Paper 2 Set B Solutions

Regn No: _________________ Name: ___________________ (To be written by the candidate)

10th NATIONAL CERTIFICATION EXAMINATION July, 2010 FOR ENERGY MANAGERS & ENERGY AUDITORS
PAPER 2: Energy Efficiency in Thermal Utilities
Date: 17.7.2010 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150

General instructions: o o o o o Please check that this question paper contains 12 printed pages Please check that this question paper contains 64 questions The question paper is divided into three sections All questions in all three sections are compulsory All parts of a question should be answered at one place
OBJECTIVE TYPE Marks: 50 x 1 = 50

Section - I: (i) (ii) (iii)

Answer all 50 questions Each question carries one mark Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB pencil, as per instructions
A boiler trial indicated 2% O2 at boiler exit and 7% O2 at stack. The in-leak air quantity between these two measurement is a) 25% b) 40% c) 50% d) 5%

A steam trap helps to a) block steam and allow condensate c) block condensate and allow air and steam A thermal insulator has a) low thermal conductivity c) high convection coefficient b) high thermal conductivity d) low convection coefficient b) block condensate and allow steam d) recover flash steam

Emissivity is a measure of materials ability to a) only absorb heat b) only radiate heat c) absorb and radiate heat d) none of the above

Enthalpy of evaporation of steam will be higher at 1 _______________________ Bureau of Energy Efficiency

Paper 2 Set B Solutions

a) 2 kg/cm2 b) 8 kg/cm2 c) 12 kg/cm2 d) 20 kg/cm2

Flash steam quantity per kg of condensate depends upon a) condensate pressure only c) condensate pressure and flash steam pressure b) condensate pressure and flow d) none of the above

Fluidized bed combustion results in _________ SO x and NOx emissions a) increased b) decreased c) no effect on d) elimination of

For combustion, controlled wetting of coal (during the coal preparation) would result in a) reduction in flue gas exit temperatures c) coal fines carryover b) decrease in the percentage of unburnt carbon d) increase in the coal fines

For transporting steam to long distance, the best quality of steam is a) slightly superheated steam c) slightly wet steam b) dry saturated steam d) very high pressure steam

Furnace oil contains 84% carbon by weight. How many kg of CO 2 does complete combustion of 1 kg of furnace oil generate? a) 2.4 b) 4.0 c) 3.6 d) 3.1

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

In a CFBC boiler, the capture and recycling of bed materials is accomplished by a) bag filters b) settling chamber c) cyclone d) scrubber system

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

Latent heat of steam at the critical point is a) 540 kCal/kg b) zero c) infinite d) equal to sensible heat

Natural draft in a combustion system is produced by a) fuel firing rate b) stack temperature c) stack height d) stack temperature and height

NOX formation chances are least in a) FBC boilers b) pulverised fuel fired boilers c) furnace oil fired boilers d) stoker fired boilers

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

Removal of dissolved gases from the boiler feed water is called a) descaling b) deaeration c) deoxidation d) none of the above

Spontaneous combustion is a loss area in a) fuel oil storage b) natural gas storage c) furnace hearth d) coal storage

Soot on boiler tubes is formed by 2 _______________________ Bureau of Energy Efficiency

Paper 2 Set B Solutions

a) poor water treatment b) low steam pressure c) high excess air d) incomplete combustion Scale losses of stock in reheating furnace will a) increase with increase of CO2 in combustion gases c) decrease with increase in excess air b) increase with increase in excess air d) have no relation with excess air

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

The concentration of solids in a boiler is controlled by a) steam venting b) blow down c) air venting d) deaeration

The dry saturated steam when throttled to a lower pressure will a) become wet b) become superheated c) remain dry saturated d) become condensate

The efficiency of a boiler was improved from 70% to 80%. The % fuel savings achieved are a) 12.5% b) 18% c) 25% d) none of the above

The element that does not contribute to heating value during combustion process is a) nitrogen b) sulphur c) hydrogen d) carbon

The furnace bed temperature of a fluidized bed boiler is about a) 850C b) 1100C c) 700C d) 1000C

The highest percentage of sulphur is present in a) FO b) LDO c) LSHS d) kerosene

The limit to reduction of stack temperature in an oil fired boiler is influenced by a) oil temperature b) air temperature c) % carbon in oil d) % sulphur in oil

The purpose of venting air from steam system is because air is a) an insulator b) a good conductor c) an inert substance d) incompressible

The waste heat boiler application is not suitable for which of the following? a) gas turbine b) diesel engine c) furnaces d) dryers

The working fluid of a steam thermo-compressor is a) high pressure air b) low pressure steam c) high pressure steam d) high pressure condensate Velocity of steam in a pipe does strongly depend on a) number of bends and valves in the pipe c) length of the pipe b) specific volume of steam d) none of the above

What is the appropriate fuel size in a coal fired FBC boiler? a) 25-50 mm b) 50-75 mm c) 6-10 mm d) less than 5 mm

Waste heat recovery systems with a high LMTD results in a) higher heat transfer area b) lower heat transfer area c) higher u-factor d) none of the above

Which data is not required to calculate the efficiency of boiler by indirect method 3 _______________________ Bureau of Energy Efficiency

Paper 2 Set B Solutions

a) blow down rate b) ambient temperature c) calorific value of fuel d) flue gas temperature

Which of the following boiler type has the lowest permissible boiler drum TDS concentration? a) low pressure water tube boiler b) fire tube boiler c) Lancashire boiler d) all of the above

Which of the following cannot be fired in a gas turbine? a) natural gas b) LPG c) naptha d) coal

Which of the following fuel requires the largest amount of excess air for complete combustion? a) furnace oil b) LDO c) coal d) natural gas

Which of the following fuels needs minimum stoichiometric air for combustion? a) coal b) natural gas c) LPG d) fuel oil

Which of the following is not one of the 3 Ts of combustion? a) time b) temperature c) turbulence d) tertiary

Which of the following is not required in the boiler efficiency evaluation by direct method? a) steam flow b) fuel flow c) feed water temperature d) oxygen % in the flue gas

Which of the following is one of the components of LPG? a) methane b) iso-octane c) hexane d) propane

Which of the following is the best way to assess boiler losses? a) benchmarking evaporation ratio c) direct efficiency evaluation b) indirect efficiency evaluation d) none of the above

Which of the following waste heat recovery systems is of thermal storage type? a) ceramic recuperator b) metallic recuperator c) regenerative burner d) waste heat boiler

Which of the following will be ideal heating medium for heat transfer in a heat exchanger? a) superheated steam c) high pressure condensate b) saturated steam d) condensate at atmospheric pressure

Which parameter influences flame profile most? a) fixed carbon b) volatile matter c) carbon/hydrogen ratio d) none of the above

Which property is most important for a fire brick? a) high porosity c) low bulk density b) thermal stability at high temperature d) chemical resistance

Which type of steam trap operates on the principal of difference in temperature of steam and condensate? a) thermodynamic trap b) inverted bucket c) thermostatic trap d) none of the above

Which type of turbine has high heat-to-power ratio? a) gas turbine b) back pressure turbine c) extraction condensing turbine d) reciprocating engine

. End of Section I .
4 _______________________ Bureau of Energy Efficiency

Paper 2 Set B Solutions

Section II: SHORT DESCRIPTIVE QUESTIONS (i) (ii) S-1 Answer all Eight questions Each question carries Five marks

Marks: 8 x 5 = 40

A 5 MW DG Set is operating at 80 % load. A waste heat recovery boiler is installed to recover heat from exhaust gas to generate steam at 10 kg/cm 2. Find out the quantity of steam generated annually after installing the waste heat recovery boiler Given Data: Flue gas exit temperature Flue gas temperature after Waste heat recovery boiler Specific heat of flue gases Specific gravity of diesel oil Air to fuel ratio Specific fuel consumption Enthalpy of steam at 10 kg/cm2 Feed water temperature Operating hours per year Solution: Average load of DG set = 5 x 0.8 = 4.0 MW or 4000 kW 1 Mark Diesel consumption = 4000 x 0.85 /4.2 = 809.52 kg/hr 1 Mark Heat available for WHR boiler = [809.52 + (809.52 x 28)] x 0.25 (450 230) = 1291184 kCal/hr 1 Mark Steam generation at 10 kg/cm = 1291184 / (660 60) = 2152 kg/hr or 2.152 tons/hr Annual steam generation = 2.152 X 6000 = 12,912 tons /year. 2 Marks
2

= 450 oC = 230 oC = 0.25 kCal/kg/oC = 0.85 = 28 kg/kg = 4.2 kWh/liter = 660 kCal/kg = 60 oC = 6000 hrs

S-2

For a 8 TPH capacity boiler, estimate the rise in temperature of water in an economizer. The flue gas temperature decreases from 315 C to 200 C in the economiser. Air to fuel ratio and evaporation ratio of the boiler are 20 kg of air/kg of fuel and 12 respectively. Assume condensate recovery and boiler blow down is nil. Specific heat of flue gas: 0.23 kCal/kg oC For 1 kg of fuel steam generated is = 12 kg For 1 kg of fuel makeup water is = 12 kg For 1 kg of fuel required combustion air is = 20 kg For 1 kg of fuel flue gas generated is = 20 +1= 21 kg
5

Ans:

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Paper 2 Set B Solutions

In economizer heat given by flue gas = heat received by makeup water 21 x 0.23 x (315-200) = 12 x 1 x T T = 46.29 C S-3 Ans: What is draft and briefly explain its importance in boilers and furnaces? Draft is the difference of pressure producing air flow through a boiler furnace, flue and chimney. 2 Marks The function of draft in a combustion system is to exhaust the products of combustion into the atmosphere overcoming the pressure drop across the boiler tubes, baffles, economizer, flue duct bends, air pollution control system etc. if draft is not properly maintained it affects the combustion system and results in high energy consumption. 3 Marks The evaporation ratio of a coal fired boiler is 5.1. Estimate boiler efficiency if steam enthalpy is 650 kCal/kg; feed water temperature is 40 0C and calorific value of coal is 4500 kcal/kg. Boiler efficiency Boiler efficiency = = = output/input x 100 100 x Q (H-h) / (q x GCV) 2 Marks 5.1 x (650-40) x 100 ----------------------= 69.13% 1 x 4500 3 Marks S-5 Sketch the schematic diagram of Back Pressure Turbine and Extraction Condensing Turbine Cogeneration systems (Note: no explanation required). 2 Marks

3 Marks

S-4

2.5 Marks for each figure

6 _______________________ Bureau of Energy Efficiency

Paper 2 Set B Solutions

S-6 Ans: What is meant by air venting in a steam system and what is its purpose? When steam is first admitted to a pipe/equipment after a period of shut down, the pipe/equipment is full of air. Further amounts of air and other non condensable gases will enter with the steam, although the proportions of these gases are normally very small compared with the steam. When the steam condenses, these gases will accumulate in pipes and heat exchangers. Precautions should be taken to discharge them. The consequence of not removing air increases heatup time and reduces plant efficiency and process performance. The presence of air affects heat transfer. 5 Marks S-7 In a heat exchanger, steam is used to heat 3 kl/hr of furnace oil from 30 oC to 100oC. 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/cm 2 with latent heat of 510 kCal/ kg is used. If steam cost is Rs.4.0/kg and electrical energy cost is Rs.7.0/kWh, which type of heating would be more economical in this particular case? (assume no losses in electrical and steam heating process) Ans: Total heat required = m Cp T = (3 x 1000 x 0.95) x 0.22 x (100-30) = 43890 kcal/hr 1 Mark a) Amount of steam required = 43890/510 = 86 kg/hr Steam cost = 86 x Rs.4 = Rs. 344/hr 2 Marks b) Amount of electricity required = 43890/860 = 51 kWh = 51 x Rs. 7 = Rs.357/ hr 2 Marks S-8 Ans: Write short notes on economic insulation thickness for energy efficiency. Insulation of any system means capital expenditure. Hence an important factor in any insulation system is to analyse the thermal insulation with respect to cost. The effectiveness of insulation follows the law of decreasing returns. Hence, there is a definite economic limit to the insulation thickness, which is justified. Excess thickness is uneconomical and cannot be recovered through heat savings. Each industry has different cost of heat loss due to variation in fuel cost and boiler efficiency. These values
7 _______________________ Bureau of Energy Efficiency

Steam heating will be more economical

Paper 2 Set B Solutions

can be used for calculating economic thickness of insulation, where thickness for a given set of circumstances, which results in the lowest overall cost of insulation and heat loss combined economic insulation thickness.

Note : figure is optional 5 Marks

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

Section III: LONG DESCRIPTIVE QUESTIONS (i) (ii) L-1 Ans: Answer all Six questions Each question carries Ten marks

Marks: 6 x 10 = 60

What is the need for boiler blow down? Explain intermittent and continuous blow down. Water contains certain percentage of dissolved solids. The percentage of dissolved solids found in boiler water depend on the untreated feed water quality, the treatment process and the boiler operating procedures, as the feed water evaporate in to steam, dissolved solids concentrate in the boiler either in dissolved or suspended state. Above certain level of concentration, these solids encourage foaming and cause carry over of water in to the steam. This leads to scale formation inside the boiler, resulting in localized overheating and ending finally in tube failure. If in therefore necessary to control the level of concentration of the solids and this is achieved by the process of blowing down, where a certain volume of water in blown off and is automatically replaced by feed water thus maintaining the optimum level of total dissolved solids (TDS)in the water . 4 Marks The intermittent blow down in given by manually operating a valve fitted to discharge pipe at the lowest point of boiler shell to reduce parameters with in prescribed limits so that steam quality is not likely to be affected. 3 Marks
8

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Paper 2 Set B Solutions

The continuous blow down is a steady and constant dispatch of small stream of concentrated boiler water and replacement by steady and constant inflow of feed water. This ensures constant TDS and steam purity at a given steam load .once blow down valve is set for a given conditions there is no need for regular operator intervention. 3 Marks L-2 Ans: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Complete combustion with minimum excess air Correct heat distribution. Operating at the desired temperature Reducing heat losses from furnace opening Maintaining correct amount of furnace draught Optimum capacity utilization Waste heat recovery from the flue gas Minimum refractory losses Use of ceramic coating Maintaining proper cycle time 1 Mark for each point Note: Any other relevant point may also be given marks L-3 A boiler utilizes bio-mass as fuel and the ultimate analysis (by weight %) of the fuel is given below: Component Carbon Hydrogen Nitrogen Oxygen Sulphur Ash % 40 7 0.5 40.5 0.5 11.5 List ten of energy conservation opportunities in an oil fired reheating furnace?

Using the basic combustion equations estimate the theoretical air requirement for 100 kg of dry fuel fired: Ans: Basic equations: C + O2 2H2 + O2 S + O2 = CO2 = 2H2O = SO2 2 Marks Theoretical amount of air for combustion 12 kg carbon requires 32 kg of oxygen forming 44 kg of CO2. 1 kg carbon requires 32/12=2.67 kg O2.
9 _______________________ Bureau of Energy Efficiency

Paper 2 Set B Solutions

(40)C + (2.67x40) O2 = (146.67) CO2 2 Marks 4 kg of Hydrogen requires 32 kg of oxygen.1 kg of Hydrogen requires 8 kg of oxygen. (7) H2 + (7x8) O2 = (63) H2O 2 Marks 32 kg Sulfur requires 32 kg oxygen to form 64 kg of SO2. 1 kg Sulfur requires 1 kg Oxygen. (0.5) S + (0.5) O2 = (1) SO2 2 Marks Total oxygen required Oxygen present in fuel Oxygen to be supplied Amount of air to be supplied = (106.67+56+0.5) = 40.5 kg = 163.17-40.5 =102.6 x100/23 = 446.08 kg 2 Marks L-4 Ans: In a steam system, mention three types of classification of steam traps and give their principle of operation. Give one example for each type. Mechanical trap Principle of operation is difference in density between steam and condensate The different mechanical traps are Open bucket (or) Inverted bucket (or) Float type 3 Marks Thermodynamic trap Principle of operation is difference in thermodynamic properties between steam and condensate The different thermodynamic traps are Disc type 4 Marks Thermostatic trap Principle of operation is difference in temperature between steam and condensate. The different thermostatic traps are Bimetallic type 3 Marks An oil fired reheating furnace has an operating temperature of around 1200 C. The average fuel oil (FO) consumption is 450 litres/hour. The flue gas exit temperature after the air preheater is 320C. Find out the percentage sensible heat loss in exhaust gases.
10 _______________________ Bureau of Energy Efficiency

= 163.17 kg = 102.6 kg

L-5

Paper 2 Set B Solutions

Other data are as under: Specific gravity of oil Calorific value of oil Average O2 percentage in flue gas Theoretical air required Ambient temperature Specific heat of flue gas Ans: Energy input

= 0.92 = 10000 kCal/kg = 13% = 14 kg of air to burn 1 kg of oil = 40 oC = 0.25 kCal/kgC = 450 lph = 450 x 0.92 = 414 kg/hr = 414 x 10000 = 41,40,000 kCal/hr 2 Marks

Sensible heat loss in flue gas Corresponding excess air = (%O2/ (21-O2)) x 100 = (13/ (21-13)) x 100 = 162 % 2 Marks Theoretical air required Actual air required Sensible heat loss in flue gas m = 14 kg of air to burn 1 kg of oil = 14 x (1+1.62) kg/kg of oil = 36.68 kg/kg of oil 2 Marks = m x Cp x T = mass of flue gas = 36.68 + 1 = 37.68 kg/kg of oil = Specific heat of flue gas = 0.25

Cp T = = =

Temperature of flue gas ambient temperature 320C - 40C 280C = = = = = 37.68 x 0.25 x (320 -40) 37.68 x 0.25 x 280 2637.6 kCal/kg of oil 2637.6 x 414 1091966.4 kCal/hr 2 Marks

Heat loss

Sensible heat loss in flue gas as % heat loss to input energy

= =

(1091966.4 x 100)/(4140000) 26.4% 2 Marks

11 _______________________ Bureau of Energy Efficiency

Paper 2 Set B Solutions

L-6 A furnace is used to heat the stock. The stock is charged through a door, which is always kept open. The door size is 700 mm x 700 mm. The furnace wall thickness is 400 mm. The furnace operating temperature is 1260 C. Calculate the hourly direct radiation heat loss through openings? Convert the heat loss in terms of oil equivalent loss if GCV of oil is 10000 kCal/kg. Other data are as under: Blackbody radiation corresponding to 1260 C Emissivity Factor of radiation Ans: Area of opening = = 70 cm x 70 cm 4900 cm2 2 Marks The factor of radiation = 0.7 Emissivity = 0.82 Total heat loss through opening = Black body radiation x Area of opening x factor of radiation x Emissivity = 30 x 4900 x 0.7 x 0.82 = 84,378 kCal/hr 6 Marks Equivalent oil loss = = 84,378/10000 8.43 kg/hr 2 Marks = 30 kCal/cm2/hr = 0.82 = 0.7

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

12 _______________________ Bureau of Energy Efficiency