22nd NATIONAL CERTIFICATION EXAMINATION

FOR
ENERGY MANAGERS&ENERGY AUDITORS JULY, 2022

PAPER 2 : ENERGY EFFICIENCY IN THERMAL UTILITIES

Duration:3 HRS Max. Marks: 150
Date:30.07.2022 Timings: 14:00-17:00HRS

General instruetions
Please check that this question paper coitains 8 printed pages
o Please check that this question paper contains 64 questions
o The question paper is divided into three sections
o All qrestions in all three seetions are compulsory
o Al parts of a question should be anstuered at one place
Marks: 50 x 1 = 50D
Section-I: OBJECTIVE TYPE

) Answer all 50 questions

() Each question carries One mark BOOKLET" with
"SECTION-I" of "MAIN ANSWER
() Please hatch the appropriate oval in
BLUE/BLACK ball point pen

Which ofthe following is correct for "Viscosity"?

a Increases with temperature
b) Increases with pressure and temperature
c Decreases with temperature
d) None of the above

2. Specifñc Heat" is measured with which unit?

a) kcal/kg b) kcal/°C
d) None of the above
c) kg/m
How much energy is released from burning of 1 kg Hydrogen?
3
a) 28,922 kcal/kg b) 36,200 kcal/kg
c) 8,084 kcal/kg d) 2,225 kcal/kg

How much air is required for burning of 3 kg of Carbon in fuel?

a) 8.0 kg b 34.7 kg
c3.6 kg d) 47.8 kg

Which of the following refers to External Water Treatment Methods?

a) lon Exchange Process b) De-aeration
c) Reverse Osmosis d) All of the above

. Which of the following is correct relating to critical point of water?

a) 221.2 bar absolute pressure and 374.18 oC
b) Latent heat is zero.

c) Super critical boilers operate above critical conditions.

d) All of the above.

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water?

Heat"
of
"Latent

for
is
rrect
correct o
increase in steam pressure, which of the following decreases.
With
Sensible
heat
b)
Latent heat decreases.
decreases.

a) Total enthalpy
decreases. d)
c) Boiling point m o i s t u r e ?

with 5%
team
or
kcal/ke, what will be
total heat stea
8. If h, is 159 kcal/kg, h, is 498
b) 632 kcal/kg
a) 649 kcal/kg
d) 624 kcal/kg
c) 657 kcal/kg

9 Which of the following is function of steam trap?

as soon as it is formed.
a) To discharge condensate
b) Not to allow steam to escape
condensable gases.
To discharge air and other
non
c)
d) All of the above.

Which of the following trap is suited for steam tracing applications

10 Ball Float trap.
a) Inverted Bucket trap. b)
d) Thermodynamic trap.
c) Thermostatic trap.

11 Recuperators are used for

of combustion air. b) Preheating of fuel.
a) Preheating the stock.
d) Preheating
c) Preheating of water.

12 The wall losses of furnace depends on .

Thermal conductivity
of refractories.
a) Emissivity of wall. b
c) Wall thickness. d) All of the above.

Determination of economic thickness of insulation depends on

13.
a) Cost and heat content of fuel.

b) Estimated cost of insulation and hours of operation.

c) Boiler efficiency.
d) All of the above.

14. The unit of surface heat loss is

a) kcal/hr m. b) kcal/hr m
d) None of the above.
c) kcal/hr °C.

15. Electrostatic precipitators can remove ash upto

b) 70-95% of
fly ash.
a) 60-85% of fiy ash.
d) 50-80% of fly ash.
c) 95-99% of fly ash.

boiler will have lowest size for 500 MW generation?

16 Which of the following
b) AFBC Boiler
a) CFBC Boiler
d) None of the above
c) PFBC Boiler

which heat is utilized and power is produced in

17 A co-generation system configuration in
next stage?
a) Combined cycle b) Bottoming cycle
d) None of the above
c) Topping cycle
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18.Simultaneous generation of steam, power and refrigeration refers to

a) Triple point. b) Trigeneration
c) Combined cycle generation. d) Bottoming cycle cogeneration,
19.
For every 15 °C rise in feed water
temperature of boiler will result into overall thermal
efhciency improvement by
a) 6% b) 1%
c) 3% d) 5%

20. Which of the following is direct contact heat exchanger?

a) Reboiler/Kettle b) Heat Pipe
c) Deaerator d) Heat Pump

21. A pinch analysis can result in.

a) Reduction in cooling water. bIncrease in cooling water.
c) Reduction in steam. d) Both a & c.

22. Regenerators utilizing waste heat widely used

are
in
a) Cement industries. b) Steel.
c) Glass melting furnace. d) Aluminium.

23. A pulp and paper industry needs steam at 3 bar and 10 bar in addition to the electric power.
The most suitable cogeneration choice among the following will be:

a) Condensing turbine b) Back pressure turbine

c Extraction cum back pressure turbine d) Bottoming cycle
24. |Low combustion temperature in FBC boiler results in reduction
of
a) SOx b) NOx
c) Co d) O,
25. An increase in bulk density of refractory increases its
a) Volume stability. b) Heat capacity.
c) Resistance to slag penetration. d) All of the above.

26. The efficiency of a reheating furnace

operating at 10 tonnes °C hour
Oil of 230 kg/hour for reheating the material from 40 °C-1100per consuming
(consider
furnace
specific heat of
material is 0.13 kcal/kg °C and calorific value of furnace oil is 10,000 kcal/ kg) is
a) 55 b) 60
c) 65 d 70

27. The device that upgrades a low temperature heat source to a high temperature sink is called:

a) Heat pipe b Heat pump

c) Plate heat exchanger d) Economiser

28. The diference between mean solid and mean gas velocity in FBC boilers is called
a) Fluidization factor b) Slip velocity.
c) Settling velocity. d) None of the above.

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

a) Low thermal conductivity b) Light weight
c) High heat capacity d) Thermal shock resistant

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on
around the
furnace
does not depend
Furnace wall heat loss Velocity of air
30. b)
external wall surfaces above.
Temperature of None of the
a) d)
c o m b u s t i o n air.
Temperature of
c)
most viscous fluid?
Which among
the following is b) Kerosene
31
a) LDO d) Furnace oil
c) HSD
600 kJ/kg, when it released to
has heat content of about retain about
419 kJ heat,
of
at 4 bar (g) pressure water c a n only available will
32. Hot condensate
each kilogram of flash steam
0 (g), bar then percentage (%)
atmospheric p r e s s u r e is 2134 kJ/kg,
the latent heat of flash steam
If
be b) 12.48%
a) 11.48% d) 14.48%
c)8.489%

Comrection factor
for LMTD is applicable for
33. b) Parallel flow.
a) Counter current.
Both a & b.
d)
c) Cross flow
turbine
waste heat recovery system in large gas
Which one is the preferred
34. b) Air preheater
a) Economiser
d) Heat wheel
c)HRSG
with which of the following?
An axial compressor
is used in conjunction
35. b) Gas turbine
steam turbine
a) Back pressure condensing turbine
Extraction c u m
c Condensing turbine d

The thermal efficiency of the

furnace increases by
statement:
36. Pick up the wrong
the furnace loading.
a) Increasing
the excess air flow rate.
b) Increasing
loss.
c) Reducing the surface heat
the CO loss and unburnt losses.
d) Minimizing

37. Major heat loss in an oil-fired boiler is accounted by.

b) Un-burnt carbon loss.
a) Blowdown loss.
d) Stack loss.
c) Surface radiation loss.

the approximate theoretical quantity of air

38. For complete combustion of every kg of FO firing,
required is
b) 14 kg
a) 12 kg
c) 16 kg d) 18 kg

39. Select the odd one among the following:

a) Condenser b) Distillation column
c) Evaporator d) Cooling tower

40. The equipment having the highest efficiency in case of cogeneration plant is

a) Electric generator. b) Boiler ID fan.

c) Steam or gas turbine. d) Boiler.
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a Oxvgen percentage (by volume) can be measured in flue gas by using
a) Ultrasonic tester
b) Potassium oxide probe
c) Copper tubes.
d) Zirconium oxide probe.
a1000 kg of water 1s to be heated from 30 DC to 70 C. The heat gained by water will be
a) 40,000 kcal/hr
b) 40,000 keal
c 40,000 kJ
d) 40,000 kJ/hr
43. Heat wheels are mostly used in situation of
al High temperature exhaust gases.
b) Heat exchange between large masses of air having small temperature differences.
e Heat transfer between a liquid and gas.
d) Corrosive gases

44. In a CFBC boiler the capture and recycling of bed materials is accomplished by.

a) Bag filter. b) Settling chamber.

c Cyclorne d) Scrubber system

45 The best quality of steam for industrial process heating is ,

a) High pressure steam. b) Wet steam.
Superheated steam d) Dry saturated steam.

46. Which ofthe following is related with heat pipe

a) Can transfer upto 100 times more thermal energy than copper.
b) Uses a pump for moving the working fiuid.
c) Consists ofseveral plates in series.
d All of the above.

47. Condensate recovery in steam system

a) Improves boiler feed water quality.
b) Maximizes boiler output.
c) Reduces water consumption.
d) All of the above.

48. Across the pressure reducing valve of a steam system

a) Output enthalpy decreases. b) Steam becomes wet.
c Steam temperature increases. d) Enthalpy remains the same.

49. The flash point of a fuel is the temperature at which fuel can be heated so that
the vapour gives off flashes momentarily when an open flame is passed over it.

a) Highest b) Lowest
c) Medium d) None of the above

50. Unit of heat to power ratio is

a) kWh/kcal b) kcal/kWh
c) kWh/BTU d) All of the above

E n d of Section - I ...s
a

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Section I1: SHORT DESCRIPTIVE QUESTIONS Marks: 8x5- 40

(0 Answer all Eight questions

() Each question carties Five marks

S-1 The ultimate analysis of Indonesinn coal is as given below

Carbon 59% Hvdrogen 4%, Sulphur 0.56% Mineral Matter 14%

Oxygen 12% Moisture 9.43%, Nitrogen 1.019%
for combustion of 2000 kg/hr of conl with 6 0
a) Find out actual mass of air supplied
3 Marks
excess air
2 Marks
b) Find out NCV of the fuel if 0CV of the coal is 5,500 keal/kg

five parameters required for determination of furnace oil fired reheating furnace
S-2 Name any

effticiency by direct method

steam jacketed kettle of 700 kg capacity as a batch process. Milkis

S-3 Milk is evaporated in a
heated firom 35 C to 100 °C, where 35% of its mass is driven off as vapour.

The other data's are given below:

Specifie heat of milk is 0.9 kcal/kg °C

Latent heat of steam at 1 kg/cm'(g) is 525 kcal/kg

lgnoring the heat required for heating the kettle, calculate

the quantity of steam required
per batch

S-4Calculate the heat loss from an uninsulated pipeline of 50mm diameter of 500m length
carrying process hquid. The surface temperature of the pipe is 150 C. After process
modification, the liquid temperature was brought down resulting in a surface temperature
of 50 c. Calculate the reduction in heat loss if the ambient temperature is 32 "C in both

the cases.

Each 2.5 Marks

S-5 Write short notes on

a) Heat wheel
b) Heat pump

A counter fow heat exchanger using hot process liquid

is used to heat water. The flow
S-6 rate of water is 10 m'/hr. The process liquid enters the heat exchanger at 95 oC and
leaves at 55 °C. The inlet and exit temperatures of water are 30 °C and 42 C respectively.
The specific heat of water is 4.18 kJ/kg °C. Calculate the heat transfer area, if the overall
heat transfer coefficient is 762 W/m oC.

S-7 A coal fired boiler is generating 40 TPH steam and operates for 8000 hrs/year. The TDS in
boiler feed water is 500 ppm. The maximum permissible limit is 3000 ppm and make up
water is 8%. The temperature of blow down water is 170 C and feed water temperature is

75 C. The GCV of fuel is 5000 kcal/kg and efficiency of boiler is 72%.

the fuel saving achieved by reduction in blow-down, if the TDS of feed water is
Calculate
reduced to 300 ppm.

S-8 Explain the difference between bottoming and topping cycle with an example.

. . End of S e c t i o n - II . . . .

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Section -

III: LONG
DESCRIPTIVE QUESTIONS
() Answer all Six Marks: 6 x 10 = 60
questions
(ii) Each question carries
Ten marks
L-1 a) Explain how a FBC boiler works. How is it different from CFBC boiler?
b) List any five
properties of refractories. Each 5 Marks

L-2 a) Explain the working of a direct contact

heat exchanger. Each 2 Marks
b) Explain any two methods of
testing of steam traps.
c)What are the benefits and
applications of pinch technology in process industry?
d) List any two
advantages of ceramic fibre.
e) Why slight positive pressure is to be maintained in a reheating furnace?
L-3 Am oil refinery has a captive power plant with petcoke fired boiler. The following are the data
collected to assess the boiler performance.

Ultimate analysis of Petcoke (%)

Carbon 88.8
Hydrogen 3.6
Nitrogen 1.2
Oxygen 1.4
Sulphur 3.6
Moisture 1.4

GCV of Petcoke
8430 kcal/kg
O, in flue gas 6%
Flue gas temperature 250 OC
Heat loss due to radiation & convection 1%
Loss due to unburnt in fly ash & bottom ash :0.5%
Specific heat of flue gas :0.29 kcal/ kg °C
Specific heat of water vapour :0.45 kcal/kg °C
Ambient Temperature
30 C
Humidity in ambient air :0.0204 kg/kg dry air
Steam generation at 110 bar (g) & 520 C
Steam enthalpy at generation pressure and temperature816 kcal/ kg
Feed water temperature
:200 °Cc
Steam drum pressure :115 bar (g)
Saturated liquid enthalpy at steam drum pressure 352 kcal/kg
Calculate the following:

a) Boiler efficiency using indirect method 8 Marks

b) Specific boiler steam generation MT/MT of petcoke (Evaporation Ratio) 2 Marks

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L-4 In a paper industry a coal fred boiler of 729% effcieney is proposed to be replaced with
paddy husk fired boiler of 65% efcieney, The boiler and steam requirement details are
given below:
GCV of coal 3900 kcal/kg
Cost of coal Rs.12,000/MT
GCV of paddy husk 3500 keal/kg
Cost of paddy husk Rs.9,000/MT
Quantit of steam requirement 20 TPH
Enthalpy of steam 760 kcal/kg
Enthalpy of feed water 120 kcal/kg
Annual operating hours ofboiler 8000 hours
Calculate the annual fuel c0st savings by changing over to paddy husk boiler.

relevant data are given in the

L-5 The co-generation configuration of a process plant along with
figure below:
P 63 kg/cm
T 486 C
H 808 kcal/kg

g bo 96%

Turbine 3 MW
n 0.96%
Mass flow rate

fuel 5.44TPH Boiler

n 0.72
GCV of fue
5000 kcalkg
P=2 kg/cm
P 8 kg/cm
T 174 °CP- -TH=649 Kcal/kg
LL H= 662 kcal/kg

Feed Water
lemp. 100 C

lf the extraction steam from the furbine is 8 TPH, calculate the following:
6 Marks
a) Energy Utilization Factor.
4 Marks
b) Heat to power ratio, kW thermal to kW electrical.

delivering steam in equal amount to a common header, both at

L-6 a) Two boilers A & B are
without super heater.
pressure of 15 bar.
Boiler A has super heater and Boiler B is
The temperature of steam supplied by boiler A is 300 °C. The temperature of resulting
235 °C. Find out the dryness fraction of steamn
mixture of steam in the common header is
boiler B. Take specific heat of superheated steam, Cp =
2.09 kJ/kg.
supplied by the
Properties of Steam at 15 bar:

Saturation temperature, tsat 198.3 °C

Sensible heat of Steam, h, 844.6 kJ/kg

Latent heat of steam, h 1945.3 kJ/kg
Total heat of steam, h, 2789.9 kJ/kg
kg/cm at
TPH of saturated steam and pressure of 10
b) An oil-fired boiler is rated for 10 feed temperature
at rated pressure with a water
F &A condition. The boiler is operating
maximum possible steam generation at the operating pressure.
of 60 C. Estimate the
The following data is provided:

100 oC is 540 kcal/ kg

Latent heat of steam at
is 662 kcal/kg Each 5 Marks
Enthalpy ofsteam at 10 kg/cm
.. End of Section III..
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