier in thermic fluid heaters
a) steam
b) mineral oil
c) water
d) all of the above
22. Dissolved CO2 in boiler feed water when left untreated would result in occurrence
of ____ in boiler tubes

a)creep b) water side corrosion c)scale d)water hammer

23. In a counter-flow heat exchanger, cold fluid enters at 30°C and leaves at 50°C,
whereas the hot fluid enters at 150°C and leaves at 130°C. The LMTD is

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a) 100°C b) 280°C c) 0°C d) 20°C

24. Which of the following is not measured in the ultimate analysis of a fuel ?

a) oxygen b) fixed carbon c) sulphur d) nitrogen

25. Ceramic fibre gives the maximum energy savings when used in

a) continuous furnace b) batch furnace

c) arc furnace d) induction furnace

26. 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

27. Fluidized bed combustion takes place in the temperature range of

a) above 10000C b) below 5000C c) 600-7000C d) 800-9000C

28. In a glass industry waste heat is used for power generation. This type of cogeneration
is called

a) topping cycle b) bottoming cycle

c) combined cycle d) none of the above
29. Select the odd one among the following

a) condenser b) distillation column c) evaporator d) cooling tower

30. In a boiler, air preheater is installed

a) before the economizer c) after economizer

b) before superheater d) after ESP

31. A pinch analysis can result in

a) reduction in cooling water b) reduction in steam

c) increase in cooling water d) both a & b

32. The main contributor for temporary hardness in Boiler water is ____.
a) calcium chloride
b) magnesium sulphate
c) calcium bicarbonate
d) calcium nitrate

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33. The amount of oxygen required to burn 0.5 kg of Sulphur is

a) 1
b) 16
c) 32
d) 0.5

34. _____ is required to accommodate expansion of steam lines.

a) prv
b) expansion loop
c) steam trap
d) air vent

35. Steam mains should be run with a falling slope of … in the direction of steam flow
for effective line condensate drainage

a) 50 mm in 30 meters b) 125 mm in 30 meters

c) 250 mm in 30 meters d) 350 mm in 30 meters

36. Degasser in water treatment is used to remove

a) Dissolved oxygen and other gas b) carbonic acid

b) Sulphuric acid d) dissolved CO2

37. In a boiler Theoretical Air to fuel ratio is 15:1. If 10% excess air is supplied, Flue gas
to Fuel ratio will be ____

a) 16:1

b) 17.5:1

c) 16.5:1

d) 17:1

38. Increased Sulphur percentage in furnace oil

a)sets lower flue gas temperature limit b) improves viscosity

c) does not add to heat value d) forms soot
39. Which among the following is most viscous fuel?

a) furnace oil b) HSD c) kerosene d) Light Diesel oil

40. The turbine heat rate is expressed as

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a) kWh/kcal b) kg/kcal c)kcal/kWh d) none of the above

41. Heat loss through openings in furnaces is directly proportional to

a) fourth power of furnace temperature
b) square of absolute furnace temperature
c) absolute furnace temperature
d) fourth power of absolute furnace temperature
42. Which of the following is an example of a basic refractory

a) Alumino-silicate b) chrome

b) Magnesite d)pure alumina

43. Which property of the refractory determines the deformation under stress?

a) creep
b) refractoriness under load (rul)
c) porosity
d) pyrometric cone equivalent (PCE)
44. Electro static precipitator in FBC boiler is used for _______

a) Bottom ash removal

b) Fly ash removal
c) SO2 removal
d) CO2 removal
45. Heat rate is likely to be the least for ________
a) back pressure turbine b) condensing turbine
c)extraction condensing turbine d) double extraction turbine

46. Which of the following is true of plate heat exchangers

a) close approach b) expandable area
c) Counter current d) All of the above
47. In FBC boilers fluidization depends largely on ---------
i) Particle size ii) Air velocity iii) Bed Material iv) Size of Boiler
a) i & iii b) ii & iii c) i & ii d) i,ii,iii,iv

48. When the boiler bed temperature exceeds beyond 950°C, the result is:
a) Low steam temperature b) clinker formation
c) Melting of lime stones d) Ash carry over

49. Automatic blowdown controls for boilers work by sensing

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a) TDS b) conductivity c) pH d) conductivity and pH

50. Latent heat of steam at the critical point is

a) infinite b) 540 kcal c) zero d) none of the above

-------- End of Section - I ---------

Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 40

(i) Answer all Eight questions

(ii) Each question carries Five marks

S-1 Explain the working of Thermic fluid heating system and why it is preferred to
steam heating in some cases?

Ans
Thermic Fluid Heaters:

• At high temperatures, steam requires a corresponding high operating

pressure and establishing high temperatures with steam can be very
cumbersome and expensive in some cases.
• In thermic fluid heaters, a special type of oil-synthetic / mineral is used as
heat carrier. This fluid can be heated up to 300 oC at atmospheric pressure.
In comparison steam would require a pressure of 85 bar to obtain this
temperature.
…………………….2.5 marks

Advantages:

– High temperature operation at atmospheric pressure

– Optional temperature level set points
– No supply or treatment of hot water and hence no heat loss due to
condensate flash steam
– No risk of corrosion
– Easy to operate

Functioning of Thermic Fluid Heaters

• Heat is transferred to the fluid through radiation. The hot thermic-fluid is

circulated to various process equipments such as dryers, heaters, de-
odouriser etc. where it gives up the heat. The return oil at a temperature 10
to 20 0C 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

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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.

• Since the thermic fluid heaters operate at a high temperature (250 – 300
0
C), the leaving exhaust gas temperatures are more than the fluid
temperature. Hence, the heat loss through the flue gas is a major
component of fuel losses. This offers potential for heat recovery if there is a
suitable application.
• The capacity is specified in terms of Lakh kilo calories per hour or Million kilo
calories per hour.

(Pg no 56 of Book 2 for explanation)

…………………….2.5 marks

In a car manufacture company, Propane is used as fuel in heaters for preheating paints.
S-2
Calculate the Air to Fuel ratio for complete combustion of C3H8 (Propane), if 15% excess
air is supplied to the heater.

C3H8 + 5 O2 --> 3 CO2 + 4 H2O

Ans
…………………….1 mark

1 mole of propane requires 5 moles of Oxygen.

Molecular weight of Propane is 44 Kg per mole.

…………………….1 mark

44 Kg of Propane requires 160 Kg of Oxygen.

Theoretical air required for combustion = 160 / 0.23 = 695.6 Kg/hr

…………………….1.5 marks

Excess air supplied is 15 %.

Actual air supplied for combustion is = 695.6 * 1.15

= 800 Kg/hr of air

Air to Fuel ratio = 800 / 44

= 18.18 or 18.2

…………………….1.5 marks

To meet a process plant’s heat and power requirements, high pressure steam at 70 MT/hr
S-3
passes through a back pressure steam turbine, for power generation and the exhaust

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steam is sent for thermal process requirements in the plant. With the following operating
data, calculate the heat to power ratio in kW/kW if the turbine and generator efficiencies
are 90% and 92% respectively.

Steam Inlet conditions Steam outlet conditions

Pressure = 50 bar Pressure = 10 bar
Temperature = 530°C Temperature = 280°C
Enthalpy of steam = 3515 kJ/kg Enthalpy = 3020 kJ/kg
Enthalpy of water = 782 kJ/kg

– Power generated = 70 * 1000 * (3515 - 3020) * 0.90 * 0.92 / 3600

Ans
= 7969.5 kW
…………………….2 marks
– Heat input to process = 70 * 1000 * (3020-782) / 3600 = 43517 kW
– …………………….2 marks
– Heat to power ratio = 43517 / 7969.5 = 5.46 kW/kW
…………………….1 mark

a) Explain why de-superheating is done after pressure reduction in PRVs?

S-4
b) Why is correction factor required for estimation of LMTD?

a) A reduction in steam pressure through a pressure reducing valve (PRV) is an

Ans
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.

…………………….2.5 marks

b) In multi pass shell and tube heat exchangers, the flow pattern is a mixture of co-
current and counter current flow, as the two streams flow through the exchanger in
the same direction on same passes and in the opposite on others. For these
reasons, the mean temperature differences is not equal to the logarithmic mean.
However it is convenient to retain the LMTD by introducing a correction factor, F
which is appropriately termed as the LMTD correction factor.

…………………….2.5 marks

S-5 What happens to steam properties such as saturation temperature, enthalpy of saturated
water, latent heat of steam, enthalpy of steam and specific volume of steam, if the steam
pressure is increased?
a) Saturation Temperature increases
Ans
b) Enthalpy of saturated water Increases.
c) Latent heat of steam decreases

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d) Enthalpy of steam increases

e) Specific Volume decreases
…………………….5 marks
( each point carries one mark respectively)

S-6 Two identical biomass fired boilers of capacity 10 TPH are operated in a chemical industry.
They each 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.

Ans Fuel energy required when both the boilers are run at 7 TPH load

Governing equation to be used :

(Fuel reqd) = [(Qty stm) * (Enth steam – Enth feedwater)] / [( GCV Fuel) * (Effy boiler)]

(Fuel reqd) = [(Qty stm) * (∆h) / (Effy boiler)]

Where : ∆h = is same in both cases = [Enth steam – Enth feed-water) / ( GCV Fuel)]

Fuel required = (2*7*∆h) / (0.75) = 18.67 h

…………………….1 mark
Fuel energy required when one boiler is running at full load and the other at part load
of 40%
Fuel required = [(10*∆h) / (0.8)] + [(4*∆h) / (0.68)]= 18.38 h
…………………….2 marks
The case where one boiler is running at full load and the other at part load of 40% is
preferred
…………………….1 marks
• % savings = [(18.67 h) – (18.38 h)] * 100 / (18.67 h)
= 1.55%
…………………….1 mark

S-7 A reheating furnace is operating with deteriorated wall insulation. The existing
average outer surface temperature of the furnace (of area = 100 m2) with
surrounding ambient air temperature of 40ºC, is recorded to be 120ºC. After
revamping the refractory, the furnace outer surface temperature reduces to 50ºC.
If the fuel oil (GCV = 11,000 kcal/kg) cost is Rs. 25,000 per tonne, and efficiency of
the furnace is 35%, estimate annual savings for 300 working days per year.

Ans Rate of heat loss from furnace surface (existing)

S = [10+(Ts – Ta) / 20] x ( Ts- Ta) kcals/hr/m2
Heat loss = S x A
 120  40 
= 100m2 x [10+   ] (120-40) kcals/hr /m2
 20 
= 112.0 x 103 kcal/hr
…………………….1 mark

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Rate of heat loss from furnace surface after revamping insulation refractory
50  40
= 100 [ 10 + ] (50-40)
20
= 10.5 x 103 kcal/hr
…………………….1 mark
Energy savings kcal/hr = (112-10.5)x 103
= 101.5x103 kcal/hr
Annual energy savings = (112-10.5) x 103 x 300 x 24
= 7.308 x 108 kcal/yr
…………………….1 mark
8
7.308 x10
Annual fuel oil savings = = 1.9 x 105 kg of fuel
0.35 x11000
……………………. 1 mark
5
1.9 x10 x 25000
Annual Cost savings = = Rs.4.75 x 106
1000
…………………….1 mark
The efficiency of a boiler on GCV basis is 85%. The fuel contains 1.0 % moisture and 12 %
S8
hydrogen. The GCV of fuel is 10,500 Kcal/kg. What is the boiler efficiency on the basis of
net calorific value?

%age of Hydrogen in fuel %age of moisture in fuel

NCV = GCV – [9 x ------------------------------------ + ------------------------------------] x584
100 100

12 1.0
NCV = 10500 – [ 9 x ----- + -------- ] x 584
100 100 100

= 10500 – [ 9 x 0.12 + 0.01] x 584

= 10500 - 636.56
= 9863.44 = 9863 kcal / kg
…………………….3 marks
85
Boiler efficiency on NCV = ------ x 10500
9863

= 90.5%
…………………….2 marks

-------- End of Section - II ---------

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 Paper 2 – Set A with Solutions

Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all SIX questions

(ii) Each question carries Ten marks

L-1
In an engineering industry, an electrically heated furnace of efficiency 80%, is used for annealing of
the components. The annealing cycle and corresponding energy consumption as follows.

S.No Heat treatment Temperature Time hrs Power drawn in

0
cycle C kW
1 Heat -Up 30 - 850 4 500
2 Holding at 850 4 100
3 Cooling 850 - 60 4 20

The electrical energy drawn in each sub-cycle is uniform and plant operates 50 batches per month.
The cost of electricity is Rs.8/kWh.
The management has decided to replace the electric furnace with FO oil fired furnace with efficiency
of 50%. The cost of F.O is Rs.30/kg. Calculate cost savings and payback period of converting from
electric to oil fired furnace. Investment for FO fired furnace is Rs.25 lakhs. The GCV of F.O is
10,000 kcal/kg
Ans Energy consumption per treatment batch :

– Heat up time = 500 x 4 = 2000kWh; …………………..1 mark

– Holding time = 100 x 4 = 400 kWh …………………..1 mark
– Cooling time = 20 x 4 = 80 kWh …………………..1 mark
– Total energy consumption per batch = 2480 kWh …………………..1 mark
– Monthly energy consumption by
electric annealing furnace including losses = 2480 x 50
= 1,24,000 kWh / month
…………………….1 mark
– Actual consumption by the components
at electrical furnace efficiency of 80% = (124000 x 0.8)
= 99,200 kWh / month
…………………….1 mark
– Eqvt FO required to be supplied to the oil
fired furnace at an efficiency of 50% = 99200 x 860 / (10000 x 0.5)
= 17062.4 kg / mth
…………………….1.5 marks
– Annual Cost of = [(124000 x 8) – (17062.4 x 30) ] x 12
= Rs.57,61,536 / yr
…………………….1.5 marks
– Payback period = 2500000 / 5761536 = 5.2 months
…………………….1 mark
L-2 Write short notes on any two of the following
a. Wet preservation method for boilers
b. Reverse osmosis
c. Reciprocating engine co-generation system

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Ans a) 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.
…………………..5 marks
b) Reverse osmosis: When solutions of differing concentrations are separated by a semi-
permeable membrane, water from less concentrated solution passes through the membrane to
dilute the liquid of high concentration, which is called osmosis. If the solution of high
concentration is pressurized, the process is reversed and the water from the solution of high
concentration flows to the weaker solution. This is known as reverse osmosis.
…………………..5 marks
c) 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.
…………………..5 marks
(Consider any two of the above)
L3 A fluidized bed boiler generates 24TPH at 22 kg/cm 2(g), out of which, 18 TPH is going to
the back pressure turbine and exhausts from it at 5kg/cm2(g) to meet the process steam
requirement in the plant. The balance steam from the boiler is passed through a PRDS to
supply 10 kg/cm2(g) steam at dry saturated condition to another process. DM water at
1050C is used for de-superheating in PRDS.
Given data:
a) Mechanical Efficiency of steam turbine = 95 %
b) Losses in gear transmission = 4%
c) Efficiency of alternator = 96 %
2
d) The total heat of steam at turbine inlet condition at 22 kg/cm (g) = 708 kcal/kg
e) The total heat of steam at turbine outlet condition at 5 kg/cm2 (g) = 658 kcal/kg
f) The total heat of the steam at PRDS exit at 10kg/cm2(g) = 670 kcal/kg

Calculate
1. Power generation from back pressure turbine
2. Steam flow rate going to process at the exit of PRDS
ANS 1: Power generation from back pressure turbine:
Enthalpy drop across the turbine per kg of inlet steam = (h1-h2)
= (708-658)= 50 kcal/kg

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…………………..1 mark
Total steam flow rate through turbine = 18,000 kg/hr
Total enthalpy drop across the turbine =18,000*50
= 900000 kcal/hr
…………………..1 mark
Mechanical Efficiency of steam turbine = 95%
Efficiency of alternator = 96 %
% losses in gear transmission = 4%

Over all efficiency of the turbo alternator = 0.95 x 0.96 x 0.96

= 0.8755 = 87.55%
…………………..2 marks
Energy output of turbine = 900000 x 0.8755
= 787950
…………………..1 mark
Power output of the alternator = 787950/ 860 = 916 kW
…………………..1 mark
2: Steam Flow rate going to process at the exit of PRDS:

Flow rate of DM water =m

Heat content of steam at exit of PRDS = Heat supplied by water and steam to PRDS
(6000 + m) x 670 = (6000 x 708) + (m x 105)
m = 403.54 kg/ hr = 403.54 kg/hr
…………………..3 marks
Steam flow at outlet of PRDS = 6000 + 403.54 = 6403.54 kg / hr
…………………..1 mark
L4 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.
Calculate annual fuel savings in TPD.
% salt concentration at inlet = 30%
Ans
% salt concentration at outlet = 55%
Input quantity of caustic solution to drier = 100 TPD
Amount of bone dry salt at drier inlet = 100x 0.3 = 30 TPD ………………..1 mark
Amount of water at drier inlet = 100 - 30 = 70 TPD ………………..1 mark
Flow rate of salt solution at drier outlet = 30 / 0.55 = 54.5 TPD ………………..1 mark
Amount of water at drier outlet = 54.5 - 30 = 24.5 TPD ………………..1 mark
Amount of water removed = 70 - 24.5 = 45.5 TPD ………………..1 mark
Ratio of steam / moisture for single effect = 1.0 ………………..1 mark
Amount of steam required for single effect = 45.5 TPD
Ratio of steam / moisture for triple effect = 0.45
Amount of steam required for triple effect = 45.5 x 0.45 = 20.475 TPD …………..1 mark
Amount of steam saved by triple effect = 45.5 – 20.45 = 25.05 TPD…………..1 mark
Evaporation ratio = 14
Amount of fuel savings = 25.05 / 14 = 1.789 TPD……………2 marks

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Write short notes on following refractory properties and their significance.

L-5
a) Porosity b) Bulk density c) Pyrometric cone equivalent d) Thermal conductivity
Ans Porosity
Low porosity is desirable as it would prevent easy penetration of refractory and also larger
number of small pores are preferred over small number of large pores
………………..2.5 marks
Bulk density
Increase in bulk density increases its volume stability, heat capacity and resistance to slag
penetration
………………..2.5 marks
Pyrometric Cone Equivalent (PCE)
temperature at which refractory will deform under its own weight is its softening
temperature indicated by PCE .
………………..2.5 marks
Thermal conductivity
It is the heat loss per unit area per unit insulation thickness per unit temperature difference
W-m2/m°C or W-m/°C. Thermal conductivity of materials increases with temperature.
So thermal conductivity is always specified at the mean temperature (mean of hot and cold face
temperatures) of the insulation material
………………..2.5 marks
Refer Book 2, Page no 156 – 157
In a Crude Oil refining unit, a counter-flow shell & tube heat exchanger is used to preheat
L-6
LDO (Light Diesel Oil) flowing at 60 m3/hr at 50°C using steam at 8 kg/cm2g as a heating
medium. Steam enters the heat exchanger through a pipe of 6” diameter. Density and
Specific heat of LDO is 830 kg/m3 & 0.7 kcal/kg°C respectively.

Properties of steam at 8 kg/cm2 is given below,

Pressure, Temperature, Specific Enthalpy

(kg/cm2g) (°C) volume (kcal/kg)
(m3/kg)
Water Evaporation Steam

8.0 170 0.22 170 490 660

a. Calculate the mass flow rate of Steam, if the maximum permissible velocity in
the pipeline is 25 m/sec.

b. Temperature of the Fuel oil, after preheating in the heat exchanger

Steam Flow rate calculation:

Ans
Diameter of the pipe = 6 inch

= 6 * 2.54

= 15.24 cm

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 Paper 2 – Set A with Solutions

………………..1 mark
2
Area of the pipe = 3.14 * D / 4

= 3.14* (15.24)2 / 4

= 182.3 cm2

= 0.0182 m2

Volume flow rate of steam = Area * Velocity

Velocity permissible = 25 m/sec

Volumetric flow rate of steam = 0.0182 * 25

= 0.455 m3/s * 3600

= 1638 m3/hr

………………..2 marks
3
Specific volume of steam = 0.22 m /kg

Mass flow rate of steam = 1638 / 0.22

= 7445 kg/hr

a. Mass flow rate of steam = 7.445 TPH

………………..1 mark
Temperature of the Fuel oil (LDO)

Heat transfer rate of Steam =m*H

= 7445 * 490

= 3648050 kcal/hr

………………..2 marks
Heat transfer rate of Steam = heat transfer rate of LDO

Heat transfer rate of LDO = 3648050 kcal/hr

Heat transfer rate of LDO = m * Cp * (T1 – T2)

= 60 * 830 * 0.7 * (T – 50)

= 3648050 / (60 * 830 * 0.7)

Delta Temperature = 104.65 °C

………………..2 marks
Outlet Temperature of LDO = (104.65 + 50)°C

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 Paper 2 – Set A with Solutions

= 154.65 °C

b) Outlet temperature of LDO = 154.65 °C

………………..2 marks
…….……. End of Section – III ………..….

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 Paper 2 Set A

19th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS & ENERGY AUDITORS – SEPTEMBER, 2018
PAPER – 2: ENERGY EFFICIENCY IN THERMAL UTILITIES

Section – I: OBJECTIVE TYPE Marks: 50 x 1 = 50

(i) Answer all 50 questions

(ii) Each question carries One mark
(iii) Please hatch the appropriate oval in the OMR answer sheet with HB pencil only, as
per instructions
1. Density of liquid fuel is measured by an instrument called
a) Anemometer b) Hydrometer
c) Luxmeter d) All the above
2. The measured O2 in flue gas is 5.5 % by volume, the excess air percentage will be
a) 41 % b) 55.9 %
c) 35.5 % d) None of the above
3. The efficiency of a reheating furnace, operating at 10 tonnes per hour consuming furnace
oil of 230 kg/hour for reheating the material from 40 °C to 1100 °C (consider 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) None of the above
4. In FBC boiler the combustion is carried out at a temperature
a) Closer to saturated steam temperature
b) Below ash fusion temperature of fuel used
c) At adiabatic combustion temperature of fuel
d) At and above ash fusion temperature of fuel
5. Turbine cylinder efficiency is given as a ratio of________________________
a) Actual enthalpy drop and isentropic enthalpy drop
b) Useful heat and power output
c) Useful power and heat output
d) All of the above
6. The effectiveness of a heat exchanger depends on
a) Specific heat of hot fluid b) Specific heat of cold fluid
c) Inlet temperature of hot fluid d) LMTD
Note: 1 Mark is awarded to all candidate who have attempted this question.
7. Efficiency evaluation requires
a) Ash in fuel b) O2 in flue gas
c) Sulphur in fuel d) NOx in flue gas
Note: 1 Mark is awarded to all candidate who have attempted this question.
8. The evaporation ratio of a coal-fired boiler is 4. Steam enthalpy is 640 kCal/kg; feed water
temperature is 55 0C, Calorific Value of coal is 4000 kCal/kg. The boiler efficiency is
________
a) 49 % b) 82 %
c) 58.5 % d) 70 %
9. Removal of dissolved gases from the boiler feed water is called
a) Degasification b) Deaeration
c) Deoxidation d) None of the above
10. Which one of the following is a high temperature heat recovery device?
a) Regenerator b) Heat pump
c) Heat wheel d) Heat pipe
11. In reheating furnace, scale losses will
a) Increase with excess air b) Decrease with the excess air
c) Have no relation with excess air d) Increase with CO2% in flue gas
12. Transfer of heat without a conveying medium is possible with
a) Conduction b) Radiation
c) Convection d) None of the above
13. Which of the following increases, when high pressure steam is discharged to atmosphere?
a) Sensible heat b) Total enthalpy of steam
c) Saturation temperature d) Specific volume
14. Removal of condensate from main steam line is done to prevent
a) Steam locking b) Air locking
c) Water hammer d) All of the above
15. For flash steam calculation, flash steam quantity available depends upon
a) Condensate pressure and flash steam pressure
b) Steam pressure
c) Steam enthalpy at atmospheric pressure
d) Total heat of flash steam
16. Air venting in a steam system is required because air is ___________.
a) A good conductor b) An insulator
c) Inert d) Diluent
17. Furnace wall heat loss does not depend on
a) Temperatures of external wall surfaces b) Velocity of air around the furnace
c) Thermal conductivity of wall brick d) Material of stock to be heated
18. In a CFBC boiler _________ are required to capture large recycled amount of bed material
a) Settling chambers b) Mechanical cyclones
c) Bag filters d) Scrubbers
19. Example for basic type of refractory is
a) Chrome b) Chrome magnesite
c) Alumina d) All the above
20. Which material is used to control SO2 emissions in FBC boilers
a) CaO b) Lime stone
c) Silica d) Sand
21. The effectiveness of a heat exchanger does not depend on
a) Specific heat of hot fluid b) Specific heat of cold fluid
c) Inlet temperature of hot fluid d) LMTD
22. Which of the following fuel needs maximum amount of excess air for complete
combustion?
a) Furnace oil b) Natural gas
c) Pulverised coal d) Wood
23. In a coal fired boiler, which parameter influences flame profile the most?
a) Fixed carbon b) Volatile matter
c) Hydrogen d) All of the above

24. Which one of the following boilers utilizes the combination of suspension and grate
firing?
a) Spreader stoker boiler b) Fluidized bed boiler
c) Traveling grate stoker boiler d) Pulverized fuel boiler
25. 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
26. The maximum possible evaporation ratio of a boiler (From & At 100 ºC basis) fired with
coal having a calorific value of 4050 kcal/kg and operating at 80 % efficiency will be
a) 5 b) 6
c) 7.5 d) 9.4
27. When solutions of differing concentrations are separated by a semi-permeable
membrane, water from less concentrated solution passes through the membrane to
dilute the liquid of high concentration. This is called
a) Reverse osmosis b) Ion exchange
c) Softening d) Osmosis
28. Radiation losses from the surface of a boiler practically
a) Increase with increase in boiler loading
b) Decrease with increase in boiler loading
c) Are independent of boiler loading
d) Are dependent on boiler loading
29. Desirable boiler water pH should be ?
a) 5 - 7 b) 7-9
c) 9 - 11 d) None of the above
30. Soot deposition on boiler tubes is due to
a) Poor water treatment b) High moisture content in fuel
c) High excess air d) Incomplete combustion
31. If 10 % air is entrained in a steam system at 5 kg/cm 2g then the saturation temperature
of steam will be
a) Less than the saturation temperature at 5 kg/cm2g
b) More than the saturation temperature at 5 kg/cm2g
c) Equal to the saturation temperature at 5 kg/cm2g
d) Equal to the saturation temperature at 5.5 kg/cm2g
32. In a pressure reduction valve, which of these does not change?
a) Temperature b) Pressure
c) Velocity d) Enthalpy
33. Steam at 6 bar has a sensible heat of 159.33 kcal/kg and latent heat of 498.59 kcal/kg.
If the steam is 95 % dry then the total enthalpy is
a) 625 kCal/kg b) 649.95 kCal/kg
c) 553 kCal/kg d) 633 kCal/kg
34. Select the wrong statement with respect to steam traps
a) Discharges condensate as soon as it is formed
b) Does not allow steam to escape
c) Capable of discharging air and other incondensable gases
d) Does not allow condensate to escape
35. Velocity of steam in steam pipe is directly proportional to _______________
a) Number of bends in pipe b) Specific volume of steam
c) Length of pipe d) Diameter of the pipe
36. In a typical industrial steam distribution, the commonly used trap for main steam pipe
lines is
a) Thermostatic trap b) Inverted bucket trap
c) Thermodynamic trap d) Open bucket trap
37. 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 d) Extraction-cum-back pressure turbine
38. In an oil fired heat treatment furnace, which of the following is not required to determine
its efficiency by direct method ?
a) Weight of input material b) Oxygen percentage in flue gas
c) Fuel consumption d) Calorific value of fuel
39. In a coke fired cupola, carbon monoxide is produced in the
a) Preheating zone b) Reducing zone
c) Combustion zone d) Melting zone
40. Tuyeres is a part of the equipment associated with
a) Induction furnace b) Re-heating furnace
c) Electrical melting arc furnace d) Cupola

41. An increase in bulk density of a refractory increases its

a) Thermal conductivity b) Heat capacity
c) Resistance to slag penetration d) All of the above
42. The storage heat losses in a batch type furnace can be best reduced by
a) Fire Clay brick b) Ceramic fibre
c) High alumina brick d) High silica brick
 43. Emissivity is a measure of material’s ability to
a) Only absorb heat b) Only radiate heat
c) Absorb and radiate heat d) None of the above
44. Which of the following depends on physical properties of fluids as well as geometry of the
heat exchanger ?
a) Overall heat transfer coefficient b) Fouling coefficient
c) LMTD d) Effectiveness
45. The waste heat boiler application is not suitable for which of the following?
a) Gas turbine b) Diesel engine
c) Oil fired furnaces d) Hot air dryers
46. Moisture content in coal
a) Increases heat loss due to evaporation and superheating of water vapour
b) Helps in binding fines
c) Aids in radiation heat transfer
d) All of the above
47. With respect to properties of steam
a) The sensible heat decreases as the pressure increases
b) The latent heat increases as the pressure increases
c) The specific volume increases as the pressure increases
d) The specific volume decreases as the pressure increases
48. Oxidation of carbon to CO2 yields 8084 kcal/kg of carbon. Oxidation of carbon to CO in
the flue gas yields 2430 kcal/kg of carbon. Oxidation of CO to CO2 will yield
a) 5654 kCal b) 5800 kCal
c) 5464 kCal d) 540 kCal
49. The maximum loss that takes place in a fully condensing steam turbine power plant is
a) Flue gas loss b) Steam distribution loss
c) Radiation and insulation loss d) Condenser losses
50. The difference between mean solid and mean gas velocity in FBC boiler is called
a) Fluidization factor b) Slip velocity
c) Settling velocity d) Terminal velocity

…….……. End of Section – I ………..….

Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 =

40
(i) Answer all Eight questionss

(ii) Each question carries Five marks

S1 Write short notes on wet and dry methods of preservation of boiler.

Ans Refer BEE Guide Book 2- Chapter 2, Page No: 54 - 55

S2 Explain the phenomenon of water hammer in steam system and how it can be eliminated ?

Refer BEE Guide Book 2- Chapter 3, Page No: 91

Ans
S3 A counter flow double pipe heat exchanger using hot process liquid is used to heat water which
flows at 20 m3/hr. The process liquid enters the heat exchanger at 180 0C and leaves at 130
0C. The inlet and exit temperatures of water are 30 0C and 90 0C. Specific heat of water is
4.187 kJ/kg K. Calculate the heat transfer area if overall heat transfer coefficient is
820 W/m2 K. What would be the percentage increase in the area if fluid flow were parallel
assuming same overall heat transfer coefficient?
 Counter Flow
Ans ▪ Water inlet temperature 30 0C
▪ Water outlet temperature 90 0C
▪ Flow rate of water 20 m3/hr
▪ Heat content in water = 20000*(60)* 4.187=5024400 kJ/hr=1395.6 kW
▪ Process fluid inlet temperature = 180 0C
▪ Process fluid outlet temperature = 130 0C
▪ ΔT1=90, ΔT2 =100
▪ TLMTD = (ΔT1- ΔT2)/(ln(ΔT1/ ΔT2)) = 10/ln(100/90) = 94.91 0C
▪ U = 820 W/m20C
▪ H= UATLMTD = 1395.6*1000/(95*820) = 17.9 m2

Parallel flow:

ΔT1=150, ΔT2 =40

▪ TLMTD = (ΔT1- ΔT2)/(ln(ΔT1/ ΔT2)) = 110/ln(150/40) = 83.2 0C
▪ U = 820 W/m20C
▪ H= UATLMTD = 1395.6*1000/(83.2*820) = 20.45 m2

% Increase in area = ((20.45-17.9)/17.9) x 100 = 14.24 % increase

A continuous process industry is operating with a 2 MW DG Set with 80 % load to meet the
S4 power requirements of the plant. The specific fuel consumption of the DG set is 4 kWh/liter. On
energy auditor’s suggestion, a waste heat recovery boiler was installed to recover heat from
exhaust gas and generating 800 kg/hr of saturated steam at 10 kg/cm 2.

The waste heat recovery boiler operating data are given below.
• Feed water temperature = 60 oC
• Enthalpy of steam at 10 kg/cm2 = 660 kCal/kg
• Specific gravity of diesel = 0.85
• GCV of diesel = 10500 kCal/kg
Calculate the following. (each carries 2.5 Marks)
a) Efficiency of DG set before waste heat recovery boiler installation
b) Cogeneration system efficiency after waste heat recovery boiler installation

Diesel consumption Litre / hour

Ans
= ((2 x 1000) x 0.8 )) / 4 = 400 litre / hour
a) DG set efficiency
= 2000 kWh/hr x 0.8 loading x 860 kcal/kWh x100 = 38.54 %
400 lit x 0.85 kg/lit x10500 kcal/kg
b) Co-gen System Efficiency after WHR boiler installation
[ 2000 kW x 0.8 loading x 860 kcal/hr/kW + (800 kg steam /hr x (660-60) kcal/kg ]x100 = 52%
[ 400 lit x 0.85 kg/lit x10500 kcal/kg]
S5 A coal fired thermic fluid heater is used to supply heat to a dryer. The hot oil circulation is
supplied at 270 oC, with a flow of 100 m3/hr and operating with temperature difference of 20
oC. 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/kg oC& 820 kg/m3
respectively.
Ans Absorbed heat in thermic fluid = m * Cp * ∆ T
= (100 * 820) * 0.55 * 20
= 902000 kcal/hr
Thermal efficiency of the heater = absorbed duty / input heat duty
Mass of coal required = absorbed duty / (efficiency * calorific value of coal)
= 902000 / (0.65 * 4200)
= 330.4 kg/hr
In a heat exchanger, steam is used to heat 3000 litres/hr of furnace oil from 30 oC to 100 oC.
S6 The specific heat of furnace oil is 0.22 kCal/ kg/ oC and the density of furnace oil is 0.95. 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/kg and electrical energy cost is Rs.8/kWh, which type of heating would be
more economical in this particular case? (assume no losses in electrical and steam heating
process)
Total heat required = m Cp ∆T
Ans
= (3000 x 0.95) x 0.22 x (100-30)

= 43890 kcal/hr

a) Amount of steam required = 43890/510

= 86 kg/hr

Steam cost = 86 x Rs.4

= Rs. 344/hr

b) Amount of electricity required = 43890/860

= 51 kWh

= 51 x Rs. 8

= Rs.408/ hr

Answer : Steam heating will be more economical

Calculate the reduction in pressure drop in meters when pipe diameter is increased from 250
S7 mm to 350 mm for a length of 500 meters. The water velocity is 2 m/s in the 250 mm diameter
pipe, and friction factor is 0.005.

Ans Pressure drop = 4fLV2/ 2gD

Pressure drop with250 mm = (4 x 0.005 x 500 x 22 )/ (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

Pressure drop with350 mm = (4 x 0.005 x 500 x1.022 )/ (2x9.81 x0.350)

= 1.515 m

Pressure drop reduction = 8.155 – 1.515 = 6.64 m

S8 In a process plant 200 kg/hr of hot condensate at 6 bar(g) having a sensible heat of
166 kCal/kg is discharged. The plant also requires low pressure steam at a pressure of 1 bar(g)
for heating application. Find out the quantity of flash steam generated in the flash vessel in
kg/hr. The condensate at a pressure of 1 bar(g) has a sensible heat of
120 kCal/ kg and a latent heat of 526 kCal/kg.
S1 – S2
Ans Flash steam available % = --------------- × 100
L2
Where,

S1 = is the sensible heat of higher pressure steam

S2 = is the sensible heat of steam at lower pressure

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

166 - 120
Flash steam generated = ( ------------------- ) × 200 Kg/hr = 17.49 kg/hr
526

…….……. End of Section – II ………..….

Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all Six questions
(ii) Each question carries Ten marks

L1 a) Write short notes on the following (each carries 2.5 Marks)

• Advantage of Micro turbine in Steam System
• Trigeneration with example

b) Why is individual trapping preferred over group trapping? (5 Marks)

Ans a)
• (Refer BEE Guide book 2, Chapter 7, Page No-209)
• (Refer BEE Guide book 2, Chapter 7, Page No-208)

b) (Refer BEE Guide book 2, Chapter 7, Page No-208)

L2 Explain the following (each carries 5 Marks)

• Advantages of using ceramic fibre in furnaces
• Advantages of using fluidized bed boilers

• (Refer BEE Guide book 2, Chapter 5, Page No:164-165)

Ans
• (Refer BEE Guide book 2, Chapter 6, Page no: 182-183)

An air preheater in a 90 TPH induced draft boiler was showing the following readings:
L3 i. Flue gas inlet temperature: 319.5 0C
ii. Flue gas Outlet temperature: 160 0C
iii. Air inlet temperature: 70 0C
iv. Air outlet temperature: 210 0C
 The steam to fuel ratio is 12 and air to fuel ratio is 14. It was found that there was air ingress
from atmosphere to flue gas side. Ambient air temperature was 30 0C. Assuming that the
specific heat capacity of air and flue gas to be the same at 0.24 kcal/kg K and the amount of
heat picked up by fresh air remains the same.
Calculate the following: (each carries 5 Marks)
a) The amount of air ingress into the flue gas path.
b) The flue gas temperature after air preheater in case of no air leak to flue gas
circuit.
a. Steam flow: 90TPH
Ans Steam to fuel ratio: 12 ➔ fuel consumed is 7.5 TPH
Air to fuel ratio: 14➔ air used in boiler is 105 TPH
Flue gas = Air + Fuel ➔ Flue gas = 105+7.5 = 112.5 TPH

Air ingress is at 30 deg C.

Making an energy balance around APH:
we get 112.5 * 319.5 + 105 * 70 + x * 30 = 105 * 210 + (112.5+x ) *160
Solving for x, we get air ingress to be 25 TPH

Flue Gas Temperature

b. ➔ 112.5 * 319.5 + 105 * 70 = 105*210+112.5* T
Solving for T, we get the corrected flue gas temperature to be 189 oC

L4 As a part of energy conservation measure, APH (Air Pre-heater) is installed in a forced draft
furnace. The APH is designed to pre-heat 240 m3/min of combustion air to 250 0C. Flue gas
enters the APH at 375 0C. Calculate the flue gas quantity leaving the stack and also determine
the improvement in furnace efficiency after the installation of APH with the following data,

Density of air : 1.15 kg/m3

Specific heat of air : 0.24 kCal/kg 0C
Specific heat of flue gas : 0.2 kCal/kg 0C
Amount of fuel fired : 920 kg/hr
Calorific value of fuel : 9850 kCal/kg
Air to fuel ratio : 18
Efficiency of furnace : 80 %
Ambient temperature : 30 0C

Ans Solution:
Amount of Air flow = 240 * 60 * 1.15
= 16560 kg/hr
Amount of fuel = 16560 / 18
= 920 kg/hr
Amount of flue gas = 16560 + 920
= 17480 kg/hr
Heat gain by combustion air = 16560 * 0.24 * (250 – 30)
= 874368 Kcal/hr
Temperature difference in flue gas = 874368 / (17480 * 0.2)
= 250 °C
Flue gas leaves the stack at temp = 375 – 250 = 125 °C
Efficiency of APH = Heat absorbed by air / Heat input * 100
= 874368 / (920* 9850) * 100
 = 9.6 %
Overall efficiency after APH = 80 + 9.6 % = 89.6 %
An oil fired Boiler is generating 100 TPH of steam at 85 % efficiency and operating 330 days in a
L5 year. The management has installed a water treatment plant with Rs. 2 Crore investment for
reducing the Total Dissolved Solids (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 %. The
temperature of blowdown water is 175 0C and the boiler feed water temperature is
45 0C. The calorific value of fuel oil is 10,200 kCal/kg. Calculate the payback period if the cost
of fuel is Rs. 45,000 per ton.
Blow down % = Feed water TDS * % make up water * 100
Ans (maximum permissible TDS in boiler water – Feed water TDS)

Initial blow down = 450 * 10 / (3000 – 450)

Initial blow down = 1.764 %
Improved blow down = 150 * 10 / (3000 – 150)
Improved blow down = 0.526 %
Reduction in blow down = 1.76 – 0.526
Reduction in blow down = 1.238 %
Reduction in blow down = 1.238 * 100 * 1000 / 100
Reduction in blow down = 1238 kg/hr
Specific heat of water is 1 kcal/kg°C
Heat savings = m * Cp * (T1 – T2) = 1238 * 1 * (175 – 45)
Heat savings = 160940 kcal/hr
Fuel Oil saving = 160940 / (10200 * 0.85) = 18.6 kg/hr
= 18.6 * 24 * 330 / 1000
= 147 MT / annum

Fuel Oil – cost savings = 147* 45000

= Rs. 66 lakh
Investment on water treatment plant = Rs. 2 Crore
Payback period = 2 / 0.66
Payback period = 3.0 years (or) 36 months
In a leather industry, a leather drier requires 80 m3/min of air at 92 0C, which is heated by
L6 wood fired thermic fluid heater. The density of air is 1.2 kg/m 3 and specific heat of air is 0.24
kcal/kg 0C. The inlet air temperature to the drier is 32 0C and the drier is operating for 8 hrs
per day.
The efficiency of the wood fired heater and its distribution piping system is 50 %. The gross
calorific value and the cost of purchased wood are 2000 kCal/kg and Rs. 5000 per ton. The
auxiliary power consumption for operating the thermic fluid heater is 10 kW.
The energy auditor recommended replacing the existing drying system with a 40 kW infrared
electric heater drier. The kW loading of the proposed drier will be 70 % over an 8 hour plant
operating period. The investment for the new drier is Rs. 10 Lakhs.

If the cost of electricity is Rs. 7/kWh, calculate the following :

a) Find out the annual energy cost savings of replacement of thermic fluid system
with infra-red heater ? (7 Marks)
b) Find out the payback period. (3 Marks)
 Cost of wood fired thermic fluid heater operation
Ans
Air flow rate (vol) = 80 m3/min x 60 = 4800 m3/hr
Air flow rate (mass) = 4800 x 1.2 = 5760 kg/hr
Sensible heat of air = m x Cp x T = 5760 x 0.24 x (92-32) = 82944 kcal/hr

Efficiency of wood fired heater =50%

Wood consumption = 82944/(2000 x0.5) per hr=83 kg per day
Cost of wood per day = 83 xRs 5 x 8 hour = Rs 3320 per day
Cost of Auxiliary electricity = 10 kW x 8 hrs x 7 = Rs.560
Total cost of operation = 3880 Rs.

Cost of Infra-red heater operation

Electric heater rating= 40 kw

Electricity consumption per day= 40 kw x 0.7 x8hr = 224 kwh per day

= 224 x Rs 7= Rs 1568 per day

Cost saving potential = 3880- 1568 = Rs2312

Annual saving potential = 2312 x 300 days = Rs. 6.94 lakhs

Investment= 10 lakhs
Payback period= 10/6.94= 17 months or 1.4 years

Or

Annual saving potential = 2312 x 365 days = Rs. 8.44 lakhs

Investment= 10 lakhs
Payback period= 10/8.44= 14 months or 1.2 years

…….……. End of Section – III ………..….

 Paper-2 Code: Green

20th NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS& ENERGY AUDITORS- September, 2019
PAPER –2: Energy Efficiency in Thermal Utilities
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

Section – I:OBJECTIVE TYPE Marks: 50 x 1 = 50

(i) Answer all 50 questions
(ii) Each question carries one mark
(iii) Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB pencil, as per instructions

1. Dolomite is a ________ type of refractory:

a) acidic b) basic c) neutral d) none of the above
2. Which of the following is not true of condensate recovery?
a) reduces water charges b) reduces fuel costs
c) increases boiler output d) increases boiler blow down
3. Calcium and magnesium bicarbonates present in feedwater fed to a boiler would form:
a) acidic solution b) alkaline solution c ) neutral solution d) none of the above
4. In steam systems, the purpose of venting air is because, air is ________.
a) a good conductor b) an inert substance c) an oxidizing agent d) an insulator
5. A bottoming cycle is one in which fuel is used for producing:
a) power primarily followed by byproduct heat output
b) heat primarily followed by byproduct power output
c) power, heat and refrigeration simultaneously
d) none of the above
6. A supercritical boiler has parameters beyond critical point, which refers to:
a) 221.2 bar (a) pressure and 374.15 0C temperature
b) 246.1 bar (a) pressure and 538.44 0C temperature
c) 306.5 bar (a) pressure and 538.82 0C temperature
d) 170.0 bar (a) pressure and 374.18 0C temperature
7. Of the total volume of natural gas, the main constituent is :
a) methane b) iso-octane c) propane d) hexane
8. For optimum combustion of fuel oil, O2 percentage in flue gases should be maintained at:
a) 2-3 % b) 14-15 % c) 23 % d) 21%
9. The draft caused solely by the difference in weight between the column of hot gas inside the chimney and

1
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Bureau of Energy Efficiency
 Paper-2 Code: Green
column of outside air is known as :
a) balanced draft b) induced draft c) forced draft d) natural draft
10. The cogeneration system which has high overall system efficiency is :
a) back pressure steam turbine b) combined cycle
c) extraction condensing steam turbine d) reciprocating engine
11. When 10 kg of fuel, with 60% carbon, is burnt with theoretical air, the mass of CO2 released will be :
a) 32 kg b) 440 kg c) 450 kg d) 22 kg
12. F & A (from and at) rating of the boiler is the amount of steam generated from :
a) water at 0 °C to saturated steam at 100 °C
b) water at feed water temperature to saturated steam at 100 °C
c) water at 100 °C to saturated steam at 100 °C
d) water at ambient temperature to saturated steam at 100 °C
13. 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
14. Which of the following statement is false?
a) LPG vapour is twice as light as air b) LPG is a mixture of propane and butane
c) LPG is a gas at normal atmospheric pressure d) LPG is required to be odorized
15. The inverted bucket operates on the principle of _______ difference between water and steam:

a) pressure b) density c) temperature d) velocity

16. Which of the following is not measured in proximate analysis?
a) volatile matter b) fixed carbon c) sulphur d) ash
17. Reduction of steam pressure, in a process heating application will:
a) reduce the steam temperature b) reduce the sensible heat
c) increase the enthalpy of evaporation d) all of the above
18. The TDS level in boiler water, in the context of boiler blow down, can be determined by measuring :
a) alkalinity of water b) thermal conductivity of water
c) electrical conductivity of water d) turbidity of water
19. De-aeration of boiler feed water helps in combating:
a) corrosion b) TDS c) silica d) hardness
20. In stoichiometric combustion of furnace oil, which of the following will be absent in flue gas ?
a) nitrogen b) carbon dioxide c) oxygen d) Sulphur dioxide
21. Furnace wall heat loss does not depend on :
a) temperatures of external wall surfaces b) velocity of air around the furnace
c) thermal conductivity of wall brick d) material of stock to be heated
22. In determining the optimal economic insulation thickness for a steam pipeline, which of the following factors need not be
considered ?

a) annual hours of operation b) calorific value c) pipe material d) cost of fuel

2
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Bureau of Energy Efficiency
 Paper-2 Code: Green
23. Which is not a property of Ceramic fiber insulation?
a) low thermal conductivity b) light weight c) high heat storage d) thermal shock resistant
24. Which property is the most important, for an insulating brick?
a) Mechanical strength b) Chemical resistance
c) Compact strength d) Porosity
25. Quality of waste heat in flue gas refers to:
a) dust concentration in flue gas b) Temperature of flue gas
c) moisture in flue gas d) corrosive gases in flue gas
26. In a low temperature waste heat recovery system, which of the following, is the most suitable?
a) Economizer b) Heat Pipe c) regenerator d) ceramic recuperator
27. Which of the following heat recovery equipment, requires a compressor for its operation?
a) thermo-compressor b) heat wheel c) Heat pump d) heat pipe
28. Pinch analysis of process streams, depicts the plot of :
a) temperature vs entropy b) temperature vs. area
c) temperature vs specific heat d) temperature vs enthalpy
29. Which of the following is true for a process heating requiring direct injection of steam?
a) Thermodynamic trap is required b) Thermostatic trap is required
c) Inverted bucket trap is required d) None of the above
30. If a vapor-liquid combination of 1 kg at 120 ºC is supplied with 50 kcal of heat without change in state and at constant
pressure conditions; its temperature will be?

a) 220 ºC b) 190 ºC c) 170 ºC d) 120 ºC

31. Which of the following constituent in flue gas is used for determining excess air?
a) % nitrogen b) % Sulphur Dioxide c) % Carbon dioxide d) %
Moisture
32. Arrange the following fuels in decreasing order of their GCV’s - (p) Bagasse, (q) Furnace Oil, (r) Coal, (s)
Hydrogen
a) s-q-r-p b) p-q-r-s
c) r-s-q-p d) q-r-s-p
33. Which of the following contributes to spluttering of flame at burner tip during combustion of fuel oil?
a) ash content b) water content
c) Sulphur content d) ambient air humidity and temperature
34. Which trap is preferred in condensate removal from steam main lines?
a) Float trap b) Thermodynamic trap
c) Thermostatic trap d) All of the above
35. In an FBC boiler, with low ash fusion coal, if the bed temperature exceeds 950°C, the result is:
a) Boiler explosion b) clinker formation
c) Melting of lime stone d) Ash carry over
36. Water logging of 3 m lift of condensate, at trap discharge, will result in back pressure of _________

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a) 0.03 kg/cm b) 0.3 kg/cm
c) 3 kg/cm2 d) 30 kg/cm2
37. When pure hydrogen is burnt with stoichiometric air, percentage CO2 on volume basis, in dry flue gas, will be :
a) 79% b) 21%
c) 0% d) 100%
38. Heat transfer rate for drying application will be low if we heat with :
a) Saturated steam b) Dry steam
c) Superheated steam d) None of the above
39. The viscosity of furnace oil will be maximum at which of the following temperatures?
a) 40 oC b) 60 oC c) 90 oC d) 105 oC
40. Carpet loss in the context of coal consumers is related to :
a) Short receipt b) Accounting mistakes c) Ash handling d) coal storage
41. Thermo-compressor is commonly used for :
a) compressing hot air b) upgrading low pressure steam
c) converting saturated steam to super-heated steam d) reverse compression of CO2
42. Latent heat of any vapour at its critical point will be :
a) highest b) above zero c) zero d) less than zero
43. The temperature at which, refractory will deform under its own weight, is it’s softening temperature, indicated
by :
a) melting point b) Pyrometric Cone Equivalent c) reform temperature d) critical
point
44. Which type of the following co-generation system has high heat-to-power ratio ?
a) gas turbine b) back pressure turbine
c) extraction condensing turbine d) reciprocating engine
45. Drain pockets are provided in a steam line for :
a) effective removal of line condensate b) effective removal of steam
c) removal of dirt d) checking of steam line
46. Capillary wick is a part of :
a) heat pump b) heat wheel
c) heat pipe d) regenerator
47. Scale losses in reheating furnaces will :
a) increase with CO in combustion gases b) increase with excess air
c) decrease with excess air d) have no relation with excess air
48. Tuyeres is a terminology associated with :
a) induction furnace b) pusher type furnace c) arc furnace d) cupola
49. The low combustion temperature in FBC boilers results in minimal formation of :
a) CO b) SOx c) NOx d) CO2
50. Turn down ratio of a burner is the ratio of______________.
a) maximum to minimum fuel input without affecting optimum excess air levels
b) minimum to maximum fuel input without affecting optimum excess air levels
c) maximum to average fuel input
d) average to minimum fuel input

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…….……. End of Section – I ………..….

Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 40

(i) Answer all Eight questions
(ii) Each question carries Five marks

S1 In an industry the process equipment need 5000 kg/hr of saturated steam at 10 kg/ cm2(g). For a steam velocity of
25 m/sec, what will be the diameter of the steam pipe in ‘mm’, given that the specific volume of steam at 10 kg/ cm2(g) is
0.1802 m3/kg.
Ans :
Specific volume of steam at 10 kg/cm2(g) = 0.1802 m3/kg
Flow rate = 25m/sec
Mass flow rate = 5000 kg/hr
= 1.389 kg/sec
Volume flow rate = 1.389 x 0.1802
= 0.25 m3/sec
Volume flow rate is also = (π/4 x D2)x25
2
Therefore, (π/4 x D ) x 25 = 0.25
Hence, Diameter of steam pipe line ‘D’ = [(0.25/((π/4) x 25)]0.5
= 0.1128m
or 112.8 mm
S2 An economizer was installed in an oil-fired boiler. The following data was obtained after commissioning the economizer.
▪ Air to fuel ratio = 18
▪ Evaporation ratio of the boiler = 12.5
▪ Specific heat of flue gas = 0.25 kcal/kg°C.
▪ Condensate recovery in the plant = Nil.
Calculate the rise in temperature of feed water across the economizer, corresponding to a drop in flue gas temperature
from 280 °C to 190 °C.
Ans :
Steam generated per kg of fuel, (from evaporation ratio) = 12.5 kg
Required combustion air per kg of fuel, (from air to fuel ratio) = 18 kg combustion air/kg fuel oil
Flue gas generated per kg of fuel = (18 +1)
= 19 kg flue gas/kg fuel oil
Heat balance across the Economizer : Heat given by flue gas = Heat received by water
((19 x 0.25 x (280-190)) = (12.5 kg x 1kcal/kgoC x ∆T)
Rise in temperature of water ∆T = 34.2 °C
S3 Compute the heat loss in percentage, due to unburnt in fly ash and bottom ash, for an AFBC Boiler, using Indian coal,
with :

▪ GCV = 4200 kcal/kg.

▪ % Ash in coal = 38.8
▪ Ratio of bottom ash to fly ash = 15 : 85
▪ GCV of fly ash = 452.5 kcal/kg
▪ GCV of bottom ash = 800 kcal/kg

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Ans:
Unburnt in fly ash
Amount of fly ash in 1 kg of coal = (0.85 x0.388)
= 0.3298 kg fly ash/kg coal
GCV of fly ash = 452.5 kcal/kg fly ash
Heat loss in fly ash = (0.3298 x 452.5 kcal per kg fly ash)
= 149.23 kcal/kg coal
% Heat loss in fly ash = (149.23 x 100 /4200 )
= 3.55 %

Unburnt in bottom ash

Amount of bottom ash in 1 kg of coal = 0.15 x 0.388
= 0.0582 kg bottom ash/kg coal
GCV of bottom ash = 800 Kcal/kg bottom ash
Heat loss in bottom ash = (0.0582 x 800 kcal per kg bottom ash)
= 46.56 kcal/kg coal
% Heat loss in bottom ash = (46.56 x 100 /4200)
= 1.11 %

S4 List five main parameters considered for the selection of refractories?

Ans : (Page No:166, Sec 5.11)
S5 What is the significance of volatile matter, in case of solid fuels?
Ans : (Page No: 9)
S6 • List three functions of a steam trap. (3 Marks)
• Explain the working principle of thermodynamic trap. (2 Marks)
Ans :
• List three functions of a steam trap. (Page 82)
• Explain the working principle of thermodynamic trap. (Page 86-87)
S7 In an industry, an electrical oven consuming 1100 kWh/batch, is proposed for replacement, by a FO fuel fired oven.
Calculate the simple payback period, given the following data:

Number of batches / years = 4000

Efficiency of electric oven = 82%
Efficiency of FO fired oven = 55%
Cost of FO = Rs.35,000/Tonne
GCV of FO = 10,200 kcal/kg
Electricity cost = Rs.6.0/kWh
Investment for FO fired oven = Rs. 125 Lakhs

Ans :

Useful heat, required per batch = (1100 x 860 x 0.82)

= 7,75,720 kcal/batch
FO input per batch = (7,75,720 /(0.55 x 10,200))

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= 138.27 kg FO/batch
FO cost per batch = (138.27 kg FO/batch x Rs.35/kg FO)
= Rs.4,839.45
Electricity cost per batch = (1,100 kWh/batch x Rs.6.0/kWh)
= Rs.6,600
Cost savings per batch on account of replacement = (Rs.6,600 – Rs.4,839.45)
= Rs.1,760.55
Annual cost savings at 4000 batches per year = (1,760.55 x 4000)
= Rs.70,42,200
(Or) = Rs.70.422 lakhs
Investment = Rs.125 lakhs
Simple payback period = (125/70.422)
= 1.78 years
S8 In a process plant, 30 TPH of steam, after pressure reduction to 20 kg/cm2(g), through a pressure reducing valve, gets
superheated. The temperature of superheated steam is 350 oC. The management desires to install a de-super heater to
convert the superheated steam into useful saturated steam at 20 kg/cm2(g) for process use. The saturated steam
temperature is 210oC.

Calculate the quantity of water required to be injected at 30 oC, in the de-super heater, in order to obtain the desired
saturated steam, using the following data:

• Specific heat of superheated steam = 0.45 kcal/kgoC

• Latent heat of steam at 20 kg/cm2(g) = 450 kcal/kg

Ans :

▪ Quantity of heat available above saturation = (30,000 x 0.45 x (350-210))

= 18,90,000 kcal/hr
By Heat & Mass balance : Q x{1 x (210-30) + 450} = 18,90,000
▪ Quantity of water (Q) required
to be added in de-super heater = 18,90,000/{1 x (210-30) + 450}
= 18,90,000/630
= 3000 kg/hr

…….……. End of Section – II ………..….

Section – III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all six questions

(ii) Each question carries ten marks

L-1 a) An open cycle gas turbine was running with naphtha as fuel. The following are the data collected during the gas
turbine operation:
Fuel (Naphtha) consumption = 300 kg/hr
GCV of naphtha fuel = 11,500 kcal/kg
Overall Efficiency of gas turbine
(which includes air compressor and alternator) = 22%
Cost of naphtha fuel = Rs.40,000/Tonne

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a) Find out the output power and cost of fuel for generating one unit of electricity.
………..6 marks

b) The management has decided to install a waste heat boiler, to generate 2 TPH of saturated steam, at 4
kg/cm2(g), with an enthalpy of 656 kcal/kg. Assuming that, 50% of the input heat is available in the turbine
exhaust gases, how much steam can be generated if the feed water temperature is 30 oC.
………..4 marks
Ans:
a)
Heat input to turbine = (300 kg Naptha/hr x 11,500 kcal/kg)
= 34,50,000 kcal/hr
Efficiency of gas turbine = 22%
Gas turbine output power = ((34,50,000 kcal/hr x 0.22)/ 860)
= 882.56 kW
Cost of generating 882.56 units of electricity = (300 kg Naptha/hr x Rs.40/kg Naptha)
= Rs.12000/hr
Cost of One unit of Electricity generation = (Rs.12000 per hour/882.56 kWh per hour)
= Rs.13.6/kWh

b)
Waste heat potential in existing gas turbine = (0.5 x 34,50,000 kcal/hr)
= 17,25,000 kcal/hr.
Heat required for raising 1 kg of steam
(feed water temp 30 oC) = (656-30) kcal/kg steam
= 626 kcal/kg steam
Steam generation potential = (17,25,000 kcal per hour/626 kcal per kg steam)
= 2755.6 kg steam/hr
= 2.7556 TPH
L-2 Explain any two of the following: (Each 5 Marks)

1. Regenerator (Page 222)

2. Heat Pipe (Page 223)
3. Gas turbine cogeneration system (Page 192)
L-3 A process industry consuming 10 TPH of saturated steam at 10 kg/sq.cm(g) pressure has been using coal as
fuel in boiler.
Typical ultimate analysis of the coal:
Carbon : 41.11%
Hydrogen : 2.76 %
Nitrogen : 1.22 %
Oxygen : 9.89 %
Sulphur : 0.41%
Ash : 38.63
Water : 5.89
Flue gas temperature = 200°C
Ambient temperature = 30°C
Enthalpy of steam = 668 kcal/kg
Feed water temperature = 80°C
Specific heat of flue gases = 0.23 kcal/kgoC
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Boiler efficiency with Indian coal =72 %
GCV of coal = 4,000 kCal/kg
Oxygen content in dry flue gases = 10%
Annual Hours of operation = 8000 hrs.

Determine:
(i) Quantity of annual coal requirement in tonnes/year (5 Marks)
(ii) Calculate % dry flue gas losses (5 Marks)

Solution:
a)
Coal requirement Q = Steam (q) x (hg – hf)/( Efficiency x GCV)
= 10 x (668-80) / (0.72 x 4000)
= 2.042 T/Hr
= 2.042 x 8000 hrs
= 16336 Tonnes/year

Theoretical air requirement for coal

= [(11.6 x C%) + {34.8 x(H2% - O2%/8)} + (4.35 x S%)] kg / kg of coal

100

= [(11.6 x 41.11) + {34.8 x(2.76 – 9.89/8)} + (4.35 x 0.41)]

100
= 5.31 kg / kg of coal

(Or)
=================================================================================================
=

C+ O2 = CO2 12+32= 44 (C%*32)/12

2H2+ O2 = 2H2O 4+32=36 (H%*32)/4
S+ O2 = SO2 32+32=64 (S%*32)/32

Total oxygen required = (41.11* 32/12) + (2.76*32/4)+ (0.41*32/32)

= (109.63) + (22.08) + (0.41)
= 132.1 kg/ 100 kg fuel

Oxygen already present in 100 kg fuel = 9.89 kg/ 100 kg fuel

Additional oxygen required = 132.1 – 9.89 kg/ 100 kg fuel

= 122.21 kg/ 100 kg fuel

Quantity of dry air required

(Air contains 23% O2 by weight ) = 122.1/ 0.23

= 531.35 kg/ 100 kg fuel

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Theoretical air required = 531.35/100

= 5.31 kg air/ kg fuel

=================================================================================================
==
Excess air = O2x100/(21-O2)
Excess air = 10 x 100/ (21 – 10) = 90.9%

Actual air= 5.31 * (100+90.9)/100

=10.137 kg air/kg coal

Heat loss in dry flue gas = m x CP (Tf – Ta) x 100 /GCV

= (10.137+ 1) x 0.23 x (200 – 30) x 100
4000
= 10.89 %

L-4 a) In a double pipe heat exchanger, flow rates of the hot and the cold water streams flowing through a heat
exchanger are 10 and 25 kg/min, respectively. Hot and cold water stream inlet temperatures are 70 °C and 27 °C,
respectively. The exit temperature of the hot stream is required to be 50°C. The specific heat of water is 4.179 kJ/
kg K. The overall heat transfer coefficient is 900 W/m2 K. Neglecting the effect of fouling, calculate the heat
transfer area for a) Parallel-flow b) Counter-flow.
………..7 marks
b) Write a brief note on the operation and application of plate heat exchangers in process industries.
………..3 marks
Ans:
a)

Rate of heat transfer, Q (watts) Q= m x Cp x 1000 x (T2-T1)

=(10/60)× 4.179 x 1000 ×(70 – 50) = 13930 W

B) Cold water exit temperature, T2 T2 = [Q/(mx Cp x 1000)]+ T1

= (13930/((25/60)* (4.179*1000)))+27
= 35°
Terminal temperature differences for parallel = (70-27) & (50 – 35); i.e.,
flow heat exchangers 43°C and 15°C respectively.
LMTD (43 – 15)/ln(43/15) = 26.59°C
Overall heat transfer coefficient U 900 W/m2 °K
Heat transfer area required for parallel flow A = Q/ (U*LMTD)
= [13930/ (900 × 26.59)]
= 0.582 m2
Terminal temperature differences for counter (70–35) and (50–27) 0C i.e.,
flow heat exchangers 35 °C and 23 °C respectively.
LMTD (35–23)/ln(35/23) = 28.58
Overall heat transfer coefficient U 900 W/m2 °K
Heat transfer area required for counter flow A = Q/ (U*LMTD)
=[13930/ (900 × 28.58)]
= 0.542 m2

Plate heat exchangers consist of a stack of parallel thin plates that lie between heavy end plates. Each fluid stream
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passes alternately between adjoining plates in the stack, exchanging heat through the plates. The plates are
corrugated for strength and to enhance heat transfer by directing the flow and increasing turbulence. These
exchangers have high heat-transfer coefficients and area, the pressure drop is also typically low, and they often
provide very high effectiveness.

However, they have relatively low pressure capability. The biggest advantage of the plate and frame heat exchanger,
and a situation where it is most often used, is when the heat transfer application calls for the cold side fluid to exit the
exchanger at a temperature significantly higher than the hot side fluid exit temperature i.e. “temperature cross”. This
would require several shell and tube exchangers in series due to the lack of purely counter-current flow.

The overall heat transfer coefficient of plate heat exchangers under favorable circumstances can be as high as
8,000 W/m2°C. With traditional shell and tube heat exchangers, the U-value will be below 2,500 W/m2°C.
L-5 a) In a fruit processing plant, 105 TPD of syrup at 33% concentration is dried to 50% concentration. The existing single
effect evaporator, where steam input for water removal ratio is 1.0 kg/kg is proposed to be replaced by a triple effect
evaporator where the ratio of steam input for water removal is 0.4 kg/kg. Calculate the annual fuel cost savings for 300
days of operation at an evaporation ratio of 13.5 in the oil fired boiler and at a furnace oil cost of Rs. 35,000/tonne.
………..7 marks

b) Why steam is recommended to be used at the lowest practicable pressure for indirect process heating?
………..3 marks
Ans.:
a)
Bone Dry material = (105 TPD x 0.33)
= 34.65 TPD
Product at 50 % concentrate = (34.65 / 0.5)
= 69.3
Water removed/ day = (105 – 69.3)
= 35.7 TPD

Initial steam consumption with single effect evaporator at 1 kg/kg = (35.7 TPD x 1.0 kg/kg)
= 35.7 TPD
Steam consumption with triple effect evaporator at 0.4 kg/kg = (35.7 TPD x 0.4 kg/kg)
= 14.28 TPD
Steam savings per day = (35.7 TPD – 14.28 TPD)
= 21.42 TPD

FO savings per day at evaporation ratio of 13.5 = (21.42 TPD / 13.5 Tonne steam per Tonne FO)
= 1.5867 TPD
Rupee savings per day at Rs. 35,000/MT = (1.5867 TPD FO X Rs. 35,000/MT FO)
= Rs. 55,535
Annual monetary savings at 300 working days per year = (Rs. 55,535 X 300 Days )
= Rs.166.6 Lakhs
b)
The latent heat in steam reduces as the steam pressure increases.

It is only the latent heat of steam, which takes part in the heating process when applied to an indirect heating system.
Thus, it is important that its value be kept as high as possible. This can only be achieved if we go in for lower steam
pressures.

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c) However, lower the steam pressure, the lower will be its temperature. Since temperature is the driving force for
the transfer of heat at lower steam pressures, the rate of heat transfer will be slower and the processing time
greater. In equipment where fixed losses are high (e.g. big drying cylinders), there may even be an increase in
steam consumption at lower pressures due to increased processing time. There are however, several equipment’s
in certain industries where one can profitably go in for lower pressures and realize economy in steam
consumption, without materially affecting production time. Therefore, there is a limit to the reduction of steam
pressure. Depending on the equipment design, the lowest possible steam pressure with which the equipment can
work should be selected without sacrificing either on production time or on steam consumption.
L-6 a) An oil fired reheating furnace has an operating temperature of around 1000 °C. Average furnace oil consumption is
330 litres/hour. Flue gas exit temperature after the air preheater is 820 °C. Combustion air is preheated from ambient
temperature of 35 °C to 215°C through the air preheater. The other data are as given below.
Specific gravity of oil = 0.92
Calorific value of oil = 10,200 kcal/kg
Average O2 percentage in flue gas = 13.5 %
Theoretical air required = 14 kg of air per kg of oil
Specific heat of air = 0.23 kcal/kg°C
Specific heat of flue gas = 0.25 kcal/kg°C
Find out :
• The sensible heat carried away by the exhaust flue gases in kcals/hr and as a percentage of the energy input.
………..4 marks
• The heat recovered by the combustion air in kcal/hr and as a percentage of the energy input.
………..3 marks
b) Explain the concept and the advantage of a self-recuperative burner?
………..3 marks
Ans:
a)
Fuel input = (330 litres/hr x 0.92 kg/litre)
= 303.6 kg/hr
Energy Input = (303.6 kg oil/hr x 10,200 kcals/kg oil)
= 30,96,720 kcal/hr
Excess air = [O2 x 100/(21-O2)]
= (13.5 x 100)/(21 - 13.5)
= 180 %
Theoretical air required = 14 kg of air/kg of oil
Actual mass of air required = 14 x (1 + 180 /100)
= 39.2 kg air/kg of oil
Mass of flue gas (m) = (39.2 + 1)
= 40.2 kg flue gas/kg oil
Specific heat of flue gas (Cp) = 0.25 kcal/kg.oC

Sensible heat loss in the flue gas = (m x Cp x ΔT)flue gas

= (40.2 x 0.25 x (820-35))
= 7889.3 kcal/kg of oil
(Or)
= (7889.3 kcal/kg of oil x 303.6 kg oil/hr)
= 2395176.3 kcal/hr
Sensible heat loss in the flue gas as
% heat loss to input energy = (2395176.3 / 30,96,720) x 100
= 77.35 %
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Heat recovered by combustion air = (39.2 x 0.23 x (215-35))
= 1622.88 kcal/kg of oil
= (1622.88 kcal/kg oil x 303.6 kg oil/hr)
= 492706.37 kcal/hr
Heat recovered by combustion air
as % of input energy = (492706.37 kcal/hr/30,96,720 kcal/hr) x100
= 15.91 %
b)

Self-recuperative burner (SRB)is based on traditional heat recovery techniques, in that, the products of combustion are
drawn, through a concentric tube recuperator, around the burner body and used to pre-heat the combustion air. A
major advantage of this type of system is that, it can be retro-fitted to an existing furnace structure, to increase
production capability, without having to alter the existing exhaust gas ducting arrangements. SRBs are generally more
suited to Heat-treatment furnaces, where exhaust gas temperatures are lower and there are no stock recuperation
facilities.

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