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Gujarat BOE-2017 Paper-1 (Boiler Engg-1) Solution

GUJARAT BOILER EXAMINATION BOARD
BOILER OPERATION ENGINEER EXAM-2017
PAPER-1
Section-A
Q.1: Note [Objective questions papers were collected back by examiner after the
examination.] Total numbers of objective question were asked- 30 Nos. (01 Marks
each) Total of 30 Marks.
Section-B
Date : 07/10/2017 Time : 10.30am to 01.00pm
Day : Saturday Marks : 70
Instructions :
1) Attempt all Questions.
2) Wherever necessary draw neat sketch.
3) Write new question on New page.

Q.2 : Attempt any One…………..Marks[20].

Q.2(1) : Calculate the efficiency of AFBC boiler by indirect method using the
following data :
Analysis of blended coal(% by mass) C =53.9% , H2 = 3.1 % , N2 = 1.1% , S = 0.3%,
Ash 23.8%, O2 = 10.5 % ,Moisture = 7.3 % , GCV = 5060 kcal/kg
Boiler operating parameter are given below :
Steam pressure = 62 kg/cm2 ,
Steam Temperature = 470 c
Actual air supplied = 8.91 kg/kg of coal
Mass of dry flur gas = 9.31 kg/kg of coal
Sp. Heat of flue gas = 0.23 kcal/kg o c
Flue gas temp = 160*C
CO2 in flue gas = 14.7 %
CO in flue gas = 325 ppm
GCV of bottom ash = 800 Kcal/kg
GCV of fly ash = 452.5 kcal/kg
Ratio of bottom ash to fly ash = 15:85
Ambient temp = 32.4*C
Loss due to hydrogen in fuel = 3.54 %
Loss due to moisture in fuel = 0.93%
Loss due to moisture in air = 0.2 %
Surface heat loss(as assessed) = 2%

Solution : Calculation of Various Losses :

1 - % Heat loss in dry flue gas ( L 1 ) = mcp ( Tf – Ta ) x 100 / GCV of fuel
= 9.31 x 0.23 x (160 – 32.4) x 100 / 5060
L1 = 5.40 %
2 - % Heat Loss due to formation of water from H2 in fuel ( given ) L2 = 3.54 %
3 - % Heat loss due to moisture in fuel ( given ) L3 = 0.93 %
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Gujarat BOE-2017 Paper-1 (Boiler Engg-1) Solution
4 - % Heat loss due to moisture in air ( given ) L4 = 0.2 %
5 - % Heat loss due to partial conversion of C to CO
Carbon available in fuel C=53.9%=0.539
% CO=325ppm=325/1000000x100=0.0325%
L 5 = % CO x C X 5654 X 100 / ( % CO + % CO2 )
= 0.0325 x 0.539 X 5654 X 100 / ( 0.0325+ 14.7 ) X 5060
=9904.39/74546.45
= 0.133 %
6 – Surface heat loss ( given ) L6 = 2 %
7 - % Heat loss due to moisture in fly ash
% Ash in coal = 23.8
Ratio of bottom to fly ash = 15 : 85
GCV of fly ash = 452.5 kcal/kg
Amount of fly ash in 1 kg of coal = 0.85 x 0.238 = 0.202 kg
Heat loss in fly ash = 0.202 x 452.5 = 91.54 Kcal/kg of coal
% Heat loss in fly ash = 91.54 x 100 / 5060 = 1.80
L 7 = 1.80 %
8 - % Heat loss due to unburnt in bottom ash
GCV of bottom ash = 800 Kcal / kg
Amount of bottom ash in 1 kg of coal = 0.15 x 0.238 = 0.0357 kg
Heat loss in bottom ash = 0.0357 x 800 = 28.56 Kcal/kg of coal
% Heat loss in bottom ash = 28.56 x 100 / 5060 = 0.56
L 8 = 0.56 %
Boiler efficiency by indirect method = 100–(L1+L2+L3+L4+L5+L6+L7+L8)
= 100 – (5.40+3.54+0.93+0.2+0.133+2+1.80+0.56)
= 100 – ( 14.563 )
= 85.44 %

Q.2(2) :A chimney 30 mtr high deals with flue gases at 288 c , when the outside air
temperature is 21 c . The air supplied for combustion is 18kg/kg of coal burnt .
Calculate –
A – The draught in mm of water column produced by the chimney.
B – The draught produced in terms of height of column of hot gases in meters
C – The velocity of flue gases in chimney,if 50%of the draught is lost in friction at
the grate an passages
D – The draught produced in mm of water and the temperature of flue gases under
the condition of maximum discharge.

Solution : Given H = 30 mtr , T = 288 c , Ta = 21 c , w = 18 kg/kg

[A] Draught in mm of water column
h= 353 H [ 1/Ta – ( w+1 ) / w x T ] = 353 x 30 [ 1/294 – ( 18+1 ) /18 x 561 ]
h= 10590 [ 0.0034 – 0.0019 ] = 10590 [0.0015 ]
h= 15.885 mm of water column
[B] available draught is 50 % of the theoretical draught
P = 0.5 x15.885 = 7.942 mmwc = 7.942 x 9.81 N/m2
Now this pressure is caused by height of gas column = hg
hg x 353 ( w+1 ) /WT x 9.81 = 7.942 x 9.81
hg x 353 ( 18 + 1 ) / ( 18x561 ) x 9.81 = 7.942 x 9.81
hg x 353 x19 / 18 x 561 = 7.942
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Gujarat BOE-2017 Paper-1 (Boiler Engg-1) Solution
hg x 0.6641 = 7.942
hg = 7.942 /0.6641
hg = 11.96 mtr .
Draught produced in terms of height of column of hot gases in mtr = 11.96
[C] Velocity of flue gases in chimney v = ( 2g hg ) 1/2
V = (2 x 9.81 x 11.96 )1/2
V = 15.32 m/sec
[D] Temperature of flue gas under the maximum discharge condition
T / T1 = 2 (w+1 ) / w
T = T1 x 2 ( w+ 1 ) / w = 294 x 2 ( 18+1 ) /18
T = 62.67 K = 347.67*c
Draught produced in mm of water under the maximun discharge
hmax = 353 H /2T1 = 353 x 30 / 2 x 294
hmax= 18.01 mm of water column

Q.3 : Attempt any Five………Marks[25]

Q.3(1) : For combustion of 500 liter/hr of furnace oil, estimate the combustion air
quantity per hour with 20% excess air .Specific gravity of furnace oil is 0.95 . (Fuel
analysis C =84% ,H = 12% ,S = 3%,O2 =1% )

Solution – Therotical air = 100/23 [ 2.67 C + 8 H + S – O ]

= 100/23 [ 2.67 x 0.84 + 8 x 0.12 + 0.03 -0.01 ]
= 14 kg of air
Excess air = 20%
Air supplied = ( 1 + 0.2 ) x 14 = 16.8 kg of air/kg of oil
Quantity of furnace oil = 500 ltr/hr = 500 x 0.95 = 475 kg/hr
Total quantity of air required = 475 x 16.8 = 7980 kg of air/hr

Q.3(2) :Feed water is provided to a boiler from the feed water tank at 60 deg c,
temperature of condensate water returning to the tank is 80 deg c, and
temperature of make up water is 27 deg c. 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).

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Gujarat BOE-2017 Paper-1 (Boiler Engg-1) Solution
Q.3(3) : A steam pipe of 100 mm dia is insluated with mineral wool. As a part of
energy saving measure, the insulation is upgraded with efficient calcium silicate
insulation. Calculate the % reduction in heat loss due to above measure with the
following data,
Boiler efficiency : 80%
Surface temperature with mineral wool : 95 deg c
Surface temperature with calcium silicate : 55 deg c
Ambient temperature : 25 deg c

Solution – Heat Loss through any Surface= [10+(Ts-Ta)/20]*(Ts-Ta)

Heat loss through mineral wool insulated pipe
= [10 + (95 – 25) / 20] * (95 – 25) ] = 945 kcal/hr-m2
Heat loss through calcium silicate insulated pipe
= [10 + (55 – 25) / 20] * (55 – 25) ] = 345 kcal/hr-m2
% Reduction in heat loss = (945 – 345)*100 / 945 = 63.5 %

Q.3(4) :Calculate the blow down loss for a boiler with an evaporation rate of 5
tones/hr, if 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 .

Solution – Blow Down % = Feed water TDS x % Make up /Permissible in boiler – Feed
water TDS
= (400 x 18) / (3000 – 400) = 2.77 %
If E.R. ks 5000 kg/hr required blow down rate is = 5000 x 0.0277
= 138.5 kg/hr

Q.3(5) : A cogeneration plant has an electrical output of 5 MW with a backpressure

turbine which has a input steam condition to the turbine as 32 TPH with enthalpy
of 3418 KJ/ kg @ 64 ata and 500 deg c and the exit condition of steam at the end of
back pressure turbine is 168 deg c, with enthalpy of 2835.8 KJ/Kg. After the
process heating all the condensate @73 deg c 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 Kcal/Kg GCV.

Solution –Total heat input into the boiler=8200x4800x4.18=164524800kj/hr

Total heat input into the turbine=32000x3418=109376000Kjs/hr
Power generation =5x1000=5000Kwh=18000000Kj/hr
Heat utilized for process heating=Heat input into the process-Heat of condensate return
=32000x[2835.8-305.14]=80981120Kj/hr
Heat to Power ratio=80981120/18000000=4.5
Energy utilization factor of the process=80981120/164524800=49.22%

Q.3(6) : For a boiler which produces 15000kg of steam per hour at 20bar from feed
water at 40*C and the fuel consumption is 1650kg/hr. Determine the condition of
steam produced.

Solution –
Fuel consumption=1650kg/hr
Steam generation=15000kg/hr
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Gujarat BOE-2017 Paper-1 (Boiler Engg-1) Solution
Steam fuel ratio=15000/1650=9.1
Steam fuel ratio is indicating that generated steam is dry saturated steam type.
From steam table, Properties of steam at 20bar
Saturation temperature Ts=212.4*c
Volume of Steam Vg=0.0995m3/kg
Enthalpy of steam hg=2797.3kj/kg

Q.3(7) : A vacuum of 722 mm of Hg was obtained with a barometer reading 756

mm of Hg. Correct the vacuum to a standard barometer of 760 mmof Hg .

Solution – Pabs = 756 – 722 = 34 mm of Hg

Corrected vacuum = 760 – 34 = 726 mm of Hg

Q.3(8) : One kilogram of steam at a pressure of 7 bar and 0.7 dry heated at
constant pressure until it becomes dry saturated.How much heat is added?What
is change in internal energy?If the process is continued until the final temperature
is 200 c ,how many KJ are required to be added? Take Kp for superheated steam
as 2.1 KJ/Kgk.

Solution – At 7 bar pressure from steam table

Hf = 697.14 KJ/Kg , Hfg = 2762.75 KJ/Kg , Saturated steam temperature = 165 c
Enthalpy of 1 kg of wet steam
h=hf+xhfg = 697.14 + 0.7 x 2762.75 = 697.14 + 1933.92 =2631.06 KJ/kg
Enthalpy of dry saturated steam
H=hf+hfg = 697.14 + 2762.75 = 3459.89 KJ/kg
Heat is added = 3459.89 – 2631.06 = 828.83 KJ/kg
Change in internal energy=3459.89-2762.71=697.18Kj/kg

Enthalpy of superheated steam

hsup =hf+hfg + mKp ( T2 – T1 ) = 697.14 + 2762.75 + 1 kg x 2.1 KJ/Kg*K x (200-165) =
3533.39 KJ/kg
Heat added during during constant pressure condition=3533.39-3459.89=73.5Kj/kg

Q.4 : Attempt any one…………….Marks[5].

Q.4(1) :A pump is delivering 40 m3/hr of water with a discharge pressure of 29 mtr.

The water is drawn from a sump where level is 6 mtr below the pump centreline.
The power drawn by the motor is 7.5 KW at 89 % motor efficiency. Find out the
pump efficiency.

Solution – Q = 40 m3/hr = 40/3600 m3/sec

Totah Head = hd-hs = 29 – ( - 6 ) = 35 mtr
Hydraulic power = Q x Totah head x g x ƪ / 1000
= 40 x 35 x 1000 x 9.81 / [3600 x 1000] = 3.815 KW
Pump shaft power = 7.5 KW x 0.89 = 6.675 KW
Pump efficiency = Hydraulic power / Pump shaft power
= 3.815/6.675 = 57.15%

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Gujarat BOE-2017 Paper-1 (Boiler Engg-1) Solution
Q.4(2) :Find out the pressure drop occurred in 500 mtr length of steam pipelines.
The bore of the pipe is 250 mm in horizontal piping. Saturated steam velocity is 20
m/second friction factor is 0.005. How much pressure drop will be reduced if pipe
dia has increased from 250 mm to 350 mm.

Solution – Pressure drop = 4 flv2 / 2gd

Pressure drop with 250 mm = 4 x 0.005 x 500 x (20)2 / (2 x 9.81 x 0.250)
= 815.50 mtr
Velocity of the steam in pipe of 350 mm diameter
= 0.25 x 0.25 x 20 / 0.35 x 0.35 = 10.20 m/sec
Pressure drop with 350 mm = 4 x 0.005 x 500 x ( 10.20 )2 / 2 x 9.81 x 0.350
= 151.50mtr
Pressure drop reduction = 815.50 – 151.50 = 664meter

Q.5 : The following data was obtained during trial of water tube boiler
Steam pressure : 15 bar
Degree of superheat : 71.10c
Temperature of feed water : 96*c
Water evaporate : 3223 kg/hr
Coal fired : 417.3 kg/hr ,
Ash : 43.3 kg/hr
% of combustible in ash : 9.68
Moisture in coal : 4.42%
GCV of 1kg of dry coal : 30800 kJ/kg .
Determine – [Marks : 20]
A – The efficiency of boiler plant including super-heater
B – The efficiency of boiler and furnace combined. Take Kp of superheated
steam – 2.1KJ/KgK.

Solution – At Feed water temperature of 96oc hf1= 405 KJ/K

At pressure of 15 bar , hg = 2615 KJ/Kg
hsup = hg + kp ( tsup – t )
Given that Degree of super heat ( tsup – t ) = 71.10c
hsup = 2615 + 2.1 ( 71.1 )=2615 + 149.31=2764.31Kj/kg
Heat output from boiler=3223x(2764.31 – 405)=7604056Kj/hr
Heat Input=417.3x30800=12852840Kj/hr
[A]Efficiency of the boiler including super-heater =Heat Output/Heat Input
=7604056/12852840=59.16%

Total combustible in ash=43.3x0.0968=4.19144kg/hr

Heat loss due to combustible in ash =4.19144x30800=129096Kj/hr
Total moisture in coal=417.3x0.0442=18.44466kg/hr
Heat loss due to moisture in coal=18.44466x2257=41630Kj/hr
Total heat loss due to combustible in ash & moisture present in fuel
=129096+41630=170726Kj/hr
Total Input heat =Heat Input+Total heat loss due to combustible in ash & moisture
present in fuel =12852840+170726=13023566Kj/hr
[B] Efficiency of boiler and furnace combined= 7604056/13023566=58.39%

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